Flint & Walling FJ05S User manual

Copyright © 2018 Flint & Walling. All rights reserved.
1
SHALLOW WELL JET PUMP
MODEL FJ05S 1/2 HP
FW1642 C
ATTACH YOUR RECEIPT HERE
Serial Number Purchase Date
intandwalling.com

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2
TABLE OF CONTENTS
Product Specications......................................................................................................................2
Safety Information ............................................................................................................................2
Package Contents ............................................................................................................................4
Preparation.......................................................................................................................................4
General Pump Information ...............................................................................................................5
Well to Pump Connection.................................................................................................................6
Pump to Tank Connection ................................................................................................................9
Tank to House Connection .............................................................................................................10
Pump Electrical Connections.......................................................................................................... 11
Pump Priming and Startup .............................................................................................................13
Care and Maintenance ...................................................................................................................15
Warranty .........................................................................................................................................15
Troubleshooting..............................................................................................................................16
Replacement Parts.........................................................................................................................17
PRODUCT SPECIFICATIONS
Power supply required...........................................................................115 volts or 230 volts, 60 Hz
(Pump is set by the factory to run on 230 volts)
Maximum water temperature...........................................................................................77°F (25°C)
Individual branch circuit required............................................................................15 Amp minimum
Discharge connection..........................................................................................................1 in. NPT
Suction connection ........................................................................................................1-1/4 in. NPT
Motor duty..................... Continuous duty with enforced air cooling and thermal overload protection
Pressure switch ........................................................................... Preset at 20 PSI “on” / 40 PSI “o󰀨”
Water depth rating ................................................................................................. Maximum of 25 ft.
MODEL HP VOLTAGE HZ AMP
CAPACITY - U.S. GALLONS PER
MINUTE AT DISCHARGE 20 PSI
5 FT. 15 FT. 25 FT.
FJ05S 1/2 115/230 60 7.8/3.6 9.5 6.5 3.5
SAFETY INFORMATION
Please read and understand this entire manual before attempting to assemble, operate or install the
product.

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3
SAFETY INFORMATION
DANGER
ELECTRICAL SHOCK HAZARD.
Always disconnect power source before performing any work on or near the motor or its
connected load. If the power disconnect point is out-of-sight, lock it in the open position
and tag it to prevent unexpected application of power. Failure to do so could result in
fatal electrical shock.
ELECTRICAL SHOCK HAZARD.
Do not handle the pump with wet hands or when standing in water as fatal electrical
shock could occur. Disconnect main power before handling unit for ANY REASON!
RISK OF ELECTRIC SHOCK.
These pumps have not been investigated for use in swimming pool areas.
ELECTRICAL SHOCK ALERT.
Follow all local electrical and safety codes, as well as the National Electrical Code (NEC) and
the Occupational Safety and Health Act (OSHA).
ELECTRICAL SHOCK ALERT.
Replace damaged or worn wiring cord immediately. Never use an extension cord.
ELECTRICAL SHOCK ALERT.
Do not kink power cable and never allow the cable to come in contact with oil, grease, hot
surfaces, or chemicals.
ELECTRICAL SHOCK ALERT.
Wire motor to correct supply voltage. See motor nameplate and wiring diagrams and check
voltage of power supply.
ELECTRICAL SHOCK ALERT.
Unit must be securely and adequately electrically grounded. This can be accomplished by
wiring the unit to a ground metal-clad raceway system or by using a separate ground wire
connected to the bare metal of the motor frame or other suitable means.
ELECTRICAL SHOCK ALERT.
Do not disassemble the motor housing. This pump has no repairable internal parts and
disassembling may cause leakage or dangerous electrical wiring issues.
ELECTRICAL SHOCK ALERT.
Make certain the electrical power source is adequate for the requirements of the pump.
ELECTRICAL SHOCK ALERT.
Never use an extension cord with this pump.
CHEMICAL ALERT.
This product contains chemicals known to the state of California to cause cancer and birth
defects or other reproductive harm.
HAZARDOUS PRESSURE ALERT.
Install pressure relief valve in discharge pipe. Release all pressure on system before working
on any component.
EXPLOSION ALERT
Do not use to pump ammable or explosive uids such as gasoline, fuel oil, kerosene, etc.
Do not use in ammable and/or explosive atmospheres.
WARNING

