Operating Instructions & Parts Manual
FW0154
0907
Supersedes
0306
Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product
described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in per-
sonal injury and/or property damage! Retain instructions for future reference.
Pressure Booster Pumps
Description
Unpacking
Pressure booster pumps increase water pressure from city mains or private water sys-
tems. Applications include providing high water pressure for washing buildings, dairy
walls or floors, hog parlors, poultry houses, rinsing or spray cooling equipment, lawn
sprinkling and insecticide spraying. Stainless steel models can handle salt-water and
contaminated water in reverse osmosis filter and other aggressive water applications.
When unpacking the unit, inspect care-
fully for any damage that may have
occurred during transit.
NOTE: Use pump with clear water
only.
Single-phase models are equipped with a capacitor start, thermal protected motor.
Three-phase models require separate overload protection.
H
Inlet I
Discharge J
G
D
A
B
C
E
F
Figure 1
IL0391
60 Hz Motor Driven Pump Dimensions (See Figure 1) •
Chart A
Stainless
Powder-Coated Cast Iron
Fitted
Dimensions In Inches
Lbs. Ship
Steel Fitted Cast Iron Fitted
Wt.
A
B
C
D
E
F
G
H
I
J
PB0508S031
PB0512S051
PB0516S071
PB0712S071
PB1014S101
PB1016S151
PB1914S201
PB2711S201
PB3506S201
PB2714S301
PB3508S301
-
PB0508C031
PB0512C051
PB0516C071
PB0712C071
PB1014C101
PB1016C151
PB1914C201
PB2711C201
PB3506C201
PB2714C301
PB3508C301
-
PB0508A031† 3-1/4 3-3/4 10-3/16 3-7/8 6-1/2 19-15/16 7-3/8 1-7/16 3/4 3/4
35
38
43
42
48
51
51
52
51
54
53
57
57
58
58
PB0512A051† 3-1/4 3-3/4 13-3/8
PB0516A071 3-1/4 3-3/4 16-1/2
PB0712A071 3-1/4 3-3/4 13-3/8
3-7/8 6-1/2 23-3/8
3-7/8 6-1/2 27
3-7/8 6-1/2 23-7/8
7-3/8 1-7/16 3/4 3/4
7-3/8 1-7/16 3/4 3/4
7-3/8 1-7/16 3/4 3/4
7-3/8 1-7/16 3/4 3/4
PB1014A101 3-1/4 3-3/4 16-5/16 3-7/8 6-1/2 27-1/4
PB1016A151 3-1/4 3-3/4 17-5/8
PB1914A201 3-1/4 3-3/4 18-1/8
PB2711A201 3-1/4 3-3/4 15-3/8
3-7/8 6-1/2 29-3/16 7-3/8 1-7/16 3/4 3/4
3-7/8 6-1/2 29-11/16 7-3/8 1-7/16 3/4 3/4
3-7/8 6-1/2 27-1/2
7-3/8 1-7/16
7-3/8 1-7/16
1
1
1
1
2
2
2
2
1
1
1
1
2
2
2
2
PB3506A201 3-1/4 3-3/4 13-15/16 3-7/8 6-1/2 25-7/8
PB2714A301 3-1/4 3-3/4 18-1/2
PB3508A301 3-1/4 3-3/4 17-1/8
PB5504A201 3-1/4 3-3/4 13-3/4
PB5506A301 3-1/4 3-3/4 18-1/16 3-7/8 6-1/2 30-3/16 7-3/8 2-1/8
PB8504A201 3-1/4 3-3/4 16-1/2
3-7/8 6-1/2 30-9/16 7-3/8 1-7/16
3-7/8 6-1/2 29-3/16 7-3/8 1-7/16
3-7/8 6-1/2 25-15/16 7-3/8 2-1/8
-
-
-
-
-
-
3-7/8 6-1/2 28-5/8
7-3/8 2-1/8
7-3/8 2-1/8
PB8505A301 3-1/4 3-3/4 19-5/16 3-7/8 6-1/2 31-1/2
50 Hz Motor Driven Pump Dimensions (See Figure 1) •58
PB0508Y031
PB0514Y051
PB0714Y071
PB1020Y101
PB1023Y101
PB2717Y201
-
-
PB0508X031 3-1/4 3-3/4 10-3/16 3-7/8 6-1/2 20-3/16 7-3/8 1-7/16 3/4 3/4
PB0514X051 3-1/4 3-3/4 14-7/16 3-7/8 6-1/2 25-7/16 7-3/8 1-7/16 3/4 3/4
PB0714X071 3-1/4 3-3/4 14-15/16 3-7/8 6-1/2 25-15/16 7-3/8 1-7/16 3/4 3/4
PB1020X101 3-1/4 3-3/4 21-11/16 3-7/8 6-1/2 33-5/16 7-3/8 1-7/16 3/4 3/4
34
41
47
53
55
56
52
54
56
59
-
-
-
PB1023Z101
PB1023X101 3-1/4 3-3/4 24-3/8
3-1/4 3-3/4 21-5/16 3-7/8 6-1/2 33-7/16 7-3/8 1-7/16
PB3508X151 3-1/4 3-3/4 16-13/16 3-7/8 6-1/2 29-11/16 7-3/8 1-7/16
3-7/8 6-1/2 36
7-3/8 1-7/16 3/4 3/4
-
-
-
1
1
1
1
PB1021Y101
PB1920Y151
-
-
-
-
-
-
3-1/4 3-3/4 22-1/2
3-1/4 3-3/4 24-1/16 3-7/8 6-1/2 34-3/8
3-1/4 3-3/4 26-1/8 3-7/8 6-1/2 37-3/16 7-3/8 1-7/16 3/4 3/4
3-7/8 6-1/2 34-3/16 7-3/8 1-7/16 3/4 3/4
7-3/8 1-7/16 3/4 3/4
PB1922Z201
(*) NOTE: Figure 1, holes in mounting base are open slotted 3/8” wide x 1/2” long; dimension A & B are centerline from these
open slotted holes. These holes are suitable for 1/4 to 3/8” bolts.
