Intermittent ballast pumps - fast fill

[bbenj10]

We have a 2023 X-Star and are also having continous issues with the ballast pumps. Sometime between 2018 and 2022, they went from 8 pumps for the four ballast zones to only 6. So now only the rear Port and Starboard zones have the second pump on them to provide a bit of redundancy in the system in case one pump fails.

I really like that you can still use the ballast if one pump is down, but now I have both pumps not working in the Starboard zone. Left my tank and bag full on the water. I pulled the hard tank vent to the soft bag to at least drain the entire soft bag to the bilge, but didn't want to try to break the pump to hose seal in case it was the relays. The boat is sitting at the dealership now for them to diagnose and hopefully get us back on the water quickly.

Pretty suprising / disappointing that a new boat has 3 of the 6 ballast pumps failed on it with only 100 hours of use. I checked all the breakers as well and none were pushed out to push back in, so hopefully it's a simple relay issue.

[stepke]

The issue was seemed to work itself out last fall, so I didn't do anything except tapping on the relays. This problem has returned this year. The top pump is having issues on fill only. I swapped the wiring between the the two starboard pumps and the issue followed to the other pump. I suspect the fill relay is bad. I have attached a picture of the relay module, which appears to be potted in rubber. Am I correct in assuming that I have to replace the entire module and that there isn't a way to replace only the one bad relay?

My port side FF pumps aren't working (2022, X24), and the fuses are NOT tripped. I would like trying to tap on the relays to see if that would "fix it". Could you indicate where they are located? I am searching for a diagram or pictures online for their location but cannot find it.

[Jacrews]

I haven’t replaced mine yet. I have been running with the single pump filling and just using the override button until water flows out the overflow. I need to order the relay assembly. I found it for $434.99 on Inboard Garage. I wish there was a way to replace one single relay instead of the entire assembly. As for the location, I can’t find the relay assembly for the forward pumps either.

[jackpine]

FWIW: Replacing the ballast relays appears to have corrected the port side ballast emptying issue. Now to clean up the gallons of water it just dumped in my garage...

It looks like the same MC part is used for all of the ballast pumps on my 8 pump XStar, although I haven't been able to find the relays for the forward pumps... I'm guessing it is almost as much fun to access as the forward pump impellers.

[jackpine]

I am having similar issues with my 2018 'Star. The problem follows the relay connector and I've verified the pumps are fine. Sadly I've already replaced one of the pumps thinking it was the pump. I guess now I have a spare pump

Did you end up replacing the relay entire assembly and did that get you back on the water?

I'm betting I've had this issue since I've had the boat... it has always listed to port and port ballast never seems to empty completely.

[Jacrews]

The issue was seemed to work itself out last fall, so I didn't do anything except tapping on the relays. This problem has returned this year. The top pump is having issues on fill only. I swapped the wiring between the the two starboard pumps and the issue followed to the other pump. I suspect the fill relay is bad. I have attached a picture of the relay module, which appears to be potted in rubber. Am I correct in assuming that I have to replace the entire module and that there isn't a way to replace only the one bad relay?

[tchur1]

Check the relays for the pumps. I had a similar issue on mine last season where they would intermittently work and not work. Hit either fill/drain (depending on tank level) and tap the relay connected to those pumps, they get stuck and when you tap them with a wrench it can free them and they start working. I ended up just replaced the relays on both port and starboard sides because they are cheap and my pumps have all run great since.

[jpwhit]

Sounds like the run-dry protection circuit that's built into the Johnson 30 GPH pump is tripping. I've never had the need to dig into one of those pumps to see how the run-dry protection works, but I always assumed its temperature based. Those pumps need a lot of water moving through them to stay cool. I guess in theory the issue could be as simple as the impeller needs to be replaced because the old one isn't drawing enough water through the pump. But for that to be the case, the impeller would need to be intact enough to load the pump, but at the same time does not move enough water to keep the pump cool. A lot of time when impellers are worn out, they also don't put a lot of load on the pump motor. In that case they don't typically overheat.

I would start by pulling all the impellers w/o mixing up which impeller goes with which pump. Then you can compare the conditions of the impellers and you can also reach in and feel how easily the motor shaft turns. The issue could also be that water has gotten into the motor bearing and they are dragging. That'll definitely cause the pump to overheat. That wouldn't happen as much if MasterCraft mounted the pumps as Johnson recommends with the motor up and the pump housing facing down.

[Jacrews]

2018 Xstar. I noticed that my starboard ballast wasn’t filling nearly as fast and sounded quiet. I popped the hatch and noticed that the top starboard ballast pump was running, but not the bottom. After the pumps turned off, I did a manual empty and the bottom starboard pump turned on. After that stopped (30 sec), I did another manual empty because the bag still had water in it. Both starboard pumps ran this time…. Another bit of info: my batteries are original and I was planning on replacing them in spring. Last weekend I got a “starting battery low, start boat to recharge” or something similar. From what I understand (if I recall correctly), the ballast pumps pull from the alternator and the battery. Could this be the issue, or do you suspect something else? No breakers are tripping, and the impellers were replaced 25 hours ago.