Berkeley Pumper User manual

OWNER’S MANUAL
Pumper and Pumper PlusTM
©2005 BE784 (Rev. 9/2/08)
Models
P60R, P90R, PP60R and PP90R
Installation/Operation/Parts
For further operating, installation, or maintenance assistance:
Call 1-888-237-5353
293 Wright Street • Delavan, WI 53115

General Information / Installation 2
ENGINE PUMP SAFETY PRECAUTIONS:
Fire and explosion hazard. Gasoline can
explode. Store gasoline away from the engine. Add gaso-
line to the engine only when the engine is off.
Burn hazard. Hot surface.The engine gets
very hot during operation. Do not touch the engine sur-
faces. Keep children away. Allow the engine to cool
before moving it indoors.
Deadly fumes. Carbon monoxide. Never
run the engine in an enclosed space. Only use outdoors
with plenty of ventilation.
Pump only water with this pump.
MODELS AND TECHNICAL
INFORMATION
Technical Data
Priming Port: ........................................................2" NPT
Max Working Pressure .......................188 PSI (1300 kpa)
Water Temperature Range ...41° F - 104° F (5° C - 40° C)
Maximum Ambient Temperature ...............104° F (40° C)
as per engine manufacturer’s data
Model Information
APPLICATION
NEVER pump flammable or explosive chemicals such as
gasoline with this pump.
INSTALLATION
Preparation for operation
1. Read these instructions first.
2. Inspect your pump for shipping damage. Report any
damage to your Berkeley dealer.
3. Fill the engine crankcase with oil, as per the engine
manufacturer’s owner’s manual.
4. Fill the fuel tank with unleaded gasoline (gasoline
engine models), as per the engine owner’s manual.
5. Make sure the suction piping is free of air leaks and is
laid so that there can be no air locks.
6. Fit a strainer to the suction line
Pump Protection
Warranty of these pumps is void unless they are operated
in accordance with this owner’s manual and the
enclosed engine manufacturer’s owner’s manual.
The pumps should be protected from the weather, floods,
chemicals, dust, vermin, insects etc. If the pump has a
fixed location; it should be housed in a weather proof,
well-vented enclosure so that engine heat and exhaust
can escape. When bolted down, flexible mounts should
be used. Depending upon application they may not have
to be bolted down.
Suction
Hazardous Suction. Can trap persons
against suction inlet. Always use strainer on suction hose
to prevent entrapment.
To maintain optimum performance from your pump, the
suction pipe should be:
• Kept to the shortest length possible - place the pump
as close to the water as possible.
• Use reinforced crush-resistant (non-collapsible) hose
or pipe.
• Have all fittings be airtight
• Have flexible pipes rise gently from the water source
to the suction/
• Use inlet port without excessive dips and sharp
angles, to avoid air locks.
• Use pipes equal to or larger than the diameter of the
suction/ Inlet port.
• Use suction strainers to prevent foreign matter enter-
ing the pump.
• Where practicable, use suction floats to aid in the
performance of your pump, by keeping suction away
from the debris on the bottom of the dam or river.
• Ensure that the suction is completely submersed.
Pump Model HP Engine Fuel
P60R 6 Robin EX17 1 gal (3.6 L) gas
P90R 9 Robin EX27 1.6 gal (6 L) gas
Pump Model HP Engine Fuel
PP60R 6 Robin EX17 1 gal (3.6 L) gas
PP90R 9 Robin EX27 1.6 gal (6 L) gas
Single Stage Pump Models
Twin Stage Pump Models
Optional roll cage can be used with any model.