Dimensions also apply to three phase models.
(†) Equipped with carrying handle. 132079 handle available as an option on other models. Add 1-3/8” to “G” if handle is included.
1
132934
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Three Phase Motor Data
Chart D
Three Phase† 60/50 Hz 3450/2850 RPM Capacitor Start
Factory
Connected
Motor
Service Factor Motor
Amps
Locked Rotor Motor
Amps
Motor
Voltage
HP
Code Letter
230V
460V
230V
460V
Voltage
3/4
1
1-1/2
2
208-230/460
208-230/460
208-230/460
208-230/460
208-230/460
230V
230V
230V
230V
230V
3.5
4.5
5.7
7.4
9.8
1.75
2.25
2.85
3.70
4.90
19.0
26.9
33.5
44.0
48.0
9.5
K
K
K
K
D
13.5
16.8
22.0
24.0
3✝✝
✝✝3 HP, 3 Phase motor operable on 60Hz only.
Material Construction
Chart E
Component
Standard Models*
Stainless Steel Models
Motor
Rear access - Nema 56J face
Rear access - Nema 56J face
Bearings
Ball-ball, permanently lubricated
Ball-ball, permanently lubricated
Impellers
Noryl with 304 stainless steel bearing insert
Noryl with 304 stainless steel bearing insert
Diffuser
Noryl
Noryl
Diffuser plates
Pump shaft
Delrin
Delrin
416 Stainless steel
316 Stainless steel
304 Stainless steel
Cast iron
304 Stainless steel
316 Stainless steel
304 Stainless steel
304 Stainless steel
Viton
Pump shaft coupling
Pump shell
Discharge & inlet casting
O-Rings
Buna-N
Seal composition
Carbon-silicon carbide, stainless steel spring
and Buna-N
Carbon-silicon carbide, stainless steel spring
and Viton
*Models with powder coated inlet & discharge also available.
Minimum Wire Size Chart (Gauge)
Chart F
Distance In Feet From Motor To Service Panel
Motor
HP
Breaker Size
(Amps)
Volts
Phase
0-50
50-100
100-150
Wire Size
14/14
12/14
10/14
10/12
6/12
150-200
200-300
1/3
1/2
3/4
1
115/230
115/230
115/230
115/230
115/230
115/230
230
1
1
1
1
1
1
1
3
3
3
3
3
14/14
12/14
12/14
10/14
10/12
10/12
10
14/14
12/14
12/14
10/14
8/12
12/14
12/14
10/12
8/12
12/14
10/14
8/12
15/15
20/15
20/15
30/15
30/20
30/20
30
6/10
11/2
2
*/10
*/10
8/12
6/12
*/10
*/10
3
10
10
10
8
3/4
1
230/460
230/460
230/460
230/460
230/460
14/14
14/14
14/14
14/14
14/14
14/14
14/14
14/14
14/14
14/14
14/14
14/14
14/14
14/14
14/14
14/14
14/14
12/14
12/14
12/14
14/14
12/14
12/14
10/12
10/12
15/15
15/15
15/15
15/15
15/15
11/2
2
3
(*) Not economical to run in 115V, use 230V.
3
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9. Do not insert finger or any object into pump or motor
openings.
10. Secure the discharge line before starting the pump. An
unsecured discharge line will whip, possibly causing per-
sonal injury and/or property damage or puncture.
General Safety Information
Carefully read and follow all safety instructions in
this manual and on pump. Keep safety labels in good
condition. Replace missing or damaged safety labels.
Do not touch an operating motor or
engine. They are designed to operate at high temperatures.
This is a SAFETY ALERT SYMBOL. When you see this
symbol on the pump or in the manual, look for one of the
following signal words and be alert to the potential for per-
sonal injury or property damage.
!
This product contains chemicals known to
the State of California to cause cancer and birth defects or
other reproductive harm.
Warns of hazards that WILL cause serious
personal injury, death or major property damage if ignored.
!
Risk of Electric Shock. This pump has not
been investigated for use in swimming pool areas.
NOTE: Pumps with the “CSA-CUS” mark are tested to UL stan-
dard UL778 and certified to CSA standard C22.2 No. 108.
!
Warns of hazards that CAN cause serious
personal injury or death, if ignored.
Warns of hazards that MAY cause minor
personal injury, product or property damage if ignored.
Pre-Installation
IMPORTANT: Indicates factors concerned with operation,
installation, assembly or maintenance which could result in
damage to the machine or equipment if ignored.
NOTE: Indicates special instructions which are important but
are not related to hazards.
HANDLING
1. Use handle supplied to lift pump.
2. Avoid impact on pump or motor. In particular, avoid
impact on discharge end of pump or rear motor access
cover.
!
LOCATION
Wire motor for correct voltage. See
“Electrical” section and Motor Data Charts
C&D of this manual, and motor nameplate.
!
In any installation where property dam-
age and/or personal injury might result from an inoperative
or leaking pump due to power outages, discharge line block-
age, or any other reason, a backup system(s) should be used.
1. Locate pump as close to the fluid source as possible, keep-
ing the inlet pipe short as possible.
2. Place unit where the pump and piping are protected from
the weather and extremes of heat, humidity and below
freezing temperatures.
