Doughboy Generation II GEN 180 User manual

365-1775
“the original portable pool”
®
*Shown with Power Pak III, not included.
Generation II
Cartridge Filter with 6 Position Valve
Model GEN 180 — Item No. 0-1802-019
Model GEN 240 — Item No. 0-1802-022
Owner's Guide

2
“READ ALL INSTRUCTIONS” Failure to follow these important
safety instructions and other basic safety precautions may result
in serious personal injury.
Before you begin installing your filter, refer to your pump
owners guide for very important installation and electri-
cal information related to your filter.
ELECTRICAL/BUILDING PERMIT
Local building codes may require obtaining an electrical
or building permit and may have regulations on set
backs and barriers that must be followed.
ELECTRICAL
We recommend you have a qualified electrical contrac-
tor install the electrical power supply as specified in your
pump instructions.
INSTALLED LOCATION
Position filter, pump and any other related components
a minimum of 4 feet from pool to prevent their being
used as a means to climb into the pool by young chil-
dren. DO NOT store toys, chairs, tables, containers or
other objects within 4 feet of the pool for the same
reason.
WARNING
SEVERE ELECTRICAL SHOCK could result if you
install your filter and pump on a deck or above pool
water level. They could fall into the water, causing
severe shock or electrocution. DO NOT install on a
deck or other surface at, above or slightly below the top
rail of the pool.
PROPERLY SUPPORTED
Filter, pump and any other related components should
be properly supported to prevent damage from misalign-
ment, settlement, vibration and mounted so as to
minimize the potential for the accumulation of debris and
moisture.
ACCESSIBILITY
The circulation system components should be installed
to allow accessibility for inspection, repair or replace-
ment.
DO NOT alter the pump electrical cord in any way or
change the plug end to any style.
DO NOT use an extension cord(s). Severe electrical
shock may occur.
IMPORTANT SAFETY INSTRUCTIONS
PREVENT SEVERE SHOCK
To prevent the risk of severe electrical shock, plug your
pump cord end into a grounding type receptacle pro-
tected by a ground fault circuit interrupter (GFCI).
Contact a qualified electrician if you cannot verify that
the receptacle is protected by a GFCI.
DO NOT allow children to operate or play around this
product unless they are closely supervised by adults at
all times.
Replace damaged cord immediately to reduce the risk of
electrical shock.
DO NOT BURY CORD
An exposed cord may accidentally become damaged or
severed by a sharp object or shovel resulting in severe
electrical shock. Position cord to prevent accidental
damage from lawn mowers, hedge trimmers or other
equipment.
BARE FEET/WET GROUND
This is a dangerous combination around electrical
equipment. Always be sure the ground under your feet
and body is dry before you touch electrical equipment.
Failure to heed this warning may cause severe personal
injury or electrocution due to severe electrical shock.
WARNING
Avoid direct water spraying with a garden hose around
electrical outlets, pump or any other electrical devices.
Severe electrical shock or electrocution may occur.
SERVICING YOUR PUMP
Always unplug your pump from the receptacle before
servicing, adjusting or repairing.
WARNING

3
Did you read the IMPORTANT SAFETY INSTRUC-
TIONS? If not, READ THEM NOW. They contain very
important safety information related to the installation of
your filter. Familiarize yourself with the installation
sequences by reading these instructions first. AVOID
SHORTCUTS that may result in reworking the installa-
tion.
BEFORE YOU BEGIN
The pool must be properly erected per your pool
assembly and installation instructions before installing
the filter. Install the surface skimmer and return fitting.
Before completing the filling of the pool to the water
level indicator marks on the skimmer face plate, the filter
and pump should be installed with all connections
secured tightly.
TOOLS REQUIRED
• Flat head screwdriver
• Crescent wrench
• Measuring tape
• Carpenters level
• Flat nose shovel
• Rags
• 5/16" Nutdriver (optional)
The following tools are for Models GEN 240 only:
• Hack saw
• File
MATERIALS REQUIRED
• Nine 12" x 12" patio blocks (All filters)
• Waste hose 1-1/2" inside diameter
• 1-1/2" Hose clamp (Model GEN 180 only)
The following material are for Models GEN 240
only:• 1-1/2" Schedule 40 PVC pipe
NOTE: Quantity depends on length of pipe
runs desired.
