Fix a 400W Fog Machine Pump

36,018

24

16

Introduction: Fix a 400W Fog Machine Pump

I've seen enough halloween related forum posts complaining about these cheapo 400W fog machines where the pump quits working, but no solutions. Here is one solution:

So I bought one of these 400W foggers a few years ago and haven't necessarily been following the rules: https://www.instructables.com/id/Care-and-Feeding-o...

Last Halloween I tried using this fogger and it wouldn't fog no matter how hard I pushed the button. Fast forward to today when I finally had a few hours to fiddle. After disassembly, I'll spare you the pictures of me removing screws, I found this fogger has a 30DSB-ZJF pump. The heating element still works well, so I am leaving that alone.

Step 1: Pump Disassembly

First I disconnected the.... ooop nope, first make sure it is unplugged and cooled down! Next disconnect the pump from the copper tubing that leads to the heating element. Now the hose from the back of the pump that comes from the tank should be disconnected, not later. Then using an adjustable wrench unscrew the nipple from the front of the pump. Then remove the small plastic piece in picture 4. Next the soul of the pump should be removed (I am not sure what it is called). It may be a bit difficult to remove, that is why it needs to be fixed. Picture 7 shows the plastic piece that needs to be removed, cleaned, and fixed.

Step 2: The Fix

Picture 1 shows the piece fully out. Make sure the washer from the nipple came out, or is least in the right place for reassembly (down inside the housing). Picture 2 shows the problem. After a few years of pumping fog the plastic melted and shrank. There are three bands colors on this piece of plastic...white(the original color of the plastic), light brown, and let's call it brown. Looking at the brown banded areas, notice they are slightly deformed or smaller than the light brown and white areas. Without a way to reshape the plastic it was decided to shove something in there to fix it. "Hey, this 3/8" drill bit just fits!" Boring out the inner diameter to 3/8" now allows the metal soul of the pump to fit tightly yet slide freely. Just what is needed. Make sure to clean out the plastic shavings from the drilling.

Step 3: Reassembly Part 1

Picture 1 shows all the components in the order they go back in. Missing is the washer for the nipple of the white/brown plastic piece. Picture 2 description is as follows. After reassembly but before screwing on the large nipple, the fogger was plugged in and allowed to heat up to where the trigger could be activated. Hold the pump as shown in picture 2 (remember the black and yellow wire have 120VAC to power the electromagnets inside). Pressing the trigger should make the white plastic vibrate something fierce. That is good!

Step 4: Reassembly Part 2

Before reattaching the large nipple, remove the stopper/spring assembly from within. The spring has lost some sprang, so stretch it out a bit, say up to 2". This will help push the inner part of the pump back in after the electromagnets push it out. You know, the pumping action. Put the spring back into the large nipple. Make sure the rubber stopper on the spring lines up with the end of the white plastic and tighten the large nipple back on. Reattach the tube from fog juice tank back on to pump assembly.

Step 5: Testing

Yeah the fogger was still plugged in and up to temperature, so the pump was tested with fog juice. Picture 1 shows the pump squirting fog juice. Insert hopeful Whoo Hoo. At this point the fogger should be unplugged and allowed to cool as the copper tubing is quite warm to the touch. Picture 2 shows the copper tubing reinserted and the nut hand tightened. Picture 3 & 4 shows the fogger plugged back in, heated up, and pumping out clouds of fog. Whoo Hoo!! Then screw the pump back into place and reinstall the cover of the now working fog machine!

As I didn't fiddle with the heater, I didn't try to figure out how it works. I am guessing when that goes out it'll be time to retire the fogger.

1 Person Made This Project!

Recommendations

  • Pocket-Sized Speed Challenge

    Pocket-Sized Speed Challenge
  • Metalworking Contest

    Metalworking Contest
  • Maps Challenge

    Maps Challenge

16 Discussions

0
arnyman23
arnyman23

6 months ago

Hello . I have some issue with my fog machine. I been looking everywhere for solution but no luck . heating element working fine, pump make some noise but when you press the power button liquid going very slow from pump . been contacted with seller and send him video , of this product and he told me that pump not working correctly its should be pumping much more faster . he promise send me new one but 4 months past and I believe he just ignoring me . maybe I can get some solution what I can do . pictures attached

HTB1QslteiqAXuNjy1Xdq6yYcVXab.jpg20190911_161007.jpg
0
arnyman23
arnyman23

Reply 6 months ago

wrong first pic . mine pump has 30dsb-zjf 220-240vac

0
infinitiy
infinitiy

Reply 6 months ago

That circuit board adds quite a bit of complexity. I guess first thing i'd recommend is probing the wires going to the pump to make sure you are getting the voltage you need. It looks like the pump is 220-240v. I assume that is also the wall voltage you are plugging into. If less than 220v, follow the wires back to see if you see something burnt or disconnected.

