Doughboy POWERLINE XP I User manual

365-2076
Dual Speed Swimming Pool Pump (Black color model)
3 FT CORD
UL/NEC Models 0-3596-206, 0-3597-206, 0-3598-206
25 FT CORD w/GFCI
UL Models 0-3596-200, 0-3597-200, 0-3598-200
6 FT CORD Models 0-3596-203, 0-3597-203, 0-3598-203
Owner's Guide
POWERLINE XP I

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Interrupter (GFCI) in accordance with
Article 680-31 of the National Electrical
Code (NEC), (Section 68-204 of the
Canadian Electrical Code [CSA]) and
local codes or ordinances. For runs
greater than 25 feet, consult your local
licensed electrical contractor.
FOR UL/NEC MODELS ONLY:
0-3596-206, 0-3597-206, 0-3598-206
Your pump is supplied with a 3-foot,
3-wire electrical cord and 3-prong
flanged, twist-lock plug.
The pump electrical cord must be
connected to a single twist lock,
grounding type receptacle that is
located a minimum of 6 feet from the
inside pool wall.
A qualified electrical contractor must
install this receptacle in accordance
with Article 680-6 of the National
Electrical Code (NEC). A Ground
Fault Circuit Interrupter (GFCI) must
be used. An ON/OFF switch must be
installed at the receptacle.
Use a Hubbell No. 2310 Receptacle,
20 AMP 125 Volt A.C. or an
equivalent receptacle that meets
NEMA Configuration L5-20R.
This pump is double insulated and
grounded. Dead metal parts are not
in contact with pool water.
FOR 6FT cord MODELS ONLY:
Your pump is supplied with a 6-foot,
3-wire electrical cord and 3-pronged
plug. The pump is double insulated
and grounded. The pump electrical
cord must be connected to a
grounded, 3-wire, 115 VAC electrical
receptacle. The receptacle must be
protected by a Ground Fault Circuit
Interrupter (GFCI) in accordance
with Article 680-31 of the National
Electrical Code (NEC), (Section 68-
204 of the Canadian Electrical Code
[CSA]) and local codes or
ordinances. For runs greater than 6
feet, consult your local licensed
electrical contractor.
and reassembled to its original
integrity. A permanently installed
pool is constructed in or on the
ground or in a building such that
it cannot be readily disassembled
for storage.
(For storable pools) The unit is
provided with a ground-fault
circuit-interrupter (GFCI). To test
the GFCI, push the test button.
The GFCI should interrupt power.
Push the reset button. Power
should be restored. If the GFCI
fails to operate in this manner,
the GFCI is defective. If the GFCI
interrupts power to the pump
without the test button being
pushed, a ground current is
flowing, indicating the possibility
of an electric shock. Do not use
this pump. Disconnect the pump
and have the problem corrected
by a qualified service
representative before using.
FOR UL/NEC MODELS ONLY:
0-3596-206, 0-3597-206, 0-3598-206
8. CAUTION — This pump is for
use with permanently installed
pools and may also be used with
hot tubs and spas if so marked.
Do not use with storable pools.
A permanently installed pool is
constructed in or on the ground or
in a building such that it cannot
be readily disassembled for
storage. A storable pool is
constructed so that it may be
readily disassembled for storage
and reassembled to its original
integrity.
FOR ALL MODELS:
9. SAVE THESE INSTRUCTIONS.
ELECTRICAL FEATURES
FOR UL MODELS ONLY:
0-3596-200, 0-3597-200, 0-3598-200
Your pump is supplied with a 25-foot,
3-wire electrical cord and 3-pronged
plug. The pump is double insulated
and grounded. The pump electrical
cord must be connected to a
grounded, 3-wire, 115 VAC electrical
receptacle. The receptacle must be
protected by a Ground Fault Circuit
IMPORTANT SAFETY
INSTRUCTIONS
FOR ALL MODELS:
When installing and using this
electrical equipment, basic safety
precautions should always be
followed, including the following:
1. READ AND FOLLOW ALL
INSTRUCTIONS.
2. WARNING — To reduce the risk
of injury, do not permit children to
use this product unless they are
closely supervised at all times.
3. WARNING — Risk of electric
shock. Connect only to a
grounding type receptacle
protected by a Ground Fault
Circuit Interrupter (GFCI).
Contact a qualified electrician if
you cannot verify that the
receptacle is protected by a
GFCI.
(For storable pool pumps) This
product is provided with a
ground-fault circuit interrupter. If
replacement of the plug or cord is
needed, use only identical
replacement parts.
(For all permanently installed
units) Connect only to a branch
circuit protected by a ground-fault
circuit-interrupter (GFCI)
4. Do not bury cord. Locate cord to
minimize abuse from lawn
mowers, hedge trimmers, and
other equipment.
5. WARNING — To reduce the risk
of electric shock, replace
damaged cord immediately.
6. WARNING — To reduce the risk
of electric shock, do not use
extension cord to connect unit to
electric supply; provide a
properly located outlet.
FOR UL MODELS ONLY:
0-3596-200, 0-3597-200, 0-3598-200
7. CAUTION — This pump is for
use with storable pools only. Do
not use with permanently
installed pools. A storable pool is
constructed so that it may be
readily disassembled for storage