• 10 to 12 1-1/2" 90 degree socket PVC elbows
• PVC pipe primer
• ABS to PVC solvent cement with applicator
INSTALLATION
INSTALLATION LOCATION
Install your filter and pump and any other related
components at least 4 feet from the pool to prevent their
being used as a means of access to the pool by young
children. Patio blocks provide firm support and keeps
standing water and weeds away from electrical parts.
DO NOT install your filter and pump directly on the
ground surface. Settling and stressing circulation lines
may occur during wet seasons. Position patio blocks as
illustrated in the following, using a shovel and
carpenter’s level to level ground before placing the
blocks.
POSITIONING FILTER/PUMP
Position filter and pump on pad as shown in Fig. 1.
Suction and return lines should be partially buried to
prevent accidental tripping that could cause personal
injury or damage to the filter system. Starting at least
12" from the pool wall, make two 3-4" deep trenches,
one from the pool skimmer to the front of pump and the
other from the pool return fitting to the filter/valve port
marked "RETURN".
Be sure the hoses are routed so that water flow through
them is not restricted.
POSITION FILTER ON BASE
Position filter in the base with the valve port labeled
“PUMP” pointing towards the pump discharge.
INSTALL PUMP DISCHARGE HOSE
The pump discharge hose is provided with a hose
barbed fitting and a 1-1/2" pipe socket fitting. Install the
hose barbed fitting to the pump discharge per the pump
instructions and discard the socket fitting unless your
option is to hard plumb this connection with PVC pipe.
(Refer to “Option for hard plumbing”). Slip a hose
clamp over each end of hose prior to installing. Push
each hose end fully onto the valve port label “PUMP”,
then tighten clamps firmly using a flat head screwdriver
or 5/16" nutdriver.
TO TOP PUMP PORT (DISCHARGE)
PUMP DISCHARGE INSTALLATION
(HOSE CONNECTION)
TO FILTER/VALVE PUMP PORT
FILTER
RETURN
PUMP
4 FT.
SKIMMER
TO WASTE

4
TO FILTER/VALVE PUMP PORT
TO TOP PUMP PORT (DISCHARGE)
MODEL GEN 240
This filter model is designed for a hard plumbing installa-
tion and is provided with a special high flow return fitting
with a 1-1/2" pipe socket for installing 1-1/2" PVC pipe.
INSTALL RETURN FITTING
MODEL GEN 240 ONLY
Discard the EYEBALL RETURN FITTING provided with
your pool and replace it with the HIGH FLOW RETURN
FITTING as shown.
CORRUGATED HOSE
CONNECTION WITH WIRE CLAMP
TO FILTER/VALVE RETURN PORT
adaptor (56) and push threaded end through the wall
from inside pool. Place the second gasket over the
threads now exposed outside the pool.
2. Hold the return fitting adaptor (56) and thread the
union adaptor (62) onto it and tighten firmly. Hint:
Using an oil filter wrench to tighten the union adaptor
will make the job easier.
3. Your pressure type pool cleaner will attach to the
return fitting adaptor.
HARD PLUMB INSTALLATIONS
Using a 1-1/2" Schedule 40 PVC pipe with ends cut
square, remove any burrs. Cut pipe to length as re-
quired between joints and loosely assemble for proper fit
prior to solvent welding. Slip the union nut (65) onto the
pipe with the female threads facing the union adaptor
(62). Then, solvent weld the union socket (64) onto the
pipe using primer and PVC/ABS solvent cement. DO
NOT Allow solvent cement to contact the sealing
surface of the union socket. When dry, assemble the
connections and tighten firmly by hand.
Locate a board large enough to cover return fitting cut-
out. From inside of pool, use the board to hold liner
against cut-out in pool wall. Keep hands away from hole
to avoid injury. From outside of pool, use the cut-out as
guide and cut away liner with a razor knife.
INSTALLATION
(without pressure type pool cleaner)
1. Slip a gasket (61) over the threads of the return fitting
(60) and push threaded end through the wall from
inside pool. Place the second gasket over the
threads now exposed outside the pool.