3. Mount unit in a dry location that is easily accessible for
inspection and maintenance. If a dry location is not avail-
able, mount it on a foundation well above the wet floor.
4. Allow ample clearance around unit for free air circulation.
SUCTION LIMITATIONS
Ground motor before connecting to
power supply.
Meet United States National Electrical
Code and local codes for all wiring.
Hazardous volt-
age. Can shock,
burn or cause
Do not handle a pump or pump motor
death. Ground
with wet hands or when standing on a wet
pump before con-
necting to power
supply.
or damp surface or in water.
Follow wiring instructions in this manual when connect-
ing to power lines.
1. Units are non self-priming.
2. Pressure booster pumps are not recommended for suction
lift applications.
!
Always disconnect power source before
performing any work on or near the motor or its connected
load.
PIPING
1. Use galvanized piping, rigid plastic or other suitable pipe
that will not collapse under suction or rupture due to pres-
sure.
Do not use to pump flammable or explosive fluids
such as gasoline, fuel oil, kerosene, etc. Do not use in flam-
mable and/or explosive atmospheres.
If hose is used, make sure it is the rein-
forced industrial type that is rated higher than the shutoff
pressure of the system. Ordinary garden hose will collapse
and starve the pump of water.
2. The diameter of the inlet and discharge pipe should be
no smaller than the corresponding ports of the pump (See
Figure 1). Smaller pipe will reduce the capacity of the
pump. Increase pipe size on long runs.
3. Avoid air pockets in inlet piping or air will accumulate at
high points, making priming difficult.
Hazardous pressure! Install pressure relief valve in
discharge pipe. Release all pressure on system before work-
ing on any component.
1. Make workshop child proof - use padlocks, master
switches; remove starter keys.
2. Wear safety glasses when working with pumps.
3. Wear a face shield and proper apparel when pumping
hazardous chemicals.
4. Use pipe compound on all joints and connections. Use
Teflon tape or plastic joint stik, on plastic pipe. Draw all
pipe up tightly.
4. Keep work area clean, uncluttered and properly lighted;
replace all unused tools and equipment.
IMPORTANT: The entire system must be air and water tight
for efficient/proper operation.
5. Provide guarding around moving parts.
6. Keep visitors at a safe distance from the work area.
7. Periodically inspect pump and system components.
8. Protect electrical cord. Replace or repair damaged or
worn cords immediately.
4
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No Air Leaks In
Inlet Pipe
Pipe Joint Compound
Will Damage Plastic
Installation
PUMP INSTALLATION
Sags Allow Air Pockets
No Sags
IMPORTANT: Pump is built to handle
clear water only; it is not designed to
handle water containing sand, silt or
other abrasives.
If Air Flows
Water
Won’t
1.Refer to Figures 6, 7, and 8 for typi-
cal installations.
IL0419
Support pump and
piping when assembling and when
installed. Failure to do so may cause
piping to break, pump to fail, motor
bearing failures, etc.
IL0418
If Air Pockets Form,
Water Won’t Flow
IL0420
Use Teflon Tape
Figure 3 - Inlet Pipe Must Not Leak
2. If the pump is used as part of a per-
manent installation, bolt to a rigid
foundation.
Figure 2 - No Air Pockets in Inlet Pipe
Mount pump in correct position or pump failure will result.
!
Use only compo-
nents that are rated for maximum pres-
sure pump can produce when used in
boosting system or any other system.
Do not exceed the total maximum
pressure boost as listed per model in
Performance Charts B.
Correct
Incorrect
PRESSURE BOOST SYSTEMS
1. On pressure boost systems, locate
the pump so that there will always
be a positive supply of water to the
pump (See Figures 6, 7 and 8).
2. For service convenience, install a
gate valve and union in the inlet
and discharge line.
IL0315
Figure 4A
Figure 4B
Do not use a globe
valve or other restricting type of valve
that will seriously restrict the pumps
discharge capacity.
SAND AND SEDIMENT TRAP FILTER
3. Install a check valve as shown in
Figure 6. Be sure check valve flow
arrows point in the direction of
water flow.
4. Whenever dirt, sand or debris is
present in the supply water, install a
strainer or filter on the inlet side of
the pump (See Figure 7).
Standard Pressure
Tank - 42 Gallon Or
Larger
Outlet
Inlet
NOTE: For heavy amounts of sedi-
ment, install a trap filter on the inlet
side of the pump (See Figure 5).
NOTE: Pressure gauges installed
before and after the filter will show
pressure differential indicating the
need for filter replacement or clean-
ing.
Clean Out
Sand Settles To The Bottom
IL0421
Figure 5
IMPORTANT: Clean all filters and strainers on a regular schedule.
5
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Pump used to boost incoming city pressure (automatic operation).
Installation (Continued)
5.A pressure gauge installed in the
inlet pipe close to the inlet port, (See
Figure 6) will show if enough water
is being supplied to the pump. See
Operation Section - Priming, Pressure
Boost Installations.
6. On installations that are using noz-
zles for mist spraying, install a filter
in the discharge plumbing to prevent
the nozzles from becoming plugged.
Multiple filters should be plumbed in
parallel.
Street Supply
Gate/Ball
Valve
(Normally
open)
Main Power Box
Check Valve
Union
Gate/Ball
Valve
(Normally
open)
To size tank
properly - Match
drawdown of
tank to capacity
of pump
Fuse
Box or
Switch
Check
Valve
Pressure
Gauge
Union
Union
Service Tee
!
Install a pressure
Inlet
Outlet
Pressure Switch
relief valve on any installation where
pump pressure can exceed the pressure
tank’s maximum working pressure or
on systems where the discharge line
can be shut off or obstructed. Extreme
over pressure can result in personal
injury or property damage.
