Pacific hydrostar 68390 User manual

3/4 HP Automatic Booster Pump
Item: 68390
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
When unpacking, make sure that the product is intact and undamaged.
If any parts are missing or broken, please call 1-800-444-3353 as soon as possible.
Visit our website at: http://www.harborfreight.com
Copyright©2011 by Harbor Freight Tools®. All rights reserved. No portion of this manual or any artwork contained herein may be reproduced in any shape
or form without the express written consent of Harbor Freight Tools. Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein. Tools required for assembly and service may not be included.

Page 2 For technical questions, please call 1-800-444-3353. SKU 68390
Before start-up, note the following:
The pump can be connected to any shock-proof plug
which has been installed according to regulations.
The plug must have a supply voltage of 120 V~ at 60 Hz.
CAUTION
This pump has been evaluated for use with water only.
WARNING
IMPORTANT! For your own safety –
before starting to run the pump, please have
the following items checked by an expert:
1. Risk of electric shock – This pump is supplied
with a grounding conductor and grounding-type
attachment plug. To reduce the risk of
electric shock, connect only to a properly
grounded, grounding-type receptacle.
2. Risk of electric shock – This pump has not been
investigated for use in swimming pool areas.
3. The electrical connections must be
protected from moisture.
4. If there is danger of ooding, the electrical
connections must be taken to higher ground.
5. Circulation of caustic uids, as well as the circulation
of abrasive materials, must be avoided at all costs.
6. The pump must be protected from frost.
7. The pump must be protected from running dry.
8. This product is not a toy. Keep it out of reach
of children. Access by children should also
be prevented with appropriate measures.
9. WARNING: Handling the Power Cord
on this product will expose you to lead,
a chemical known to the State of California
to cause cancer, and birth defects or other
reproductive harm. Wash hands after handling.
(California Health & Safety Code § 25249.5, et seq.)
10. The warnings, precautions, and instructions
discussed in this instruction manual cannot
cover all possible conditions and situations
that may occur. It must be understood by the
operator that common sense and caution are
factors which cannot be built into this product,
but must be supplied by the operator.
Specic Pump Safety Warnings
1. Do not use with swimming pools or marine areas.
2. Do not use extension cords with this Pump.
3. Do not operate Pump on earth, clay or sand surfaces.
4. Do not allow the Motor to get wet.
5. Wear non-skid rubber boots when
any water is on the oor.
6. Inspect insulation regularly; do not
use if insulation damaged.
7. Use indoors only.
8. People with pacemakers should consult their
physician(s) before use. Electromagnetic elds in
close proximity to heart pacemaker could cause
pacemaker interference or pacemaker failure. In
addition, people with pacemakers should:
• Properly maintain and inspect to avoid electrical
shock.
• Any power cord must be properly
grounded. Ground Fault Circuit Interrupter
(GFCI) should also be implemented – it
prevents sustained electrical shock.
9. Secure the intake and discharge pipes (not included)
to a solid surface to ensure the stability of the Pump.
10. When connecting intake and discharge pipes
to Pump, be sure to use thread tape (not
included) and securely fasten pipes in place.
11. Mount the Pump on a at, level surface before use.
12. Prior to use, and periodically thereafter, check to
make sure all connections are tight and secure.
13. Industrial applications must follow
OSHA requirements.
Fluid Type
The Pump is designed for use with water with a maximum
temperature of 77° F (25°C). Do not use the pump for
other uids, especially not fuels, cleaning uids, or other
chemical products.