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4
PACKAGE CONTENTS
SAFETY INFORMATION
CAUTION
PRODUCT DAMAGE MAY RESULT
This pump is not to be used for irrigation or water systems.
PRODUCT DAMAGE MAY RESULT
Protect the power cable from coming in contact with sharp objects.
PRODUCT DAMAGE MAY RESULT
Do not run pump dry.
PRODUCT DAMAGE MAY RESULT
Pump and plumbing must be full of water before startup.
PRODUCT DAMAGE MAY RESULT
Do not pump water which contains sand, mud, silt, or debris.
INJURY MAY RESULT
Be careful when touching the exterior of an operating motor. It may be hot enough to be painful or
cause injury.
Description Quantity
Pump 1
PREPARATION
Before beginning installation of product, make sure all parts are present. If any part is missing or
damaged, do not attempt to assemble the product. Compare parts to package contents list.
Estimated Installation Time: 2 hours.
Tools Required for New Installation (not included): pipe wrench, pliers, Phillips screwdriver, pipe clamp,
2-step PVC glue system (primer and sealer), thread tape, tire gauge or compressor
Parts Required for New Installation (not included): well seal, 1-1/4 in. to 1 in. male PVC adapter (2),
1-1/4 in. male PVC adapter, 1 in. male PVC adapter, 1-1/4 in. foot valve, 1-1/4 in. PVC pipe and
couplings, 1 in. PVC pipe and couplings, 1-1/4 in. PVC elbow, 1 in. PVC elbow, 1 in. discharge tee,
galvanized bushing, pressure gauge (optional) or pipe plug, 1-1/4 in. union (optional), 1 in. union
(optional), electrical wire, electrical wire strain relief, 1 in. x 1 in. x 1 in. tee, 3/4 in. x 3/4 in. slip coupling,
1 in. x 1 in. slip adapter, 1 in. x 3/4 in. slip adapter

Copyright © 2018 Flint & Walling. All rights reserved.
5
IL1104
Water Level
25 ft.
Max
Suction
Lift
3/4 or 1 in.
Discharge Pipe
1-1/4 in.
Suction
Pipe
Discharge
to Home
Pipe
Support
Foot Valve
Ventilation - Ventilation and drainage must be provided to prevent damage to the motor from heat
and moisture.
Freezing - Pump and all piping must be protected from freezing. If freezing weather is forecast, drain
pump or remove completely from the system.
Water Supply - The water source must be able to supply enough water to satisfy the capacity of
pump and water needs. See performance chart on page 2.
Suction Lift - Suction lift is the vertical distance from the lowest level of the water to the pump intake.
Pump will move water as long as it is within 25 vertical ft. of the water source.
Horizontal Distance - The horizontal distance is the horizontal measurement between pump suction
and the water source. This distance may a󰀨ect the ability of pump to operate. If it is more than 100 ft.,
call the manufacturer for assistance: 1-800-742-5044.
IL1472
Water Level
25 ft.
Max
Suction
Lift
3/4 or 1 in.
Discharge Pipe
1-1/4 in.
Suction
Pipe
Discharge
to Home
Pipe
Support
Drive Point
Check
Valve
1
2
GENERAL PUMP INFORMATION
Typical Pump Setup
1. Shallow well jet pumps are designed for use
where the suction lift is 25 ft. or less. They
can be used with drilled or cased wells.
2. Jet pumps can also be used with dug wells,
driven wells or with cisterns or lakes.