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IMPORTANT:
INSTRUCTIONS AND
SAFETY INFORMATION
If you have purchased a filtration
system, follow the instructions
provided with your filter instructing
you to prepare the filter and pump
foundation using patio blocks and a
level.
Failure to use a pump base will cause
the motor to overheat and will void
any warranty.
Install filter and pump a minimum of 6
feet from the pool wall so they may
not be used as steps by children.
PUMP ASSEMBLY
1. Align the rectangle peg on the
base with the mating hole in the
pump housing (see pic below)
and refer to exploded view. Turn
the pump upside down and place
the pump base into the notches in
the pump. Attach the pump to the
pump base using the four (4) 5/8"
hex head screws supplied.
2. Place the O-rings over the
threads of the hose adaptors and
screw them into the intake and
discharge ports on the pump.
Caution: Do not over-tighten.
INITIAL START-UP
1. If you have a Doughboy filtration
system, follow the "Initial Start-
Up" instructions in the filter
owner's guide.
2. For best results, be sure to
select the HI speed switch
setting for initial startup, pump
priming, vacuuming and
backwashing the filter. Use the
LO speed switch setting for
surface skimming and filtering
over a longer period of time or
when energy savings is desired.
3. If this pump has been purchased
as a replacement (and you are
not referring to the filter
instructions), the pump will have
to be primed after all hose
connections have been made and
pool has been filled to the proper
level. To prime the pump, loosen
the pump strainer pot lid to allow
air to escape. Tighten lid when
water begins to flow between
strainer pot body and lid. Do not
overtighten.
CLEANING STRAINER
BASKET
1. Stop pump. Insert a winterizing
disk, or stuff a rag into the return
fitting to close off water flow from
the pool.
2. Remove skimmer basket. Stuff a
rag into the bottom of the
skimmer outlet port.
3. Remove strainer pot lid, lift out
basket, and clean thoroughly.
When replacing the basket, align
notch in basket with rib in strainer
pot. Clean and lubricate O-ring
with a non-petroleum lubricant.
Consult your pool store for proper
lubricant. Replace lid. Remove
winterizing disk and/or rags, and
replace basket and skimmer lid.
Only hand-tighten the lid.
MAINTENANCE
Make sure the pump is discon-
nected from the electrical source
before attempting any maintenance
work.
LUBRICATION:
Periodically lubricate the O-ring under
the strainer cover with a non-
petroleum lubricant recommended for
A.B.S., Noryl and Acrylic plastics.
Consult your pool dealer for lubricant
selections.
If you have questions or require
assistance, contact your local pool
dealer.

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PROBLEMS:
1. Motor will not start.
2. Pump will not prime.
3. Motor will stop without being turned off,
then restart later.
4. High pressure gauge reading with low
return flow.
5. Low pressure gauge reading with low
return flow.
6. Leak from front of pump.
REMEDIES:
1. Make sure pump is plugged into a
grounded, 3-wire, 115 V. electrical
receptacle that is not overloaded with
other appliances.
2. Check for improper or loose
connections, open switches or relays,
blown circuit breaker or fuses.
3. The use of an electrical extension cord
may cause a low power source. Have
a qualified electrician install a Ground
Fault Circuit Interrupter (GFCI) for
direct electrical access.
1. Make sure pool is filled to proper level.
Make sure pump, strainer pot and
hoses leading to and from pump are
filled with water. Make sure strainer
cover is secure and cover O-ring is
clean and properly sealed. Keep hose
connections tight to prevent water and/
or air leaks.
2. Clean out strainer basket, skimmer
basket and hoses if necessary.
1. Have a qualified electrician install a
Ground Fault Circuit Interrupter (GFCI)
for direct electrical access, or use a
heavier gauge extension cord.
2. Properly elevate pump 2 to 3 inches
above foundation according to
instructions.
3. Locate bind and remove cause.
4. Replace motor.
1. Backwash Filter.
2. Plug skimmer and return fitting, then
clear debris from return line.
1. Plug skimmer and return fitting, then
disassemble pump and clean impeller.
2. Plug skimmer and return fitting, then
clear debris from suction line.
1. Replace pump O-ring.
2. Replace pump seal set.
3. Replace pump volute.
TROUBLE SHOOTING CHECKLIST
NOTE: ALWAYS BE SURE PUMP IS DISCONNECTED FROM ELECTRICAL SOURCE
BEFORE ATTEMPTING ANY MAINTENANCE OR REPAIR WORK.
POSSIBLE CAUSE:
1. Pump not plugged in.
2. Faulty electrical outlet.
3. Low voltage.
1. Air in pump.
2. Clogged inlet and/or outlet
connections.
1. A too long or too light extension cord.
2. Blocked air vents on bottom of pump
housing causing motor to overheat.
3. There may be a bind in motor causing
overload.
4. Thermal protector in motor is faulty.
1. Filter is dirty.
2. Plugged or restricted return line.
1. Plugged or restricted impeller.
2. Clogged skimmer basket and/or
plugged suction line leading to pump.
1. Defective pump O-ring.
2. Worn pump seal set.
3. Cracked pump volute.