Page 3For technical questions, please call 1-800-444-3353.SKU 68390
Specications
Max. Pumping
Capacity 1100 Gallons Per Hour
Electrical
Requirements 120V~ / 60Hz / 11.1 A
Motor 3/4 Horsepower Electric
Power Cord Length 5 FT.
Max. Lift Capacity 164 FT.
Pressure 14.5 - 45 PSI
Inlet / Outlet Size 1 IN. NPT
236418
JTS-441
Unpacking
When unpacking, make sure that the item is
intact and undamaged. If any parts are missing
or broken, please call Harbor Freight Tools at
1-800-444-3353 as soon as possible.
Installation
Please note!
1. Do not install the pump by suspending it
unsupported from its power cord or discharge hose.
The pump must be suspended from the handle.
2. Remove Shipping Plug (24) before installation.
Installing
1. Set the Pump on a level, solid and dry foundation.
Mount horizontally, keeping the suction and
discharge ports as horizontal as possible.
2. Secure the Pump to the mounting surface
by installing bolts (not included) through
the mounting holes in the base plate.
3. The Pump is supplied with 1” NPT
connections to be tted in the suction and
discharge ports. See Figure 1, above.
4. The Pump is equipped with a check valve to prevent
backow during priming and regular operation.
NOTE: We recommend tting the check valve in
the Pump’s suction port. See Figure 1, above.
5. If the Pump is installed with long pipes (as
shown above), the pipes must be properly
supported on either side of the Pump to prevent
straining the connections. If the Pump is
drawing water from a well, t a foot valve (not
included) to the end of the suction pipe.
6. WARNING! Do not allow the Pump to get wet.
120V Outlet
Pump Intake
Pump Discharge
Figure 1
Check
Valve
Base Plate
7. If a hose is used for the suction pipe, make sure
it is a non-collapsible hose. Route the hose to
the desired discharge area. The hose should
be kept as short as possible with a minimum
number of turns. If necessary, additional plastic
90° elbows should be used to prevent kinking.
8. NOTE: The maximum delivery
height of the Pump is 32 feet.
9. Verify the pump is well-primed and there are
no leaks in the system before starting. Open
one tap at the outlet for air discharge.
Operation
Consider the following points before starting the pump:
1. Verify that the pump rests on the oor.
2. Verify that the delivery pipe is properly connected.
3. Verify that the electrical connection is 120V~, 60 Hz.
4. Verify that the electrical socket is in good condition.
5. Verify that water and moisture cannot
get near the power supply socket.
6. Verify that the pump is installed so as to prevent
running dry.

Page 4 For technical questions, please call 1-800-444-3353. SKU 68390
7. Note the controls on the Pressure Control Box.
This device will protect against run-dry operation,
overheating, improper starting, and pressure drops.
Figure 2
Reset Button
Starting
Pressure Dial
Power-on LED
Pump-on LED
Temp Failure LED
Water Failure LED
Pressure
Control
8. NOTE: The Pump does not have an ON/
OFF Power Switch. The Pump is turned
on once the power cord is plugged in.
9. Turn the Starting Pressure Dial to set the system
pressure anywhere between 15 to 45 PSI.
10. Turn on the water supply leading to the pump.
If the water supply is inadequate to reach
the pump, remove the Priming Plug (22)
and ll the pump housing with water.
11. Plug in the power cord. The POWER-ON LED will
light, indicating that voltage is present. The Pump is
ready to operate.
NOTE: Once the system pressure drops below the
pressure which you’ve set on the Pressure Dial, the
system will automatically shut off.
NOTE: The Pump will not activate until the
RESET button is pressed and then released.
12. Once the Pump is running and pumping
water, the PUMP-ON LED will light.
13. If no water is coming into the Pump, the WATER
FAILURE LED will light and the Pump will shut off.
Press the RESET button to restart the Pump.
14. Once the inside temperature of the Pump exceeds
158° F (70° C), the TEMPERATURE FAILURE
LED will light and the Pump will shut off.
15. WARNING! Do not turn or adjust the
Automatic Pressure Controller. This is a
pre-set setting and twisting it will break the
glue joint and cause the Pump to leak.
16. The Pump will continue to run until water is pumped.
The Pump will stop automatically 7 to 9 seconds
after the pressure inside the system reaches
the maximum working pressure of the Pump.
17. If running the Pump in continuous
mode, unplug the Power Cord from the
electrical outlet to turn off the Pump.
Maintenance
TO PREVENT SERIOUS INJURY FROM
ACCIDENTAL OPERATION:
Unplug the Pump from its electrical
outlet before performing any inspection,
maintenance, or cleaning procedures.
Quarterly Maintenance
The below maintenance must be performed at least
once every 3 months under optimal conditions.
For frequent use, or dirty areas,
more frequent maintenance is required.
1. BEFORE EACH USE, inspect the general condition
of the Pump. Check for loose screws, misalignment
or binding of moving parts, cracked or broken
parts, damaged discharge hose, and any other
condition that may affect its safe operation.
2. AFTER EACH USE, clean the external surfaces of
the Pump with clean cloth. Then store the Pump in a
clean, dry and safe location out of reach of children.