Installation / Operation 3
Discharge
The length and diameter of the discharge hoses will
affect the pressure and flow rate at which your pump
operates. Long pipe runs and small diameter pipes lower
pressure. Pressure ratings of all components must exceed
the maximum pressure of the pump by an appropriate
safety factor. We recommend the use of the Berkeley’s
own hose kit
• Suitable for either flexible or rigid piping.
• Models include 1-1/2" NPT side outlets.
• Models include 2" NPT front outlets.
• All have 2" priming inlets
OPERATION
Operation Guidelines
• Pumping water containing solids will reduce the life
of the pump, and may affect warranty
• Pumping chemicals or agricultural products may
affect the warranty. Please ask your Berkeley dealer
about viton seals.
• The pump should be drained after use and flushed
out with clean, fresh water. Flushing will extend the
pump’s life.
• Store your pump in a dry location.
• Service the engine as recommended in the engine
manufacturer’s owner’s manual.
• Drain the fuel if the pump will not be used for more
than two months. The engine will be difficult or
unable to start if the fuel is stale.
• Always use original service parts as supplied and rec-
ommended by Berkeley and the engine manufacturer.
Failure to do so may void warranty.
Operation Procedure
a) Connect suction piping, and ensure that the suction is
completely submerged.
b) Remove the priming plug and fill the pump with
water. Your pump is equipped with a suction flap
valve and is capable of drawing air out of normal size
suction pipes or hoses.
c) Replace the priming plug - screw it down tightly to
seal.
d) Follow Engine Manufacturer’s Instructions for starting
the engine.
If only a small amount of water is pumped, and then
flow stops, switch off the engine and check the suc-
tion pipe/hose assembly for possible air leaks. Repair
leaks before starting priming procedure again.
Berkeley Pumper™ single stage pumps, when filled with
water, will gradually draw air out of the suction line to a
maximum prime depth of 6m.
The Berkeley Pumper Plus™ Twin models will prime to a
maximum depth of 11.5 ft. (3.5m). If priming a long or
larger diameter pipe, additional water may have to be
added to the pump at 3-minute intervals.
• Switch off the engine each time.
• Do not remove any caps while the pump is operating.
• Ensure that your pump is filled with water before
operating.

Maintenance 4
Remove spark plug
wire from engine before working
on pump.
HOUSING REMOVAL
1. Remove the 4 suction flange
bolts using a 13mm socket.
2. Remove suction flange.
• Remove gasket and flap valve
assembly.
3. Remove the front bolt on both
sides of handle using a 19mm
socket or box wrench.
4. Remove handle
• Remove 4 bolts on the dis-
charge housing using a 13mm
socket.
• Remove housing & gasket.
5. Remove all casing bolts & nuts
using 14mm socket & box
wrench.
6. Remove casing from pump
• Remove drain plug from casing.
7. Gently pry the diffuser away from
the seal plate using a screwdriver.
Figure 1: Suction Flange Removal
Figure 7: Remove Diffuser
Figure 6: Remove Casing
Figure 5:Casing Nut Removal
Figure 4: Remove discharge
Assembly
Figure 3: Remove Front Bolts
Figure 2: Suction Flange Removal
Tools Required
1. 13mm socket
2. 14mm socket
3. 15mm socket
4. 19mm socket
5. 24mm socket
6. 14mm box wrench
7. Medium screwdriver
8. Hammer
9. Loctite No 124
Engine-Driven Pump
Disassembly: Single

Maintenance 5
8. Push the impeller wear ring out
of the diffuser by pressing with
your thumbs.
9. Remove the casing O-Ring from
diffuser and seal plate.
10.Gently tap the impeller counter-
clockwise using a hammer &
screwdriver and remove it from
the engine shaft.
• Ensure that the flat blade of
screwdriver is flat against
impeller vane.
11. Remove rotating mechanical seal
from back of impeller extension.
12.Remove the 4 bolts holding seal
plate to engine using a 13mm
socket and then remove seal
plate.
13.Remove bolt seals from seal
plate using a screwdriver.
• Turn the seal plate around and
remove the stationary ceramic
mechanical wear face.
Pump is now completely
disassembled.
Figure 13: Remove Bolt Seals
Figure 12: Seal plate Removal
Figure 11: Remove Rotating Seal
Figure 10: Remove Impeller
Figure 9: Remove casing O-Ring
Figure 8: Remove Impeller Wear
Ring