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6
1. Thread 1-1/4 in. male PVC adapter (not
included) into a 1-1/4 in. foot valve (not
included). Hand tighten, then tighten 1/2 turn
with a pipe wrench.
CAUTION: Dry-t entire assembly to ensure proper t before gluing or taping parts.
CAUTION: Follow all proper gluing procedures as specied by the glue manufacturer. Always
glue in a vertical direction whenever possible to prevent glue from dripping inside pipe or ttings
CAUTION: Use pipe tape and pipe paste compound on all male threads. Tighten with wrench to
a snug t and add another 1/4 turn to ensure proper seal.
1
1-1/4 in. male
PVC adapter
1-1/4 in. Foot valve
Pipe And Fittings
3. Use galvanized steel or NSF PW Schedule
40 PVC pipe and ttings. This material is
designed for water pressure and will seal
against air and water under pressure. Do
not use DWV ttings, as these are designed
for drains without pressure and will not seal
properly.
CAUTION: The entire system must be
air and water tight for e󰀩cient operation and to
maintain prime.
Wire Size:
The wire size is determined by the distance from the power source to the pump motor and the
horsepower rating of the motor. See the wire chart on page 11 for proper wire size.
1 in. NPT
Discharge
1-1/4 in.
Suction
3
GENERAL PUMP INFORMATION
WELL TO PUMP CONNECTION (SUCTION PIPE)

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7
WELL TO PUMP CONNECTION (SUCTION PIPE)
3. Before sliding the pipe assembly into the
well, rmly clamp the assembly with a pipe
clamp (not included) to prevent the assembly
from sliding down into the well.
2. Using a 2-step PVC system (not included),
attach enough 1-1/4 in. PVC pipe and
couplings (not included) to the adapter to
equal the depth of the well, minus 5 ft.
2
3
1-1/4 in. PVC pipe
Pipe clamp
25 ft. maximum
Water level
5 ft. minimum
4
IL1535
Approx.
12 in.
Well Seal
4. Remove the pipe clamp and slide a well seal
(not included) over the PVC pipe and onto
the well casing. The PVC pipe should extend
approximately 12 in. above the top of the well
seal, depending on the height of the pump.
NOTE: Do not let the assembly slide down into the
well. Tighten the well seal until the rubber gaskets
are tight against the well casing and the PVC pipe.
51-1/4 in. PVC
Elbow
5. Using a 2-step PVC system, attach a 1-1/4 in.
PVC elbow (not included) onto the rigid PVC
pipe extending from the well seal.

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8
WELL TO PUMP CONNECTION (SUCTION PIPE)
6
1-1/4 in. Male
PVC adapter
6. Wrap thread tape (not included) around the
threads of a 1-1/4 in. male PVC adapter (not
included). Thread the adapter into the 1-1/4 in.
opening in the front of pump.
8
1-1/4 in. PVC Pipe
Well
8. Using 2-step PVC system, attach 1-1/4 in.
PVC pipe and couplings as needed to connect
the 1-1/4 in. male PVC adapter to the 1-1/4 in.
PVC elbow attached to the top of the well pipe
in Step 5.
NOTE: Be sure the pipe slopes downward slightly
from pump to the well to prevent air pockets.
7
1-1/4 in. Union
7. An optional 1-1/4 in. union (not included)
is recommended for easy connection and
disconnection.

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9
1
1 in. Discharge Tee
1. Wrap thread tape around threads of a 1 in.
discharge tee (not included). Using a pipe
wrench, thread the 1 in. discharge tee into the
1 in. opening in the top of pump.
3
1 in. male PVC adapter
3. Wrap thread tape around the threads of a 1 in.
male PVC adapter (not included) and thread
the adapter into the discharge tee.
PUMP TO TANK CONNECTION (DISCHARGE PIPE)
Pressure Gauge or
Pipe Plug with Bushing
2. Install a 1 in. MPT x 1/4 in. FPT galvanized
bushing and (optional) pressure gauge (both
not included), or a pipe plug (not included). Do
not tighten, as you will prime pump later at this
location.
2
4. Continue with 1 in. ttings and pipe to
the pressure tank. An optional 1 in. union
(not included) is recommended for easy
connection and disconnection. 1 in. union
To pressure tank
4