2. Hold the return fitting (60) so the opening is facing
away from the skimmer and slightly downward.
Thread the union adaptor (62) onto the return fitting
and tighten firmly. Hint: Using an oil filter wrench to
tighten the union adaptor will make the job easier.
INSTALLATION
(with pressure type pool cleaner)
1. Slip a gasket (61) over the threads of the return fitting
RETURN LINE
INSTALLATION
HI- FLOW
RETURN PAK
PUMP DISCHARGE
INSTALLATION
(HARD PLUMB)
OPTION FOR HARD PLUMBING
If your option is to hard plumb the pump discharge to
filter inlet, it will be necessary that you order a “hard
plumb adaptor” (P/N 348-1036) and one “Clamp” (P/N
387-1024). Refer to “Cut and loosely assemble piping”
and “Solvent welding” for PVC piping assembly, then
install as shown.
INSTALL RETURN LINE
An 8 foot long hose is provided for filter Model GEN 180
and a special high flow return fitting with filter Model
GEN 240 for the return line.
MODEL GEN 180 ONLY
Slip a hose clamp over the ends of the hose and push
one end onto the filter/valve RETURN port and the other
end onto the pool RETURN fitting. Tighten clamps
firmly using a flathead screwdriver or 5/16" nutdriver.
POOL RETURN
FITTING

union plug after backwashing.
MODEL GEN 240
Loosen the waste port “Union Nut” and remove both the
union nut and socket fitting. Caution: Take care not to
lose the o-ring seated in the valve body. Slip union nut
onto 1-1/2" PVC (N.P.S.) drainage pipe (not supplied)
with female threads facing end of pipe. Then solvent
weld the union socket onto the pipe end, using ABS to
PVC Cement available at your pool store. Avoid
allowing solvent to run onto the end sealing surface.
Position onto the waste port, making sure o-ring is in
place and firmly hand tighten union nut.
ELECTRICAL OUTLET
Refer to your pump owners guide for detailed informa-
tion pertaining to the requirements and regulations for
safe electrical installation of the power supply, recep-
tacle outlet, switching and ground fault interrupter.
FINISH FILLING POOL
Finish filling your pool, referring to skimmer installation
and pool assembly instructions for proper water level.
VALVE OPERATIONS
Your filter has multiple positions of operation, which are
explained below. To change positions of the valve,
make sure the pump is OFF. Press down on the valve
handle enough to free the locking notch. Rotate the
handle so the tab LOCKS into the notch in the desired
position.
5
SKIMMER CONNECTION
HARD PLUMB
ADAPTOR
TO FRONT PUMP PORT
(SUCTION)
Insert the o-ring (63) into the union adaptor groove, then
secure the cemented pipe assembly onto the union
adaptor (62) with the union nut (65).
SOLVENT WELDING
Contact your pool dealer for ABS to PVC Solvent
Cement and PVC Primer and follow directions on labels.
TO WINTERIZE POOL
Drain pool down below the return fitting. Loosen union
nut (65) and pull back the union socket (64). Insert the
winterizing disc (66) between o-ring (63) and union
socket. Retighten union nut onto union adaptor firmly.
INSTALL SUCTION LINE
An 8 foot long hose is provided for filter Model GEN 180
and a hard plumb adaptor with clamps for filter Model
GEN 240 for adapting hard plumbing to the skimmer
outlet.
MODEL GEN 180 ONLY
The pump suction is provided with a hose barbed fitting
and a 1-1/2" pipe socket fitting. Install the hose barbed
fitting to the pump suction per the pump instructions and
discard the socket fitting. Slip a hose clamp over each
hose end and push one end onto skimmer outlet and the
other end onto the pump suction port. Tighten clamps
firmly using a flathead screwdriver or 5/16" nutdriver.
MODEL GEN 240
The pump suction is provided with a hose barbed fitting
and a 1-1/2" pipe socket fitting. Use the socket fitting
and discard the barbed fitting. Refer to HARD PLUMB
INSTALLATION and SOLVENT WELDING for assem-
bling piping between skimmer and pump suction. Slip
clamp onto small end of hard plumb adaptor and push
onto skimmer outlet. Slip clamp onto large end of
adaptor and insert pipe. Tighten clamps firmly.