SINGLE ASSEMBLY
Remove spark plug
wire from engine before working
on pump.
1. Push ceramic wear face into seal
plate.
• Push bolt seals into seal plate.
• Do not use grease as a
lubricant.
2. When installing seal plate onto
engine ensure that slot in back of
seal plate is facing downward.
• This will allow water to drain
out of pump and not into
engine should seal failure
occur.
3. Insert one of the long casing bolts
into right hand centre seal plate
hole.
• Push spacer onto the 4 seal
plate bolts & apply Loctite
243 to the thread.
• Using 13mm socket tighten all
seal plate bolts firmly to
engine.
4. Fit casing O-Ring to seal plate.
5. Fit rotating section of mechanical
seal to extension on back of
impeller.
• Do not use lubricant on
mechanical seal faces.
6. Turn the impeller clockwise onto
the engine shaft until firm.
Maintenance 6
Figure 18: Install Rotating Seal
Figure 19: Install Impeller
Figure 17: Install casing O-Ring
Figure 16: Fasten Seal Plate to
Engine
Figure 14: Install Seals
Figure 15: Orient Seal Plate

Maintenance 7
7. Press impeller wear ring into the
diffuser.
8. Fit diffuser over the impeller &
up to the seal plate.
• Fit O-Ring to front of diffuser.
9. Fit casing to pump ensuring that
O-Ring seats correctly into
groove in casing.
• This can be viewed through
the front inlet on casing.
10.Using 14mm socket & box
wrench to tighten the casing
evenly from corner to corner to
ensure even compression of the
casing O-Ring.
• Angled metal foot fits onto
the 2 bottom bolts and should
cover the bottom of pump
casing to prevent damage.
11. Fit flap valve and gasket to suc-
tion housing.
• Ensure that the gasket fits prop-
erly with the raised lugs on
housing fitting slots in gasket.
12.Fit discharge gasket and dis-
charge housing to casing.
• Using 13mm socket tighten
bolts in suction and discharge
flange.
• Bolts only need to be tightened
firmly to prevent stripping the
thread.
13.Fit handle to long bolts on side
of casing.
• Using 19mm socket tighten
handle sockets onto casing
bolts.
14.Pump is now fully assembled
ready for use.
• Bench test the pump up to top
pressure to ensure there are no
seal, O-Ring or gasket leaks
prior to returning to service.
This completes Assembly
of the single-stage pump.
Figure 20: Install Impeller Wear Ring
Figure 22: Fit Casing
Figure 24: Install Flap Valve
Figure 25: Fasten Suction and
Discharge Flanges
Figure 26: Install Handle
Figure 23: Fasten Casing
Figure 21: Install Diffuser

Maintenance 8
Remove spark plug
wire from engine before working
on pump.
2. Using 19mm socket or box
wrench, undo 2 bolts at bottom
of handle and remove handle.
3. Using 13mm socket remove 4
suction flange bolts and remove
flange.
4. Remove gasket and flap valve
from suction flange.
5. Using 13mm socket remove 4
bolts from discharge housing and
remove both housing & gasket.
6. Using 14mm socket remove 6
casing bolts and nuts and
remove casing from pump.
7. Remove front O-Ring and front
cover plate from pump.
8. After removing front cover plate
press impeller wear ring out.
Figure 32: Remove front O-Ring
Figure 33: Remove Wear Ring
Figure 29: Remove Flap Valve
Figure 30: Remove Discharge
Housing
Figure 31: Remove Casing
Figure 28: Remove Suction Flange
Figure 27: Remove The Handle
Tools Required
1. 13mm socket
2. 14mm socket
3. 15mm socket
4. 19mm socket
5. 24mm socket
6. 14mm box wrench
Engine-Driven Pump
Disassembly: Twin

Maintenance 9
9. Using 15mm socket or box
wrench undo impeller retaining
bolt counter-clockwise and
remove impeller from shaft
extension.
10.After removing impeller from
shaft extension remove front
diffuser.
11. Remove impeller spacer from
engine shaft.
12.Remove 2nd diffuser from pump.
13.Remove 2nd impeller from shaft
extension.
14.Remove O-Ring & impeller wear
ring from front of 2nd diffuser.
Figure 34: Remove Impeller
Figure 37: Remove Second Diffuser
Figure 38: Remove Second Impeller
Figure 39: Remove Wear Ring
Figure 35: Remove Front Diffuser
Figure 36: Remove Spacer