Page 5For technical questions, please call 1-800-444-3353.SKU 68390
Troubleshooting
Problem Possible Causes Possible Solutions
Motor will not run. 1. Fuse is blown or circuit
breaker tripped.
2. Power cord not plugged in.
1. Disconnect power and replace fuse
or reset circuit breaker.
2. Plug into grounded outlet.
Motor runs hot and
overload kicks off;
motor does not run
and only hum.
1. Voltage is too low.
2. Impeller not moving freely.
1. Check voltage being supplied to pump.
2. Check that impeller moves freely and is not clogged.
Motor runs but
no water is being
delivered.
1. Improper priming.
2. Clogged water lter.
3. Discharge valve closed.
4. Pipe size too small.
5. Impeller is plugged.
6. Pipes are frozen.
1. Re-prime according to instructions.
2. Stop pump, shut off water, and change lter cartridge.
Filter should be installed on discharge side of pump.
3. Open valve.
4. Re-pipe using pipe of the same size as
suction and discharge ports on pump.
5. Clean impeller.
6. Thaw pipes.
Pump does not
deliver water to
full capacity.
1. Corroded pipes.
2. Piping size is too small.
3. Pump not being supplied
with enough water.
4. Low voltage.
1. Replace with plastic or new steel pipes.
2. Re-pipe using pipe the same size as
suction and discharge ports on pump.
3. Enlarge inlet pipe; check well pump system.
4. Make sure outlet is 120 volts.
Pump vibrates
and/or is noisy.
1. Impeller damaged.
2. Worn motor bearings.
3. Mounting plate or base not rigid.
4. Foreign object in pump.
1. Replace impeller.
2. Replace bearings.
3. Reinforce mounting.
4. Disassemble pump and remove.
Follow all safety precautions whenever diagnosing or servicing the tool.
Disconnect power supply before service.

Page 6 For technical questions, please call 1-800-444-3353. SKU 68390
Part Description Qty.
1 Motor Cover 1
2 Fan 1
3 Hex Bolt 4
4 Rear Cover 1
5 Round Spring 1
6 Rotor 1
7 Bearing 2
8 Stator 1
9 Lock Nut 9
10 Front Cover 1
11 Washer 1
12 Rear Fluid Housing 1
13 Seal 1
14 O-Ring 2
15 Impeller 1
16 O-Ring 1
17 Front Fluid Housing 1
18 O-Ring 1
19 Connector 1
20 O-Ring 1
21 Pump Housing 1
22 Hex Bolt 2
23 O-Ring 2
24 Shipping Plug 1
25 Hex Screw 8
26 Pressure Controller 1
Part Description Qty.
27 Power Cable 1
28 Lock Nut 2
29 Spring Washer 2
30 Flat Washer 4
31 Pump Base 1
32 Hex Bolt 2
33 Seal 1
34 Wire Housing 1
35 Flat Screw 4
36 Screw Frame 1
37 Screw 2
38 Terminal 1
39 Cable Jacket 1
40 Nut 1
41 Capacitor 1
42 Seal 1
43 Wire Housing Cover 1
44 Screw 2
45 O-Ring 2
46 Screw 2
47 Hex Bolt 1
48 Flat Washer 1
49 Handle Cover 1
50 Handle 1
51 Motor Cable 1
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM
IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR
MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS
QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS QUALIFIED TO REPLACE
ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY
STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND
LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY
ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS
THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.
PARTS LIST
Record Product’s Serial Number Here:
Note: If product has no serial number, record month and year of purchase instead.
Note: Some parts are listed and shown for illustration purposes only,
and are not available individually as replacement parts.

Page 7For technical questions, please call 1-800-444-3353.SKU 68390
ASSEMBLY DIAGRAM
- 8 -
PARTS ASSEMBLY DIAGRAM

Page 8 For technical questions, please call 1-800-444-3353. SKU 68390
LIMITED 90 DAY WARRANTY
Harbor Freight Tools Co. makes every effort to assure
that its products meet high quality and durability
standards, and warrants to the original purchaser
that this product is free from defects in materials and
workmanship for the period of 90 days from the date
of purchase. This warranty does not apply to damage
due directly or indirectly, to misuse, abuse, negligence
or accidents, repairs or alterations outside our facilities,
criminal activity, improper installation, normal wear and
tear, or to lack of maintenance. We shall in no event
be liable for death, injuries to persons or property, or
for incidental, contingent, special or consequential
damages arising from the use of our product. Some
states do not allow the exclusion or limitation of incidental
or consequential damages, so the above limitation of
exclusion may not apply to you. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
To take advantage of this warranty, the product or part
must be returned to us with transportation charges
prepaid. Proof of purchase date and an explanation
of the complaint must accompany the merchandise. If
our inspection veries the defect, we will either repair
or replace the product at our election or we may elect
to refund the purchase price if we cannot readily and
quickly provide you with a replacement. We will return
repaired products at our expense, but if we determine
there is no defect, or that the defect resulted from
causes not within the scope of our warranty, then
you must bear the cost of returning the product.
This warranty gives you specic legal rights and you may
also have other rights which vary from state to state.
3491 Mission Oaks Blvd. • PO Box 6009 Camarillo, CA 93011 • [phone]