WASTE LINE HOOKUP
The discharge waste water will contain pool water
treatment chemicals that may harm certain plants and
vegetation. Therefore, position the discharge end of the
waste line in a safe, out-of-sight area capable of accept-
ing 200 to 400 gallons of waste water.
MODEL GEN 180
Install a 1-1/2" inside diameter waste discharge hose
(not supplied) on the waste port located on the 6
position valve. Slip a 1-1/2" hose clamp (not supplied)
over one end of the hose. Then, push hose onto the
port fully and tighten clamp firmly.
IMPORTANT
The union plug (#340-2046) must be removed from the
waste port and replaced with the union hose adaptor
(#340-1969) prior to backwashing the filter. Replace the
FROM
PUMP
TO POOL
RETURN
TO WASTE
CLAMPS
SUCTION LINE INSTALLATION
(HARD PLUMB)

6
over tighten.
2. Plug in your pump to the GFCI protected receptacle.
Refer to “WARNINGS”.
3. Start pump. Check all fittings and hose connections
for leaks and correct if necessary, note the pressure
reading on the pressure gauge. Clean the car-
tridges when the pressure has increased 5 pounds.
FILTER OPERATION
Because all pool installations vary in environmental
conditions (wind, rain, airborne debris, heat and pool
use, etc.), it is impossible to provide an accurate filtering
time for normal usage. Determine how long your filter
must operate each day. Generally, 6 to 8 hours of
filtering each day is sufficient to maintain pool clarity if
the pool chemical treatment is correct. Consult your
local pool store for helpful advice in keeping your pool
clean and sanitary.
When possible, avoid operating your filter during peak
electricity demands in your community. Check with your
local electric utility company for the best times they
recommend for operating your filter pump.
FILTER: Normal pool filtering position. May also be
used when vacuuming the pool.
CLOSED: This position is used only when servicing
pump or cleaning strainer basket. In this position, flow
from the return fitting is prevented from back flowing
through filter. Stuff a rag into the skimmer’s bottom
outlet when performing this operation to prevent flow of
water coming out strainer housing. Remove rag when
resuming normal operation.
WINTERIZE POSITION: This position allows you to
drain trapped water from the filter valve and relieve
compression on the rotor valve gasket during winter
storage. CAUTION: Do Not operate pump in this
position as waste water contaminants will be discharged
from the filter back into the pool.
RECIRCULATE: This position allows you to increase
the water flow rate to circulate chemicals throughout the
pool more quickly. Pool water passes through the valve
on top of the filter, bypassing internal filter components
and travels back to the pool at a rapid rate. This posi-
tion may also be used when servicing the filter to shut
off flow from the return fitting and the pump. Filter cover
may be removed from valve when in this position
PUMP TO WASTE: This position allows you to vacuum
heavy debris or larger amounts of settled contaminants
from the pool floor directly to waste.
INITIAL START UP
A newly filled pool is normally filled with unfiltered water
and usually requires continuous filtering for 24 to 48
hours along with chemical treatment of the pool water.
Excessively contaminated water with suspended
particles and algae, may require you to clean the
cartridges once or twice during this initial stage of
filtering the new raw water. After this initial filtering
stage, the cleaning intervals will be extended (less
frequent) allowing longer time periods between cleaning
the cartridges.
1. Loosen the pump strainer pot lid to allow air to
escape. Tighten lid when water begins to flow
between strainer pot lid and strainer body. DO NOT
WHEN TO CLEAN CARTRIDGES
The cleaning of the cartridges may occur depending on
local environmental conditions and sudden changes.
Windy areas or a sudden high windy day, spring time
pollen releases, excessive pool use or neglect in pool
chemical treatment can cause your filter to work harder,
removing excess amounts of airborne particulates.
Frequently check the pressure gauge reading and clean
the cartridges when required. Clean cartridges when
the pressure gauge increases 5 pounds above the clean
filter starting pressure.
CLEANING CARTRIDGES
As the cartridges become saturated with dirt and debris,
the return flow back to the pool will diminish. At this
time the cartridges must be cleaned.