Maintenance 10
15.Using 24mm socket remove
hexagonal shaft extension from
engine shaft. If shaft extension is
tight give ratchet handle a sharp
hit with a hammer in an counter-
clockwise direction to loosen.
16.Remove rotating section of
mechanical seal from engine
shaft. Remove seal plate bolts
using 13mm socket and remove
the seal plate.
17.Remove the bolt seals and the
stationary mechanical seal wear
face from seal plate.
Pump is now
fully disassembled.
Figure 40: Remove Shaft Extension
Figure 41: Remove Seal Plate Bolts
Figure 42: Remove Seal Plate and
Seals

Maintenance 11
TWIN ASSEMBLY
Remove spark plug
wire from engine before working
on pump.
1. Insert spacer and bolt seals onto
seal plate bolts.
2. Insert stationary mechanical wear
face and casing O-Ring onto seal
plate. Do not use grease on either.
Soap may be used if necessary.
• Insert one long casing bolt into
right hand side of seal plate
prior to assembling to engine.
3. When installing seal plate onto
engine ensure that drain slot on
the back is facing downward.
Should the mechanical seal leak
this will allow water to drain out
of pump and not into the engine.
4. Apply Loctite 243 to seal plate
bolts and using 13mm socket,
assemble pump seal plate to
engine.
5. Carefully insert rotating mechani-
cal seal onto shaft extension
ensuring carbon face will seat
against ceramic wear face in seal
plate.
• Using 24mm socket, screw
hexagonal shaft extension onto
engine shaft.
6. Slide 1st impeller onto shaft
extension.
Figure 48: Install First Impeller
Figure 46: Install Seal plate Bolts
Figure 47: Install Seal and Extension
Figure 45: Seal Plate Drain Location
Figure 44: Prepare Seal Plate
Figure 43: Insert Spacer

Maintenance 12
7. Place casing O-Rring around rear
edge of seal plate.
• Insert impeller wear ring into
diffuser, turn diffuser around
and push diffuser over impeller
onto seal plate.
8. When positioning rear diffuser
ensure locating lug is in the
uppermost position.
9. Insert O-Ring on front of rear
diffuser.
• Insert spacer onto shaft
extension.
10.Ensure that locating lug on front
diffuser is installed in the upright
position.
• Place front diffuser over shaft
up to the rear diffuser.
11. Slide impeller onto shaft.
• Using 15mm socket or box
wrench tighten bolt & washer
into shaft extension to hold
front impeller.
12.Insert impeller wear ring into
front suction plate.
13.Ensure that protruding lug on
front diffuser locates into cavity
as shown in front cover plate
when putting in position over
front impeller.
Figure 51: Insert Diffuser O-Ring
Figure 52: Fasten Impeller
Figure 53: Install Wear Ring
Figure 54: Position Front Diffuser
Figure 52: Install Front Diffuser
Figure 50: Locate Diffuser
Figure 49: Install Diffuser

Maintenance 13
14.Push casing over the whole
assembly ensuring that locating
lugs and cover plate O-Ring all
seat properly. If assembly is not
correct the casing will not push
up neatly to the seal plate.
• Using 14mm socket tighten 6
casing bolts & nuts in a diago-
nal pattern to ensure even com-
pression of casing O-Rring.
15.The metal foot fits under the
pump casing onto 2 bottom cas-
ing bolts.
• The angle should face forwards
under pump casing to prevent
powder coating being scratched
causing possible corrosion.
16.Using 13mm socket install dis-
charge gasket & 4 way flange to
the top of pump casing.
17. Place gasket & flap valve assem-
bly onto suction flange as shown.
• Ensure that lugs on flange
locate correctly through holes
in gasket.
18.Using 13mm socket firmly tight-
en suction housing into place.
• Do not over-tighten as threads
in casing may strip.
19.Place handle over 2 long casing
bolts.
• Using 19mm socket or box
wrench tighten the 2 handle
bolts to casing.
• Pump is now fully assembled.
• Install on test bench and run
up to top pressure to ensure no
leaks from casing O-Ring, gas-
kets or mechanical seal.
This completes assembly
of the pump.
Figure 55: Install Casing
Figure 56: Install Support Foot
Figure 57: Install Discharge Flange
Figure 58: Install Flap Valve
Figure 59:Tighten Suction Housing
Figure 60: Install Handle