Pressure
Switch
Pressure
Gauge
IL0422
This unit is not
waterproof and is not intended to
be used in showers, saunas or other
potentially wet locations. The motor
is designed to be used in a clean dry
location with access to an adequate
supply of cooling air. Ambient tem-
perature around the motor should
not exceed 104ºF (40ºC). For outdoor
installations, motor must be protected
by a cover that does not block airflow
to and around the motor. This unit is
not weatherproof nor is it able to be
submersed in water or any other liq-
uid.
Pressure
Relief
Valve
Drain
Figure 6
IMPORTANT: A contained air pressure tank and pressure switch is required to
keep the pump from rapid cycling and prevent the motor from over heating.
Install the tank and switch on the house side of system.
Pump used to boost water pressure in mist spray applications (automatic opera-
tion).
Fuse Box
or Switch
Pressure Gauge
Thermostat
To avoid dangerous or fatal elec-
trical shock, turn off power to motor
before working on electrical connec-
tions.
Gate/Ball Valve
From Water Source
Line Filter
Pressure
Relief
Valve
Supply voltage must be within
10% of nameplate voltage. Incorrect
voltage can cause fire or seriously
damage motor and voids warranty. If
in doubt, consult a licensed electrician.
Gate/Ball Valve
(Normally open)
Solenoid
Valve
Use wire size specified in wiring
Chart F. If possible, connect pump
to a separate branch circuit with no
other appliances on it. If motor wiring
diagram differs from diagram shown
below, follow diagram on motor.
To Nozzles
To Drain
IL0423
Figure 7
NOTE: Install solenoid valve on discharge side of pump.
IMPORTANT: Clean all filters and strainers on a regular schedule.
6
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Pump used to boost incoming pressure from a wall hydrant (manual operation).
Installation (Continued)
Hose Adapter
Wall Hydrant
!
Ground motor
Pressure Gauge
before connecting to
electrical power sup-
ply.
Pressure
Relief Valve
Service Tee
Hose Adapter
Failure to ground
motor can cause
Inlet
High Pressure Reinforced Hose
severe or fatal electri-
cal shock hazard.
Hazardous
voltage. Can
Outlet
shock, burn or
cause death.
Ground pump
before connecting
to power supply.
Do not ground to
a gas supply line.
Spray
Nozzle
IL0424
High Pressure Reinforced Hose
Figure 8
Proper rotation of
pump impeller is critical on three phase
motors. See Motor Rotation under
Operation section and Figure 12.
230 Volts
Single Phase
115 Volts
Single Phase
WIRING
Line
Line
1. Install, ground, wire and maintain
this pump in accordance with your
local electrical code and all other
codes and ordinances that apply.
Consult your local building inspector
for local code information.
2. Ground the pump permanently using
a wire of size and type specified
by local or United States National
Electrical Code. Do not ground to
a gas supply line.
3.Connect ground wire first. Connect
to ground first, then to green ground-
ing terminal provided on the motor
frame, identified as GRD. Ground con-
nection MUST be made to this termi-
nal. Do not connect motor to electrical
power supply until unit is permanently
grounded; otherwise serious or fatal
electrical shock hazard may be caused.
4. Connect the other end of the ground
wire to a properly grounded service
panel or to a control panel ground
bar if it is connected to the power
supply ground.
L1
L1
L2
L2
A
B
A
B
Y
E
L
L
O
W
W
H
I
T
E
G
R
A
Y
R
E
D
T
A
N
Y
E
L
L
O
W
W
H
I
T
E
G
R
A
Y
R
E
D
T
A
N
IL0180
NOTE: Dual voltage motors, change the red and
gray wire to the voltage required.
Figure 9 - Wiring Diagram for Single Phase 1/3 - 2 HP
Motors
230 Volts
Single Phase
Line
L1
L2
A
B
IMPORTANT: Check local and/or
United States National Electric Codes
for proper grounding information.
Y
E
L
G
R
A
Y
L
O
W
Make certain that
the power supply conforms to the elec-
trical specifications of the motor sup-
IL0181
NOTE: Single voltage (230V) motor, and can not be connected to 115V.
plied. See Motor Data Charts.
Figure 10 - Wiring Diagram for Single Phase 3 HP Motors
7
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Installation (Continued)
5.Specific Wiring Procedure (Refer to Figures 9, 10, & 11
and Minimum Wire Size Chart).
a. Select the voltage you are to use, either 115V or 230V
single phase, 230V or 460V three phase.
Low Voltage 230V
High Voltage 460V
5
4
5
6
4
6
b. The 1/3, 1/2 and 3/4 HP single phase pumps are factory
connected for 115V at the motor. The 1, 11/2, 2 and 3
HP pumps are factory connected for 230V at the motor.
Three phase models are factory connected for 230V at
the motor.
c. If the motor wiring must be changed to conform to your
specific voltage requirements then the motor, pressure
switch or other controls should be rewired to conform
to one of the wiring diagrams (either 115V or 230V,
single phase; 230V or 460V, three phase). Single phase 3
HP motors are 230V only and cannot be wired for 115V
service.
8
7
9
8
7
9
1
1
3
2
2
3
L2
L1
L2
L1
L3
L3
IL0182
1 - Tan
4 - Yellow
7 - Purple
8 - Gray
2 - Red
5 - Black
6 - Blue
3 - Orange
9 - White
d. The motor wiring diagrams are Figures 9, 10, & 11 and
also are located on the motor label of the pump.
CONNECTION FOR 3 PHASE, 9 LEADS. IF YOUR 3 PHASE
LEADS ARE COLOR CODED, MATCH NUMBER ABOVE TO THE
CORRESPONDING COLOR.