0
cyberace27
cyberace27

8 months ago

I feel as though mine has a plastic insert that is black. I cant seem to get it out as the plastic is bending. What should I do?

0
infinitiy
infinitiy

Reply 8 months ago

I'd say, if you're pulling on it try using something not too sharp to push from the other side if possible. Otherwise without seeing what you are seeing, I'm not sure I could recommend anything else.

0
ScottW24
ScottW24

Question 9 months ago

I tore the pump in ours down and it's still not showing any signs of life. I stumbled on an image somewhere -- and of course can find it now -- that showed there were some electronics in the line, and sure enough, ours seems to have it. (I recall seeing a diode and a few other components in the diagram that is on one of the connecting wires)
I'm suspicious these might be the problem on ours. Do you have any idea what the electronics in the one wire is? I'll keep hunting for the schematic I saw, but haven't had any luck thus far.

Update: OK, I found out the electronics is just a single 1n4007 diode (striped end toward the pump) and was able to confirm the diode was in fact working. I tore the pump down again, cleaned the parts more meticulously and put it back together again. About the only thing I did different is I didn't rank down the large plastic part on the front quite as tight this time and hooked it straight to 115v by following the wires to the heating coil which were on removeable blade connectors.
This time, connected straight to the wall (through the fogger fuse) the pump operated. I put it back together and it started pumping fluid but never quite made it to creating fog. (I could hear the fluid reach the pump and waited another few minutes but nothing!)
I again pulled the front off, this time without removing the pump, checked the parts again, and this time stretched both of the springs a big, put it back together and it started spitting smoke as soon as it warmed up this time! Woo hoo!

I already have a pump on order so I guess now it will be a backup. Thanks for posting the pics as it helped me make sure I put everything back together in the right order.

0
infinitiy
infinitiy

Answer 8 months ago

I am glad you got it working! Sorry I didn't respond right away as my fog machines were still tucked away until Sunday afternoon so I wasn't able to open one up to look.

0
Mollysmama
Mollysmama

10 months ago

After looking everywhere for a fix for my works fog machine, your the only one that actually had a solution. Thanks alot. I now have a working fog machine. Wait until I tell the guys at work that I fixed it when they couldn't :-).

0
infinitiy
infinitiy

Reply 10 months ago

I'm super glad this was able to help get your fog machine working again!

0
HankW8
HankW8

3 years ago

Should you hear any noise at all coming from the pump if this is the issue? I'm not hearing anything and curious if this could still fix the problem or if the pump is actually no good because I can't hear anything.

0
xenoinc
xenoinc

Reply 1 year ago

I too did not have any nose in mine. After disassembling the motor's components, wiping off any corrosion, and drying, it worked like a charm! The plug-in test with your thumb over the end was the best sigh of relief! Had to blow air through the clogged exit-point too.

Side note, I have the same model of the motor but an older model of the fog machine, the motor's components are all metal & no plastic.

0
infinitiy
infinitiy

Reply 3 years ago

No, since everything is stuck, the pump won't make a sound. At least it didn't for me. Also, once you crack open the case make sure all the wires are connected. I just bought a used fogger that didn't work. It ended up being the spade plug was loose and had disconnected from the pump spade terminal.

0
Cul8rmom1
Cul8rmom1

1 year ago

FYI if you disconnect the connections to the heating element the pump will stay on without having to let it heat up. Awesome post!! Also it looks like if you screw in or out the piece of the pump you can adjust the flow rate.

image.jpgimage.jpg
0
DavidN71
DavidN71

2 years ago

Thanks, our church has one for plays. The fog solution is organic and the safe version of glycol antifreeze, so it does caramalize eventually. The fog and cleaning solutions are sold separate from the machine and someone didn't read the instructions and clean out the machine before storing it away. Once I followed your instructions the pump works again. If you can't hear the pump, it's stuck. Otherwise it makes a clearly audible clicking sound. Thanks again.

0
oysterrancher
oysterrancher

2 years ago

Great post. My over 10 year old machine stopped working this Halloween. The pump wasn't making noise so I assumed it was toast. I went and bought another fogger, but wasn't very happy with its performance(The Fog Machine, $28.88 at Wamart). Today had time to investigate further. Found your post while looking online for parts. Took it apart, cleaned it, seems to be working great. Not sure exactly what was wrong, but it did the trick. Thanks.

0
sgreen
sgreen

4 years ago

I have the same one, I will take it apart and see if it's the same problem.