Repair Parts – Single Stage
Models
P60R P90R
Key B82932 B82934
No. Part Description Qty. B82933 B82935
1 Discharge Gasket 1 510960 510960
2 Discharge Flange - 2" BSP 1 410943S 410943S
3 Handle* 1 305590 –
4A Cap & Washer 2" BSP 2 505331 505331
4B Cap & Washer 1" BSP 2 502340 502340
5 Diffuser 1 411420 411420
6 Wear Ring 1 510970 510980
7 Impeller 1 512140 511210
8 Seal - Mechanical 1 700270 700724
• Seal Plate Bolt Spacer 4 609070 –
9 Bolt 4 700644 700644
• Washer 4 601870 601870
10 Casing O-Ring 1 702216 702216
11 Seal Plate (Yoke) 1 305493S 305503S
12A 3/8” Casing Nuts (Set/12)*** 6 700197 700197
12B 3/8” Casing Nut w/Bushing for Handle* 2 609010 –
13 Screw (Set/8 M8) 1 707302 707302
14 Suction Flange - 2" BSP 1 410863S 410863S
15 Flap Valve Assembly Gasket 1 410880 410880
16 1/4" Drain Plug (Including O-Ring) 1 503362 503362
17A Casing Bolts - 3/8” x 2”*** 6 702639 702639
17B Casing and Handle Bolts - 3/8” x 3”* 2 702806 –
18 Casing 1 305483S 305483S
19 Diffuser O-Ring 1 705901 705901
20 Bracket 1 608960 –
• Cap Strap (Triple) 1 505382 505382
• Roll Cage Assembly** 1 B72301 B72301
• Not illustrated.
* B82932 Only
** B82933, B82935 Only
*** B82932 uses 4.
1
2
4A
3
4B
5
678910 11
12B
12A
19
20
13
13
14 15 16 17A 17B 18
5866 0808
Repair Parts 14
Models
P60R
P90R

• Not illustrated.
* B82936 Only
** B82937, B83149 Only
*** B82936 uses 4
1
1
2345
67
8
910
11
29
30
12
13
13 16 21
23
24
28
22
1516 17 1819 20
14A14B
25
26
27
5867 0808
Repair Parts – Multi-Stage
Models
PP60R PP90R
Key B82936 B83148
No. Part Description Qty. B82937 B83149
1 Screw (Set/8) M8 8 707302 707302
2 Suction Flange - 2" BSP 1 410863S 410863S
3 Flap Valve Assembly Gasket 1 410880 410880
4 3/8” x 2” Casing Bolts*** 6 702639 702639
5 3/8” x 3” Casing and Handle Bolts* 2 702806 –
6 Cap and Washer - 2” BSP 2 505331 505331
7 Cap and Washer - 1” BSP 2 502340 502340
8 Handle* 1 305590 –
9 Discharge Flange - 2” BSP 1 410943S 410943S
10 Discharge Gasket 1 510960 510960
11 Suction Cover O-Ring 1 705901 705901
12 Suction Cover 1 305555 305555
13 Wear Ring 2 510970 510980
14A Impeller Screw 1 702592 702592
14B Spring Washer 1 705886 705886
15 Impeller Washer 1 609040 609040
16 Impeller 2 512120 512130
17 Interstage Diffuser 1 305538 305538
18 Interstage Diffuser O-Ring 1 702261 702261
19 2nd Stage Diffuser 1 305515 305515
20 Spacer Sleeve 1 608770 608780
21 Stub Shaft 1 608930 608950
22 Mechanical Seal 1 700270 700724
• Seal Plate Bolt Spacer 4 609070 –
23 Bolt 4 601870 601870
• Washer 4 700644 700658
24 Seal Plate 1 305493S 305503S
25 3/8” Casing Nut w/Bush for Handle* 2 609010 –
26 Casing Nuts (Set/12)*** 6 700197 700197
27 Bracket 1 608960 –
28 Casing O-Ring 1 702216 702216
29 Casing 1 305483S 305483S
30 1/4" Drain Plug (Includes O-Ring) 1 503362 503362
• Cap Strap (Triple) 1 505382 503382
• Anti-Vibration Feet (Set/2) 1 801356K 801356K
• Roll Cage Assembly** 1 B72301 B72301
Repair Parts 15
Models
PP60R
PP90R