1. STOP PUMP and unplug from receptacle.
2. PLUG SKIMMER AND RETURN
To prevent the backflow of pool water from exiting
the filter tank when the cover is removed, stuff a rag
into the following openings:
A - Inside skimmer, bottom hole.
B - Return inlet fitting opening from inside of pool.
3. DRAIN TANK
Remove the tank drain cap. Pull valve handle to
full up position with a counterclockwise twisting
motion. Allow the tank to start draining. When the
tank cover is removed, the drainage flow will in-
crease.
4. DISCONNECT HOSE/PIPING
Disconnect the pump discharge connection at the
valve and the return line at the valve.
5. REMOVE TANK COVER WITH VALVE
Loosen the V-Clamp knob counterclockwise and
remove the clamp. Lift cover with valve straight up
until clear. Note: Hard plumbed lines may have to
be shifted to one side in order to clear cover from
tank. Set aside, taking care not to scratch or dent
the O-Ring sealing surface on cover. Remove tank
O-Ring from tank flange. Allow tank to drain com-
pletely.
6. REMOVE CARTRIDGE LOCATOR
Grip the center coupling/pipe assembly and un-
screw counterclockwise and lift it and cartridge
collector out of the tank. Unscrew the lower riser
tube and remove from tank.
7. LIFT OUT CARTRIDGES
Carefully rotate and lift out each cartridge, taking
care not to damage the cartridge pleated material.
CAUTION: Never lay cartridge on its side on a
rough textured surface such as concrete, asphalt,
gravel, etc.. Damage to the pleated filtering material
may occur. THIS WILL SERIOUSLY REDUCE
FILTERING PERFORMANCE.
8. FLUSH OUT TANK
With a garden hose, flush out tank through drain
and remove any large debris that may have passed
through the skimmer and/or pump strainer baskets
and into the filter.

16. CLOSE TANK DRAIN
Replace the drain cap and gasket. Tighten securely
by hand.
17. REMOVE RAGS FROM RETURN AND SKIMMER
18. RESUME NORMAL OPERATION
Start pump and check for any leaks around cover,
drain and connections. Correct if necessary.
VACUUMING YOUR POOL
Use the FILTER position on your valve when vacuuming
under normal conditions. Debis is caught in the filter at
a very rapid rate while vacuuming. Consequently, the
filter must work harder causing a rapid increase in filter
pressure as will be indicated on your pressure gauge.
Frequent cleaning of the cartridges may be necessary
during this process depending on the amount of dirt
being vacuumed of the pool floor. If the bottom of the
pool is extremely dirty with heavy sediment and debis,
you may wish to use the PUMP TO WASTE position on
your valve. This will help prevent a quick heavy buildup
of debris in your filter.
NOTE: The pool water level will decrease when using
PUMP TO WASTE position. Be sure to check the pool
water level and refill as required.
MAINTENANCE
Preventative maintenance will provide continued smooth
performance and extend the life of your filter for many
years. Neglect will cause parts to wear or bind, leaks to
occur and result in costly repairs. Keep moving parts
lubricated and a clean environment around your filter
and related components.
LUBRICATION
There are various types of lubricants available.
However, most are intended for moving metal parts.
Unfortunately, these lubricants will harm or degrade the
plastics. DO NOT use petroleum base lubricants. Many
people consider “PETROLEUM JELLY” safe for babies
and can be applied to anything. But, it will DESTROY
most plastics. Silicone lubricants available at your pool
dealer are safe for use on plastics.
LUBE STRAINER O-RING
Before removing pump strainer lid, prevent the backflow
of water from your skimmer and filter from exiting out the
strainer housing opening. You will experience some
water coming out the strainer housing (residual from
hoses and filter tank), but not a large volume.
1. Remove skimmer cover and basket and plug inside
bottom hole with rag.
2. Rotate valve handle to the CLOSED position.
3. Remove pump strainer lid, referring to your pump
owner’s guide and lubricate the o-ring and mating
seal areas with silicone lubricant.
4. Replace strainer lid.
5. Remove rag from skimmer. Resume normal filter
operation.
It is good practice to keep silicone lubricant handy near
the filter and pump for periodically lubricating these vital
areas.
7
9. CLEAN CARTRIDGES
Attach the BLASTER NOZZLE to a garden hose.