6. Remove the rear access cover of the motor.
7. Make the wiring change and replace the rear access cover.
NOTE: To reverse rotation, interchange any two incoming lines
!
Replace rear access cover before starting
(Power) leads.
or operating pump. Failure to do so can result in personal
injury.
Figure 11 - Wiring Diagram for Three Phase Motors
IMPORTANT: Do not use an extension cord or splice wires.
Joints should be made in an approved junction box. If the
above information or the following wiring diagrams are con-
fusing, consult a licensed electrician.
8. All units are not supplied with pressure switches, float
devices, on/off switches, or the like (control devices).
Controls should be wired in at this time, utilizing whatever
instructions come with the controls. All units supplied
with cords, will run whenever cord is plugged into power
and will turn off whenever cord is disconnected from
power.
Operation
Unit must be full of fluid before operat-
ing. Do not run dry, or against a closed discharge. Do not
pump dirty water or abrasive liquids. To do so will cause
pump failure and will void the warranty.
VALVES
The inlet valve should be in the full open position and the
discharge valve should be partially open, permitting some
back pressure to be exerted against the pump when starting
up. Open valve after start up is completed.
PRIMING
MOTOR PROTECTION
All single phase motors have built in thermal protection for
all voltages. The overload protects the motor against burn-
out from overload of low voltage, high voltage and other
causes. The device is automatic and resets itself once the
temperature has dropped to a safe point. Frequent tripping
of the device indicates trouble in the motor or power lines
and immediate attention is needed.
NOTE: Before starting the pump it is absolutely necessary
that both the pump and the inlet pipe be completely
filled with water.
PRESSURE BOOST INSTALLATIONS
Priming is automatic when pump is connected to a pressure
source such as a hydrant or city main (See Figures 6, 7 & 8).
1. Open valves or nozzle on inlet and discharge side of pump.
!
Never examine, make wiring changes or
touch the motor before disconnecting the main electrical
supply switch. The thermal device may have opened the
electrical circuit.
2. To relieve trapped air, allow water supply to run a mini-
mum of 30 seconds before starting the pump.
IMPORTANT: An adequate flow of water going into the
pump is required so that the pumps impellers and shaft seal
do not run dry and fail.
3. If you installed a pressure gauge at the pump inlet, a read-
ing of 2 psi minimum should show whenever the pump is
in operation (See Figures 6, 7 & 8).
Three phase motors do not have a built in thermal protec-
tion. It is recommended that a properly sized magnetic or
manual starter (both with properly sized heaters) be used
with all three phase motors. Install starters following instruc-
tions of the starter manufacturer. See Motor Rotation under
Operation Section for changing rotation on three phase
motors.
All motors (single and three phase) should be equipped
with a correctly fused disconnect switch to provide protec-
tion. Consult local or United States National Electric Codes
for proper fuse protection based on motor data chart (See
Charts C, D and Wire chart F).
This reading insures that there is an ample supply of water
into the pump inlet housing.
8
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bling, reapply thread sealer.
PUMP DISASSEMBLY
To disassemble the pump, refer to the exploded parts view,
Figures 17 & 18 Tools Required
• Block of wood (2” x 4” x 12”)
Piece of 3/4” pipe (12” to 24” long)
• Pipe wrench
• Strap wrench
• 1/4” Dowel rod (about 24” long)
• 9/16” Open end wrench
• 3/8” Open end wrench
1. To stabilize pump during disassembly, place block of wood
underneath pump barrel.
2. Thread pipe into pump inlet port. This acts as a handle.
3. Using the pipe wrench, remove the discharge head, turn-
ing CCW (counter clockwise).
4. With the strap wrench, loosen the barrel, turning CCW
(counter clockwise). DO NOT use pipe wrench on pump
barrel.
Operation (Continued)
MOTOR/PUMP ROTATION
1. Single phase models are one (1) rotation only (counter-
clockwise when facing the pump end) and cannot be
reversed.
2. Proper rotation of pump impeller is critical for three phase
pumps. Pump motor should turn counterclockwise (CCW)
when facing pump end. Momentarily “bump” (apply
power for less than a second) the motor to check for
proper rotation. To change rotation on three phase units,
interchange any two (2) incoming line (power) leads.
Do not go over recommended maximum
operating pressure (see Specifications), while maintaining
minimum flow of 1.5 GPM thru the pump. Do not restrict
the inlet line to the pump.
If driver (electric motor) is overloaded, a valve can be
installed in the discharge line to increase the back pressure
and reduce driver loading.
5. Holding the impeller stack in place, position pump in
upright position, standing unit on the motor end cover.
6. Use the 1/4” dowel rod to hold the stages down and in
place on the pump shaft. Remove pump barrel.
7. Slide the stages off the pump shaft onto the 1/4” dowel
rod. Leave stages on rod and carefully set aside.
NOTE: There may be some small .010” shim washers located
next to the pump shaft coupling. Keep these shims for re-
assembly.
START - UP PROCEDURE
Once the preceding instructions have been completed, the
pump can be started.
1. During the first few hours of operation, inspect the pump,
piping and any auxiliary equipment used in connection
with the unit.
2. Check for leaks, excessive vibration or unusual noises.
8. Through the side opening of the mounting frame, hold
the motor shaft with 9/16” wrench. Remove the shaft and
coupling from the motor using the 3/8” wrench on the hex
shaped pump shaft.
NOTE: If the hex shaft comes free, leaving the coupling
attached to the motor, use vise grips to free the coupling.
MECHANICAL SEAL REPLACEMENT
1. Follow instructions under “Pump Disassembly”.
2. Remove the mechanical seal assembly.
a. The rotary portion of the seal assembly (carbon ring,
Buna-N gasket and spring will slide easily off the end of
shaft).