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10
3. Attach a 1 in. pipe (not included) to the elbow
and a 1 in. x 3/4 in. reducer bushing (not
included) to the pipe.
4. Attach a 3/4 in. pipe (not included) to the
reducer bushing. Install an optional 3/4
in. union (not included) and continue with
pipe and 3/4 in. x 3/4 in. x 3/4 in. tee (not
included).
Glue
1 in. x
3/4 in.
Reducer
Bushing
1 in. Pipe
Glue
Tee
Union
3/4 in. pipe
Reducer
bushing
3
4
5
IL1366
Glue
Elbow
2. Attach a 1 in. elbow (not included) to the pipe. 2
3
IL1365
Glue
Adapter
Pipe
1. Most pressure tanks will have a 1 in. inlet
elbow on the bottom. Connect to this elbow
with a 1 in. MPT x 1 in. slip (glue) adapter and
short piece of pipe.
1
TANK TO HOUSE CONNECTION

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11
TANK TO HOUSE CONNECTION
5. Attach the pipe from the pump to the tee
installed in Step 4. Then, from the tee,
install 3/4 in. pipe and optional shut o󰀨
valve (not included) to connect tee to
house plumbing.
IL1369
Glue
To House
Plumbing
From Pump
Shut off valve
5
PUMP ELECTRICAL CONNECTIONS
WARNING:
• Always disconnect pump from electricity before performing any work on the motor.
• Under-sized wiring can cause motor failure and even re. Use proper wire size specied in the
Wire Size Chart.
• Replace damaged or worn wiring cord
immediately.
• Do not kink power cable and never allow the
cable to come in contact with oil, grease, hot
surfaces, or chemicals.
• The pump must be properly grounded using
the proper wire cable with ground.
CAUTION:
• Protect the power cable from coming in
contact with sharp objects.
• All wiring should be performed by a qualied
electrician in accordance with the National
Electric Code and local electric codes.
• Connect the pump to a separate electrical
circuit with a dedicated circuit breaker. Refer
to the Wire Size Chart for proper fuse size.
WIRE SIZE CHART
Distance from
Motor to Meter
Recommended Copper
Wire and Fuse Sizes
Single Phase Motors
1/2 HP
115 Volt 230 Volt
0-50 Ft.
50-100 Ft.
100-150 Ft.
150-200 Ft.
200-300 Ft.
14
12
10
8
*
14
14
14
14
12
Fuse Size (Amps) 15 15
(*) Not economical to run in 115 V, use 230 V
6. IMPORTANT: Air pressure in the tank
must be 2 PSI lower than the “cut-in” of
the pressure switch. Pump has a 20/40
PSI pressure switch, so tank pressure
must be set at 18 PSI. Locate the air
valve/stem on the tank and check
pressure with a tire gauge (not included).
If air needs to be removed, press down on
valve to bleed o󰀨 air. Use a tire pump or
air compressor to add air if needed.
Tire gauge
Tank
Air Valve/Stem
6

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12
PUMP ELECTRICAL CONNECTIONS
Wiring the pressure switch
CAUTION: Make certain that the power source
matches the pump requirements. This pump has
a dual voltage motor and can run on either 115 V
or 230 V.
Pump is pre-set at the factory to run on 230 V.
1. To change pump voltage, remove the square
voltage switch cover at the top of pump and
move the voltage switch as shown.
1
115 V
Setting
230 V
Setting
2. To connect the pressure switch, remove the
switch cover and insert an electrical wire
strain relief (not included) into the opening in
the side of the pressure switch.
IL1376
Wire from
motor
Pressure
switch
Strain
relief
Wire from
motor
Wire from
power
supply
3. Thread the electrical wire (not included) from
the power supply through the strain relief and
tighten both screws on the strain relief. Do
not crush wire.
2
3
Outside
terminal
Two wires
from power
supply
Outside
terminal
Wire from
motor
Wire from
power
supply
4. Connect the two wires from the power supply
to the two outside terminals on the pressure
switch.
4