Position cartridge in an upright position, supporting
with one hand when cleaning. Hold the blaster
nozzle away from the cartridge about 18". Starting
at the top of the cartridge, spray between each
pleat, working downward.
NOTE: Before solution cleaning the cartridges, be
aware that chlorine and acids kill lawns and plant
life. Clean the cartridges in a suitable area.
10. SOLUTION CLEAN CARTRIDGES
If the cartridge becomes impregnated with algae,
pour a mild chlorine solution (1 part chlorine to 4
parts water) over all pleated surfaces and let soak
for 10 minutes. Hose off thoroughly. Then, mix a
solution of warm water and detergent (1 cup per 5
gallons of water). Add one cup of chlorine or
household bleach.
Totally submerge the cartridges and soak for 15-30
minutes. Agitate the cartridge vigorously to dislodge
trapped particles.
11. RINSE
Rinse cartridges thoroughly before reinstalling in the
filter. If the cartridges are not rinsed clean, soapy
bubbles will appear on the pool surface near the
return fitting.
12. HARD WATER
Hard water will eventually coat the cartridges with
calcium deposits that cut off good filtering perfor-
mance. To correct, mix a solution (1 part muriatic
acid to 4 parts water). Soak the cartridges fully
submerged about 15 minutes. Rinse thoroughly
with clean water.
NOTE: Muriatic acid solution will kill lawns and
plant life. Perform this service in a suitable area.
13. REINSTALL CARTRIDGES
Grasping the cartridge handle, lower each cartridge
into the tank and align the hole on the bottom of
each cartridge with a manifold elbow port. Push
cartridges down until fully seated.
14. REPLACE CARTRIDGE LOCATOR
Install the riser tube by screwing clockwise into the
manifold collector (be carefull not to cross thread).
Tighten firmly by hand. Slide the cartridge locator
(slotted ribs facing down) over the riser tube. Align
and insert the curved ribs of the cartridge locator
onto the top of each cartridge. Secure the assembly
by screwing the coupling and pipe assembly on the
end of the riser tube.
15. REPLACE TANK COVER
Wipe the tank O-Ring and the mating sealing
surfaces of the tank and cover clean. Position the
O-Ring on the tank sealing surface. Then, being
sure to maintain proper alignment of the valves
PUMP and RETURN ports to your pools plumbing,
guide the end of the coupling/pipe assembly into the
bottom of the valve. Be sure to position the cover
groove over the tank o-ring and carefully push cover
down onto o-ring. Check that o-ring is seated
evenly in cover groove. Install the v-clamp and
tighten until the ends of the clamp are approxi-
mately 3/8" apart.

8
3. After servicing, reassemble and install in reverse.
Make sure tank O-Ring and sealing areas are free
of any dirt or grit and the o-ring is evenly seated
before replacing cover.
WINTERIZING FILTER
In areas subject to freezing damage, it is mandatory that
the filter, pump and any related components be re-
moved from the pool and stored indoors. (Refer to
individual components owners guide such as pump,
skimmer, chlorinator, etc., for specific winterizing
instructions.)
1. Siphon water level down below skimmer opening by
using your vacuum hose and allow water to flow to
an area that can accept a couple of thousand
gallons or more.
2. Drain tank completely.
3. Disconnect all line connections.
4. Remove V-Clamp from filter and remove cover and
gasket.
5. Remove cartridges, flush out tank, clean cartridges
thoroughly and allow to dry completely.
6. Reinstall cartridges only after they have dried
completely. Replace cover and drain cap.
7. Store all components in a warm dry area indoors.
DAMAGE CAUSED BY FREEZING TEMPERATURES
IS NOT COVERED BY PRODUCT WARRANTY.
LUBE VALVE SHAFT
To lubricate the O-Ring on the valve shaft, depress
valve handle fully and apply lubricant on the shaft
between handle and valve cover. Then, rotate handle to
distribute lubricant. Resume normal filter operation by
rotating handle to the Filter position and start pump.
REPAIRS
Servicing should be performed by a qualified dealer. If
disassembly is attempted, mark each of the parts
assembled position as it relates to its mating parts. This
assures proper alignment when reassembled. Malfunc-
tion will occur if not properly assembled. See your
dealer for original replacement parts.