IL0539
Figure 12 - Correct Motor/Pump Rotation (all units)
NOTE: See rotation arrow on inlet casting.
b. Using two (2) screwdrivers, pry the ceramic seal and rub-
ber gasket from the recess of the mounting ring (See
Figure 14).
Maintenance
Disconnect power supply and depressur-
ize system before servicing pump or removing any compo-
nent.
The precision lapped faces of the mechan-
ical seal are easily damaged. Handle the replacement seal
carefully. Short seal life will result if seal faces (ceramic &
carbon) are nicked, scratched or dirty.
3. Clean the seal cavity of the mounting ring and the motor
thoroughly.
ROUTINE
Pump should be checked routinely for proper operation.
Replace or clean all filters and line strainers on a regular
basis.
4. Wet outer edge of rubber cup on ceramic seat with liquid
soap solution. Use sparingly (one drop only).
DRAINING
This pump cannot be completely drained because of internal
design. Most of the liquid can be drained by tilting the dis-
charge forward after removing discharge casting; or, the liq-
uid can be drained through the inlet port. Store in heated
areas.
CLEANING
If used for spraying insecticides, pump should be thoroughly
flushed with clean water after using.
LUBRICATION
The motor has prelubricated bearings. No lubrication is
required.
SERVICING THREE-PHASE UNITS
Loctite (thread sealer) is used on the threads between the
motor shaft and the pump shaft coupling. When reassem-
9
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2. Remove cap screws that connect the motor to the
mounting ring and pull motor away.
3. Replace motor with standard Nema 56J jet pump motor
by positioning motor against the mounting frame and
assembling with four (4) cap screws.
IMPORTANT: Because damage to the shaft seal can occur in
disassembly, a new seal will be necessary.
PUMP REASSEMBLY
Before reassembling the pump, carefully inspect the com-
ponent parts of the cartridge (stage) assembly, looking for
damage, wear or heat distortion. Pay careful attention to
spacing direction of components, and location of shims.
Refer to Figure 16 for proper facing and parts arrangement.
If damage to Stage components is evident, a complete car-
tridge assembly or individual stage assemblies are available
for replacement (See Replacement Parts List).
1. Reassembly should follow the reverse order of the disas-
sembly procedure with special care given to replacement
of the rotary seal.
Maintenance (Continued)
NOTE: Liquid soap solution - one drop of liquid soap com-
bined with one teaspoonful of water.
5. With thumb pressure, press ceramic seal half firmly and
squarely into seal cavity. Polished face of ceramic seat
is up. If seal will not seat correctly, remove, placing seal
face up on bench. Reclean cavity. Seal should now seat
correctly (See Figure 14).
6. If seal does not seat correctly after recleaning cavity,
place a cardboard washer over polished seal face and
carefully press into place using a piece of standard clean
3/4” pipe as a press (See Figure 15).
IMPORTANT: Do not scratch seal face.
7. Dispose of cardboard washer and recheck seal face to
be sure it is free of dirt, foreign particles, scratches and
grease.
8. Inspect shaft to be sure it is free of nicks and scratches.
9. Apply liquid soap solution sparingly (one drop is suffi-
cient) to inside diameter of rubber rotating member.
10. Slide rotating seal member (carbon face down toward
ceramic face) and spring over the shaft.
IMPORTANT: Do not nick or scratch carbon face of seal
when handling.
MOTOR REPLACEMENT
The motor can be replaced with any standard Nema 56J jet
pump motor (of proper HP for each pump) by referring to
the following instructions.
1. Follow steps as outlined under Rotary Seal Replacement
and Pump Disassembly.
2. Check top and bottom of o-rings for damage. It is recom-
mended that new o-rings be used.
3. Do not use pipe compound of Teflon tape on barrel
threads. The o-rings will prevent pump from leaking.
4. After pump is reassembled, tighten the discharge head to
a torque of 45-50 ft/lbs. If torque wrench is not available,
tighten firmly but avoid distortion or damage to plastic
internal parts.
5. After reassembly, apply power momentarily to unit (15 to
30 seconds). The pump and motor should rotate freely or
with a light rubbing.
3/4” Pipe
Press Carefully
Cardboard
Washer
Protects Seal
Face
Seal
Seal Cavity
IL0554
Figure 13 - Remove Mechanical Seal
Figure 14 - Press In Seal
Figure 15 - If Necessary, Press With
Cardboard And Pipe
10
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Troubleshooting Chart
Symptom
Possible Cause(s)
Corrective Action
Pump won’t
start or run
at full speed
1. Blown fuse or open circuit breaker
1. Replace fuse or close circuit breaker. See wire size chart for
proper break/fuse size
2. Power supply in OFF position
2. Turn power on
3. Low voltage
3. Incorrect voltage at motor (check volt-
age with motor running)
a. Voltage must be within 10% of motor rated voltage.
Check incoming voltage. Contact power company
b. Make certain that voltage of motor matches voltage of
power supply. See motor name plate and motor wiring
diagrams
c. Check wire size from main switch to pump. See wire
size chart for correct wire size
4. Loose, broken or incorrect wiring
5. Defective motor
4. Rewire any incorrect circuits. Tighten connections, replace
defective wires
5. Replace motor
6. Pump hydraulic components clogged/
worn/damaged
6. Replace worn parts or entire pump. Clean parts if required
Pump oper-
ates, but
delivers little
or no water
1. Manual or solenoid valves plumbed
into system restricting flow
1.
a
Check all valves on pump inlet and discharge sides of
system to be sure they are opened properly to allow
flow to and from the pump
b. Bleed trapped air in pump which keeps water from
reaching the pump. (Normally
due to closed valve in discharge plumbing)
2. In-line filter restricting flow
3. Low line voltage
2. Check all in-line filters to be sure they are not plugged or
restricted
3. See low line voltage corrective action (above)
4. Inadequate water supply to booster
pump
4. Check pressure on inlet side of booster to be sure positive
pressure is maintained to the booster pump
5. Undersized piping
5. Replace undersized piping
6. Leak on inlet side of system
6. Make sure connections are tight. Repair leaks as necessary
7. Clean, repair or replace as needed
7. Inadequate, defective or plugged foot
valve and/or strainer
8. Worn or defective pump parts or
pump.