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13
PUMP ELECTRICAL CONNECTIONS
Wire
from
motor
Wire from
power
supply
Ground Screws
Green
ground
wire
5. Connect the green ground wire from the
power supply to the remaining green ground
screw in the pressure switch and re-attach
the pressure switch cover.
5
PUMP PRIMING AND STARTUP
PRIMING
CAUTION: All pumps must be primed
(lling the cavity with water) before they are
rst operated. This may take several gallons
of water, as the suction pipe will be lled in
addition to the cavity of pump.
1. Remove pipe plug or pressure gauge (not
included) at the top of the discharge tee and
the vent plug in front of the discharge tee.
Vent plug
Priming plug
or pressure
gauge
Suction
Pipe
1
2. Slowly ll the discharge tee with water until
water overows the vent plug opening.
Replace the vent plug loosely.
NOTE: It will take several minutes to fill pump
and suction pipe completely.
Discharge Tee
Vent plug
Vent plug
opening Priming plug
opening
2
3. Be sure entire suction pipe is filled when
priming. Depending on the length of suction
pipe, many gallons will be needed to fill the
entire system.
Suction
Pipe
3

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14
PUMP PRIMING AND STARTUP
4. Check to be sure water in the cavity of pump
stays constant. If water level goes down, it
could indicate a leak in the foot valve, check
valve or suction pipe.
Water Level
Check for leaks
Suction
pipe
4
5. Once pump is lled, wrap the pressure
gauge or discharge tee plug and vent plug
threads with thread tape and thread into
pump. Tighten with wrench.
NOTE: Before turning on breaker, open several
outlets or faucets to allow water ow during
priming.
Vent Plug
Pressure
Gauge or
Discharge
Tee Plug
5
20
20
20
20
Breaker Box
6. Turn on breaker to start pump.
IMPORTANT: If the pump hums instead
of pumping or turns o󰀨 repeatedly, shut pump
o󰀨 immediately. Check voltage. Make sure
your incoming voltage matches the pump
wiring voltage. See PUMP ELECTRICAL
CONNECTIONS.
IMPORTANT: If pump fails to prime within
ve minutes:
Turn power o󰀨 at the breaker box and check
all pipe connections for leaks. All connections
must be water and air tight in order for pump to
operate.
7. Check suction pipe for any sagging. Support
suction pipe in a straight line to the pump.
NOTE: Look for leaks or a milky color in the
discharged water, which indicates an air leak.
Re-prime if necessary, following steps 1 through
6 above. Reset breaker at the breaker box. All
connections must be water and air tight in order
for pump to operate.
6
To Pressure
Tank
Foot Valve
1 in.
Discharge Pipe
1-1/4 in.
Suction Pipe
Well
7