Troubleshooting 16
CAUSE CORRECTIVE ACTION
1. ENGINE
A. Speed too low Refer to engine manual.
B. Rotating and/or reciprocating Refer to engine manual.
parts drag
C. Speed too high Maximum engine speed not to exceed engine manufacturer’s
recommendation.
D. Loose or broken parts Refer to engine manual.
2. PUMP
E. Not primed Reprime, inspect suction system for air leaks, and or clack assembly.
F. Pump takes too long to prime Check for air leaks or defective check valve.
G. Flow through pump completely Locate and remove obstruction. Attach strainer.
or partially blocked
H. Internal leakage Check clearances between face of vanes and case. Should not
exceed 1/32".
I. Rotating parts drag Inspect. Repair.
J. Loose or broken parts Inspect. Repair.
3. SYSTEM
K. Pressure required by system Compare pump pressure and flow rate against pump performance
at design flow rate exceeds chart. Reduce system pressure requirement. Increase pressure
pressure rating of pump capability of pump.
L. Obstruction in suction piping Locate and remove obstruction. Attach strainer.
M.Suction lift too high Check with gauge or measure vertical distance between water
surface and center line of pump, allowing for friction loss in suction
pipe. Reduce rate of flow to obtain desired lift. Refer to pump
performance chart.
N. Discharge head too low Decrease rate of flow.
O.Suction inlet not immersed Make sure suction inlet is fully submersed.
deep enough
P. Leaky suction line or Repair or replace suction line. Tighten connections.
connection admitting air

Warranty 17
LIMITED WARRANTY
BERKELEY warrants to the original consumer purchaser (“Purchaser” or “You”) of the products listed below,
that they will be free from defects in material and workmanship for the Warranty Period shown below.
Product Warranty Period
Water Systems Products — jet pumps, whichever occurs first:
small centrifugal pumps, submersible pumps 12 months from date of original installation, or
and related accessories 18 months from date of manufacture
Hydro-Flow Filters 1 year from date of purchase
Signature 2000®Fibrewound Tanks 5 years from date of original installation
Pro-SourceTM Steel Pressure Tanks 5 years from date of original installation
Pro-SourceTM Epoxy-Lined Tanks 3 years from date of original installation
Sump/Sewage/Effluent Products 12 months from date of original installation, or
18 months from date of manufacture
Our warranty will not apply to any product that, in our sole judgement, has been subject to negligence,
misapplication, improper installation, or improper maintenance.Without limiting the foregoing, operating a
three phase motor with single phase power through a phase converter will void the warranty. Note also that
three phase motors must be protected by three-leg, ambient compensated, extra-quick trip overload relays of
the recommended size or the warranty is void.
Your only remedy, and BERKELEY’s only duty, is that BERKELEY repair or replace defective products (at
BERKELEY’s choice).You must pay all labor and shipping charges associated with this warranty and must
request warranty service through the installing dealer as soon as a problem is discovered. No request for
service will be accepted if received after the Warranty Period has expired.This warranty is not transferable.
BERKELEY SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, OR CONTINGENT
DAMAGES WHATSOEVER.
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS AND
IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.THE FOREGOING WARRANTIES
SHALL NOT EXTEND BEYOND THE DURATION EXPRESSLY PROVIDED HEREIN.
Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on
the duration of an implied warranty, so the above limitations or exclusions may not apply to You.This warranty
givesYou specific legal rights andYou may also have other rights which vary from state to state.
This warranty supersedes and replaces all previous warranty publications.
In the U.S.: BERKELEY, 293 Wright St., Delavan,WI 53115
In Canada: 1800 Courtney Park Drive East, Unit 5-7, Mississauga, Ontario L5T 1W1

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