8. Replace worn parts or entire plugged impeller Clean parts if
9. Suction lift too great
9. Pump should be operated under
flooded suction only
10. Pump not primed
10. Prime pump - Make certain inlet pipe is drawn up tight and
pump and pipe are full of water
11. Incorrect rotation, motor running
backwards
11. Reverse motor rotation can occur on three phase units. To
correct, interchange any two incoming power leads.
Excessive
noise while
pump in
1. Pump not secured to firm foundation
2. Piping not supported
1. Secure properly
2. Make necessary adjustments
3. Clean or correct
3. Restricted inlet line
4. Cavitation (noise like marbles in pump)
4. a. Reduce speed on direct drive
b. Increase inlet pipe size
c. Too viscous (material being pumped too thick
5. Replace bearings or motor
1. Replace shaft (rotary) seal
5. Worn motor bearings
Pump leaks
1. Worn mechanical seal (leaks at shaft)
2. Worn o-ring seals
2. Replace o-ring seals, located inside both ends of the stainless
steel shell
11
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Booster Pump Parts Drawing
1A
1
9
2
10A
5
7
1B
10
6A
6E
6D
8
6A
ITEM NO. DESCRIPTION
1
1A
1B
2
3
4
Motor
†Governor
†Switch Motor
Seal, Rotary
Barrel
Discharge Head
Discharge Bearing
O-ring (2)
Plate, Diffuser
Impeller
5
4A
4
6B
4A
5
6C
3
6A
6B
6C
6D
6E
7
8
9
10
10A
Diffuser
IL0593
Diffuser Bearing
Shim as Required
Shaft and Coupling Assembly
Mounting Ring
Hex Head Bolts (4)
†MotorAccess Cover
†Screws, Access Cover (2)
*See note below parts included in cartridge assembly.
†ODP Motor Only
Internal Parts Detail
IL0308
Figure 16 - Cartridge Assembly Includes Discharge Bearing, Shaft & Coupling Assembly, Diffuser Plate, Impellers, Diffuser
Bearings, Diffusers and O-rings
NOTE: Illustration shows only two stages. Pump has multiple stages. Individual parts are not available separately.
12
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FORM NO. FW0045
0907
SUPERSEDES 0206
PAGE 4-7A REPAIR PARTS
PRESSURE BOOSTER PUMP REPAIR PARTS
(For Pricing Refer To Repair Parts Price List)
Replacement Motors
9
10
IL0565
POWDER
COATED
STAINLESS
STEEL
POWDER
COATED
STAINLESS
STEEL
ITEM REPLACEMENT MOTORS
QTY
CAST IRON
CAST IRON
SINGLE PHASE 60 HZ
96J103
THREE PHASE 60 HZ
ODP NEMA J 1/3 HP
ODP NEMA J 1/2 HP
ODP NEMA J 3/4 HP
ODP NEMA J 1 HP
ODP NEMA J 1-1/2 HP
ODP NEMA J 2 HP
ODP NEMA J 3 HP
Motor Cover w/Screws
Screws, Motor Cover
96J103
96J105
96J107
96J110
96J115
96J120
96J630
136132R
136133
96S103
96S105
96S107
96S110
96S115
96S120
96S630
136132R
136133
96J105
96J107
96J110
96J115
96J120
96J630
136132R
136133
96J305
96J307
96J310
96J315
96J320
96J330
136132R
136133
96J305
96J307
96J310
96J315
96J320
96J330
136132R
136133
96S305
96S307
96S310
96S315
96S320
96S330
136132R
136133
9
1
10
*
1
2
SINGLE PHASE 50 HZ
96J003
THREE PHASE 60/50 HZ
ODP NEMA J 1/3 HP
ODP NEMA J 1/2 HP
ODP NEMA J 3/4 HP
ODP NEMA J 1 HP
ODP NEMA J 1-1/2 HP
ODP NEMA J 2 HP
Motor Cover w/Screws
Screws, Motor Cover
96J003
96J005
96J007
96J010
96J015
96J820
136132R
136133
96S003
96S005
96S007
96S010
96S015
96S820
136132R
136133
96J005
96J007
96J010
96J015
96J820
136132R
136133
96J305
96J307
96J310
96J315
96J320
96J305
96J307
96J310
96J315
96J320
96S305
96S307
96S310
96S315
96S320
136132R
136133
9
1
10
*
1
2
136132R
136133
136132R
136133
SINGLE PHASE 60/50 HZ
THREE PHASE 60/50 HZ
021011
TEFC NEMA J 1/2 HP
TEFC NEMA J 3/4 HP
TEFC NEMA J 1 HP
TEFC NEMA J 1-1/2 HP
TEFC NEMA J 2 HP
TEFC NEMA J 3 HP
020691
021008
021009
020692
020693
021010
020691
021008
021009
020692
020693
021010
021011
021012
020688
020647
020689
020690
021012
020688
020647
020689
9
1
020690
* Not Shown
13
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FORM NO. FW0046
0907
SUPERSEDES 0206
PAGE 4-8A REPAIR PARTS
PRESSURE BOOSTER PUMP REPAIR PARTS
(For Pricing Refer To Repair Parts Price List)
7
10
8
3
1
6
9
4
4
2
IL0565
POWDER
COATED
136905
STAINLESS
STEEL
136640
ITEM
DESCRIPTION
QTY
CAST IRON
1
2
Discharge Head 3/4” NPT
Mounting Ring 3/4” NPT
1
1
132000
132002
5 - 7 - 10 - 19 GPM,
60 HZ & 50 HZ
136904
136639
See
replacement
motors.