Copyright © 2018 Flint & Walling. All rights reserved.
15
CARE AND MAINTENANCE
Winterizing
CAUTION: Drain the entire system if
there is danger of freezing.
1. To drain pump, remove the drain plug
located on the front of pump and the vent
plug located on the top of pump.
Vent Plug
Drain
Plug
1
WARRANTY
This product is warranted for one year from the date of purchase or two years from the date of manufacture, whichever occurs
first. Subject to the conditions hereinafter set forth, the manufacturer will repair or replace to the original consumer, any portion of
the product which proves defective due to defective materials or workmanship. To obtain warranty service, contact the dealer from
whom the product was purchased. The manufacturer retains the sole right and option to determine whether to repair or replace
defective equipment, parts or components. Damage due to conditions beyond the control of the manufacturer is not covered by this
warranty.
THIS WARRANTY WILL NOT APPLY: (a) To defects or malfunctions resulting from failure to properly install, operate
or maintain the unit in accordance with printed instructions provided; (b) to failures resulting from abuse, accident or
negligence or use of inappropriate chemicals or additives in the water; (c) to normal maintenance services and the
parts used in connection with such service; (d) to units which are not installed in accordance with normal applicable
local codes, ordinances and good trade practices; and (e) the unit is used for purposes other than for what it was
designed and manufactured.
RETURN OF WARRANTED COMPONENTS: Any item to be repaired or replaced under this warranty must be returned
to the manufacturer at Kendallville, Indiana or such other place as the manufacturer may designate, freight prepaid.
THE WARRANTY PROVIDED HEREIN IS IN LIEU OF ALL OTHER EXPRESS WARRANTIES, AND MAY NOT BE
EXTENDED OR MODIFIED BY ANYONE. ANY IMPLIED WARRANTIES SHALL BE LIMITED TO THE PERIOD
OF THE LIMITED WARRANTY AND THEREAFTER ALL SUCH IMPLIED WARRANTIES ARE DISCLAIMED AND
EXCLUDED. THE MANUFACTURER SHALL NOT, UNDER ANY CIRCUMSTANCES, BE LIABLE FOR INCIDENTAL,
CONSEQUENTIAL OR SPECIAL DAMAGES, SUCH AS, BUT NOT LIMITED TO DAMAGE TO, OR LOSS OF,
OTHER PROPERTY OR EQUIPMENT, LOSS OF PROFITS, INCONVENIENCE , OR OTHER INCIDENTAL OR
CONSEQUENTIAL DAMAGES OF ANY TYPE OR NATURE. THE LIABILITY OF THE MANUFACTURER SHALL NOT
EXCEED THE PRICE OF THE PRODUCT UPON WHICH SUCH LIABILITY IS BASED.
This warranty gives you specific legal rights, and you may have other rights which vary from state to state. Some states
do not allow limitations on duration of implied warranties or exclusion of incidental or consequential damages, so the
above limitations may not apply to you.
FOR YOUR WARRANTY PROTECTION, THE WARRANTY REGISTRATION MUST BE COMPLETED AND
RETURNED TO THE WARRANTY INFORMATION CENTER WITHIN TEN DAYS OF INSTALLATION.
In those instances where damages are incurred as a result of an alleged pump failure, the
Homeowner must retain possession of the pump for investigation purposes.

Copyright © 2018 Flint & Walling. All rights reserved.
16
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION
Little or no
discharge
1. Pump is not primed 1. Follow priming instructions (page 13)
2. Suction lift too high or too long 2. Move pump closer to water source.
Lift should be less than 25 ft.
3. Hole or air leak in suction line 3. Repair or replace. Use pipe tape and
pipe sealing compound
4. Foot valve too small 4. Match foot valve to piping or install
one size larger foot valve
5. Foot valve or suction line not
submerged deep enough in water
5. Submerge lower in water
6. Voltage switch incorrect 6. Be sure 115 V or 230 V power supply
matches voltage switch setting on
pump
7. Casing gasket leaking 7. Replace
Pump will not
deliver water
or develop
pressure
1. Pump is not primed 1. Follow priming instructions (page 13)
2. Leak in suction line 2. Repair or replace. Pipe dope all
threads
3. Discharge line is closed and priming
air has nowhere to go
3. Open several outlets or faucets
during priming procedure
4. Foot valve is leaking 4. Replace foot valve
5. Foot valve not submerged below
water level
5. Lower foot valve and reprime
Pump vibrates
and/or makes
excessive
noise
1. Mounting plate or foundation not rigid
enough
1. Reinforce
2. Foreign material in pump 2. Disassemble pump and clean
3. Impeller damaged 3. Replace
Pump will not
start or run
1. Voltage switch incorrect 1. Be sure 115 V or 230 V power supply
matches voltage switch setting on
motor
2. Blown fuse or open circuit breaker 2. Replace fuse or close circuit breaker
3. Loose or broken wiring 3. Tighten connections, replace broken
wiring
4. Stone or foreign object lodged in
impeller
4. Disassemble pump and remove
foreign object
5. Thermal overload has opened circuit 5. Allow unit to cool, restart after reason
for overload has been determined

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17
REPLACEMENT PARTS LIST
For replacement parts, call our customer service department at 1-800-742-5044,
7:30 a.m. - 5 p.m., EST, Monday - Friday.
PART DESCRIPTION PART NO.
BO-rings / Nozzle / Venturi Kit 023735
CDi󰀨user 023707
DImpeller 023709
EMechanical Seal 023720
F O-Ring 023721
GPressure Switch 023722
B
C
D
E
F
G