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PUMP & MOTOR PARTS LIST
ITEM P/N QTY DESCRIPTION MODEL
1 1121-1429 1 Strainer Cover All
2 308-1065 1 Strainer O-Ring All
3 1107-1018 1 Strainer Basket All
4 1121-2008 1 1/4" Pipe Plug w/O-ring(not shown) All
5 321-1021 6 1/4" -20 Flange Nut All
6 340-2288 1 Strainer Pot All
7 308-1064 1 Pump O-Ring All
8 340-2682 1 Pump Volute All
9 1107-1388 1 Impeller 1 HP Models
1107-1547 1 Impeller 1-1/2 - 2 HP Models
10 1121-1057 1 Seal Set All
11 1107-1659 1 Pump Housing All
12 330-1106 6 1/4"-20 x 2" Flange Bolt All
13 300-1150 1 1 HP Motor 60 HZ 0-3596-xxx
300-1149 1 1.5 HP Motor 60 HZ 0-3597-xxx
300-1149 1 2 HP Motor 0-3598-xxx
13a 310-1054 1 Baffle foam (not shown) All
14 1121-1967 1 Motor Enclosure All
14a 340-2608 1 Strainer cover wrench (not shown) All
15 330-1023 4 8 x 5/8" Hex Washer Screw All
16 343-1074 1 Switch Hole Plug Not required
17 1100-1707 1 Power Cord - 6' 1 HP -203 models
1100-1708 1 Power Cord - 6' 1.5-2 HP -203 models
1100-1115 1 Power Cord - NEC/UL - 3' -206 models
1100-1695 1 Power Cord 25' GFCI 1 HP 0-3596-200
1100-1696 1 Power Cord 25' GFCI 1.5-2 HP 0-3597-200, 0-3598-200
18 303-1715 1 Strain Relief Bushing - 25' & 6' -200 & -203 models
303-1120 1 Strain Relief Bushing - 3' models -206 models
19 330-1057 4 10-16 x 5/8" Hex Washer Screw All
20 340-2285 1 Pump Base All
21 348-1041 4 Stem Bumpers All
22 308-1042 2 O-Ring, Hose Adaptor All
23 340-2290 2 Hose Adaptor All
24a 1100-1712 1 Jumper Wire - blue
24 1100-1400 1 Jumper Wire
25 303-1350 1 Switch
26 303-1110 1 Switch Nut
ALL MODELS
27 365-2076 1 Owner's Guide
28 — 1 Warranty

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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.
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CAUTIONS
1. Do not install pump and filter
system where flooding may
occur. This could damage the
pump motor.
2. Do not install filter and pump on a
deck, or similar surface, above
pool water level. They could fall
into the pool water, causing
severe electrical shock.
3. Do not allow children or adults to
climb, sit or stand on the filter or
pump. They could easily fall and
injure themselves. Install the
filter and pump a minimum of 6
feet from the pool wall so they
may not be used as steps by
children.
WARNINGS
1. Always be sure the ground under
your feet and body is dry before
you touch the filter and pump
electrical equipment. Failure to
follow this warning may cause
injury due to severe electrical
shock.
2. Make sure pump is disconnected
from electrical source before
servicing pump and filter
equipment.
LOCAL CODES
Contact your local building
department for applicable codes or
regulations governing the installation
of swimming pool equipment.
CONTRACTED
ELECTRICIANS
Always have a licensed electrician
install electrical components to make
sure electrical integrity is maintained
in accordance with the pump data
label. Improper installation to power
supply may damage the pump motor.
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EXPLODED VIEW
Swimming Pool Pump
Doughboy Recreational
315 North Sebastian St. • West Helena, AR 72390
Visit our website at www.doughboy-pools.com
DB 0912-621 Made in the United States of America Copyright © 2012
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