1
2
Discharge Head 1” NPT
Mounting Ring 1” NPT
1
1
136635
136634
137796
137794
139166
139100
27 - 35 GPM,
60 HZ & 50 HZ
1
2
Discharge Head 2” NPT
Mounting Ring 2” NPT
1
1
021585
021584
-
-
-
-
55 - 85 GPM,
60 HZ & 50 HZ
ITEMS 9 & 10
3
4
*
Seal, Rotary w/Spring
O-Ring
1
2
4
131100 †
131925 ■
121106
131100 †
131925 ■
121106
136682 ‡
136607 ▲
121106
ALL SERIES
60 HZ & 50 HZ
Hex Head Cap Screws 3/8” x 3/4”
(†) Buna N - Carbon/Silicon Carbide (‡) Viton - Carbon/Silicon Carbide (■) Buna N (▲) Viton (*) Not Shown
(8) 132079 Handle available as an option
CAST IRON CI
POWDER COATED PC
STAINLESS STEEL SS
DESCRIPTION MATERIAL
CI & PC
PB0508AXXX
PB0508CXXX
PB0508SXXX
PB0512AXXX
PB0512CXXX
PB0512SXXX
PB0516AXXX
PB0516CXXX
PB0516SXXX
PB0712AXXX
PB0712AXXX
PB0712SXXX
PB1014AXXX
PB1014CXXX
PB1014SXXX
PB1016AXXX
PB1016CXXX
PB1016SXXX
MATERIAL
ITEM
PART NUMBER
135163
132939
136683
133336
136636
132003
138447
138450
138446
138449
138448
134097
136684
133336
136636
132003
134998
136685
134996
136637
134997
135814
136686
135813
136638
135815
5
Cartridge Assembly ‡
SS
CI & PC
SS
135161
138938
135162
6
7
Shaft & Coupling Assembly
Barrel/Shell
CI, PC & SS
CAST IRON CI
PB1914AXXX
PB1914CXXX
PB1914SXXX
PB2711AXXX
PB2711CXXX
PB2711SXXX
PB2714AXXX
PB2714CXXX
PB2714SXXX
PB3506AXXX
PB3506CXXX
PB3506SXXX
PB3508AXXX
PB3508CXXX
PB3508SXXX
MATERIAL
POWDER COATED PC
STAINLESS STEEL SS
DESCRIPTION MATERIAL
CI & PC
ITEM
PART NUMBER
137222
139162
137221
139159
137223
135627
139163
136624
139157
135628
136629
138946
136628
137535
136630
136626
139164
136625
139156
136627
136632
139165
136631
139158
136633
5
Cartridge Assembly ‡
SS
CI & PC
SS
CI, PC & SS
6
7
Shaft & Coupling Assembly
Barrel/Shell
MATERIAL
ITEM
CAST IRON CI
DESCRIPTION MATERIAL
PB5504XX
PB5506XX
PB8504XX
PB8505XX
PART NUMBER
5
6
7
Cartridge Assembly ‡
Shaft & Coupling Assembly CI
Barrel/Shell
CI
022293
022289
022291
022294
022287
022292
022295
022288
138151
022296
022287
022290
CI, PC & SS
CAST IRON CI
PB0508XXXX
PB0508ZXXX
PB0508YXXX
PB0514XXXX
PB0514ZXXX
PB0514YXXX
PB0714XXXX
PB0714ZXXX
PB0714YXXX
PB1020XXXX
PB1020ZXXX
PB1020YXXX
PB1022XXXX
PB1022ZXXX
PB1022YXXX
PB1023XXXX
PB1023ZXXX
PB1023YXXX
MATERIAL
POWDER COATED PC
STAINLESS STEEL SS
DESCRIPTION MATERIAL
CI & PC
ITEM
PART NUMBER
135163
138150
138682
138149
138444
138151
021032
021033
138149
138444
138151
135907
138683
135906
138154
135098
135911
138684
135910
137103
135912
5
Cartridge Assembly ‡
SS
020280
020278
020278
020279
CI & PC
SS
CI, PC & SS
135161
138938
135162
6
7
Shaft & Coupling Assembly
Barrel
CAST IRON CI
PB1920XXXX
PB1920ZXXX
PB1920YXXX
PB2717XXXX
PB2717ZXXX
PB2717YXXX
PB3508XXXX PB3514XXXXT
MATERIAL
POWDER COATED PC
STAINLESS STEEL SS
DESCRIPTION MATERIAL
CI & PC
PB3508ZXXX PB3514ZXXXT PB1922ZXXX
PB3508YXXX PB3514YXXXT
PART NUMBER
ITEM
020982
020095
020971
020093
020094
020980
138949
020916
138948
138947
136632
139165
136631
139158
136633
021017
021026
021015
021020
021016
139435
*
139434
021425
139436
5
Cartridge Assembly ‡
SS
CI & PC
SS
CI, PC & SS
6
7
Shaft & Coupling Assembly
Barrel
(‡) Cartridge assembly includes: impellers, diffusers and shaft & coupling assembly. Components not available individually. Sold as assembly only.
14
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