CAUTION
BEFORE removing filter or pump from pool for servic-
ing, prevent the backflow of water from your skimmer
and return fitting inlet from flowing out of disconnected
hoses.
1. Remove skimmer cover and basket and plug inside
bottom hole with rag.
2. Referring to the instructions for your return fitting,
install the Shutoff disc. Option; stuff a rag into the
return fitting opening.
3. Disconnect hoses on filter or pump as necessary
when removing for service or repairs.
DRAIN TANK
See Caution Above
1. Remove tank drain cap to drain.
2. Remove V-Clamp, cover and large O-Ring from
tank.

9
OWNER'S GUIDE
WARRANTY CARD
TO TOP PUMP PORT
TO POOL RETURN
TO FRONT PUMP PORT
TO SKIMMER
TO WASTE
HI-FLOW RETURN PAK
NOTE: CARTRIDGE CONFIGURATION
FOR GEN 180 SHOWN
(See Parts List for GEN 240 part quanities)
EXPLODED VIEW
MODELS GEN 180 and 240

1121-1544
1121-1545
330-1172
1121-1543
308-1225
330-1245
340-2148
340-1962
307-1001
340-1970
308-1206
340-1957
1107-1599
340-2145
340-1930
340-1929
340-1932
340-1932
340-2023
340-2024
330-1237
330-1237
1119-1065
1119-1065
1107-1573
340-1950
340-1949
1107-1402
1107-1510
308-1251
340-2017
308-1234
387-1030
330-1235
340-1835
340-2046
308-1241
340-1969
387-1003
346-1035
343-1100
340-1837
1121-1476
307-1022
340-1187
308-1044
327-1007
327-1006
396-1018
1107-1519
330-1234
378-1016
340-1188
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
PARTS LIST
GENERATION II, MODELS GEN 180 AND 240
10
ITEM PART # QTY DESCRIPTION
Tank - Model (GEN 180)
Tank - Model (GEN 240)
#10 x 1/2" Screw
Tank Internal Adaptor w/Insert
5/16" Thread Seal
5/16-18 x 1-1/4" Bolt
Tank Base
Drain Cap
Drain Cap Gasket
Drain Fitting Nut
O-Ring - 1.287 I.D.
Drain Fitting
Threaded Adaptor Assembly
Manifold Support
Manifold Collector- Bottom (GEN 180)
Manifold Collector- Bottom (GEN 240)
Manifold Elbow (GEN 180)
Manifold Elbow (GEN 240
Manifold Collector - Top (GEN 180)
Manifold Collector - Top (GEN 240)
#10 x 3" Screw (GEN 180)
#10 x 3" Screw (GEN 240)
60 Sq. Ft. Cartridge (GEN 180)
60 Sq. Ft. Cartridge (GEN 240)
1-1/2" Riser Tube Assembly
Cartridge Locator (GEN 180)
Cartridge Locator (GEN 240)
Coupling/Pipe Assembly (GEN 180)
Coupling/Pipe Assembly (GEN 240)
O-Ring - 11.475 I.D.
Valve/Tank Adaptor
O-Ring - 5.850 I.D.
V-Clamp
12-24 Nut
Union Nut
Union Plug (GEN 180 only)
O-Ring - 1.984 I.D.
Union Hose Adaptor (GEN 180 only)
1-1/2" Wire Hose Clamp
1-1/2" x 8' Hose (GEN 180 only)
Air Relief
Union Socket (GEN 240 only)
Valve Body/Gasket Assembly
Valve Gasket
Valve Rotor
O-Ring - .862 I.D.
Friction Washer
Bearing Washer
Spring
Valve Cover w/Decal
12-24 x 1-1/4" Screw
Valve Handle Pin
Valve Handle
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
3
4
1
1
3
4
3
4
1
1
1
1
1
1
1
1
1
6
2
1
2
2
4
2
1
2
1
1
1
1
2
2
1
1
6
1
1

340-1791
387-1024
348-1036
387-1023
340-2051
308-1110
340-2052
308-1241
340-2047
340-2048
340-2099
11
ITEM PART # QTY DESCRIPTION
PARTS LIST
GENERATION II, MODELS GEN 180 AND 240
340-1195
340-1189
387-1023
346-1049
340-1224
308-1039
395-1014
343-1042
368-1066
365-1775
56
57
58
59
60
61
62
63
64
65
66
1
1
1
1
1
2
1
1
1
1
1
Return Fitting Adaptor
#36 Band Clamp
Hard Plumb Adaptor
#28 Band Clamp
Return Fitting
Return Gasket
Union Adaptor
O-Ring - 50mm I.D.
Union Socket
Union Nut
Winterize Disc
Pin Retainer
Valve Handle Cap
#28 Band Clamp
1-1/2" x 4' Hose
Hose Adaptor
O-Ring - 1.925 I.D.
2" Pressure Gauge
Nozzle Blaster w/Washer
Warranty Card
Owner's Guide
46
47
48
49
50
51
52
53
54
55
NOTE: Item 35 includes items 33 and 36.
HI-FLOW RETURN PAK - MODEL GEN 240 ONLY
ITEM PART # QTY DESCRIPTION
1
1
2
1
1
1
1
1
1
1

TROUBLESHOOTING CARTRIDGE FILTERS
PROBLEM POSSIBLE CAUSE REMEDIES
1 - High gauge pressure, 1 - Cartridge contaminated with 1 - Clean cartridges.
low return flow. suspended solids. 2 - Chemically shock pool with
2 - Algae growth on cartridge cloth. chlorine or clean cartridges.
3 - Calcium crustation on cartridge 3 - Solution clean cartridges with mur-
cloth. iatic acid, refer to “Hard Water”.
2 - Very high pressure, no return 1 - Cartridge cloth completely 1 - Clean cartridges.
flow clogged with suspended solids
or algae growth.
3 - Low gauge pressure, low return 1 - Skimmer or pump strainer baskets 1 - Clean out baskets.
flow, bubbles returning to pool. clogged and restricting flow. 2 - Fill pool to proper level.
2 - Pool water level low, pump 3 - Firmly secure pump strainer lid.
drawing in air. 4 - Replace hose or tighten all
3 - Pump strainer lid not firmly suction connections.
secured. 5 - Replace vacuum hose to a larger
4 - Crack in suction hose or loose diameter and smooth inside.
connection. 6 - Remove restriction.
5 - Vacuum hose too small in
diameter.
6 - Vacuum cleaner clogged with
debris.
4 - High return flow, low gauge 1 - Opening in cartridge cloth. 1 - Replace cartridge.
pressure. Pool water won’t clear . 2 - Cartridge not seated inside filter. 2 - Reassemble cartridges inside
up. 3 - Pool water chemically out of filter.
balance. 3 - Chemically treat and balance
pool water condition.
5 - Short filter cycles. 1 - Cartridges clogged with 1 - Clean cartridges.
contaminants or algae. 2 - Clean cartridges, (Refer to “Hard
2 - Calcium crustation on cartridge Water”).
cloth. 3 - Chemically treat and balance
3 - Vacuuming large amounts of pool water condition.
sediments from pool floor.
6 - No gauge pressure, low or no 1 - Pump impeller plugged with 1 - Service pump to remove
flow, pump running OK. debris or impeller threads are obstruction or replace impeller.
stripped. 2 - Clean out baskets.
2 - Skimmer or pump basket clogged.
7 - Debris flowing into pool from 1 - Opening in cartridge cloth. 1 - Replace cartridge.
return inlet. 2 - Cartridge not seated properly. 2 - Reassemble cartridges inside
filter.
Note: Contact your pool dealer for any problems you cannot solve.
Change of Design: Doughboy Recreational expressly reserves the right to change or modify the design
and construction of any product in due course of our manufacturing procedures, without incurring any
obligation or liability to furnish or install such changes or modifications on products previously or
subsequently sold.
“the original portable pool”
®
DOUGHBOY RECREATIONAL • 10959 Jersey Blvd., • Rancho Cucamonga, CA 91730-5194
DB 1197-013 Made in the United States of America Copyright © 1997
PREVENT
DROWNING
Watch children
at all times.
You can be
permanently injured.
Shallow water.
WARNING
Do not remove or cover.
RESCUE:
NO DIVING!