Pacific hydrostar 68476 Assembly instructions

Item 68455 shown.
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Email our technical support at: [email protected]
Owner’s Manual & Safety Instructions
Save This Manual Keep this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the
back of the manual near the assembly diagram (or month and year of purchase if product has no number).
Keep this manual and the receipt in a safe and dry place for future reference.
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-888-866-5797 as soon as possible.
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.
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
REV 15i

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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 VAC 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,
be certain that it is connected 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 flooding, the electrical
connections must be taken to higher ground.
5. Circulation of caustic fluids, 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. Access by children should also be
prevented with appropriate measures.
9. Position the Pump on a flat, level, solid surface.
Also secure the discharge pipe (not included) to a
solid surface to ensure the stability of the Pump.
10. Do not use with an extension cord.
If a GFCI-protected outlet is not close enough
to the Pump, contact a licensed electrician to
install a new one. All wiring must be performed
by a licensed electrician and comply with
the National Electric Code. Do not remove
the round grounding pin from the plug.
11. Turn off power to all circuits before walking on
a wet floor. If you cannot turn power off first,
contact an electrician to turn off the power.
12. Install a backup pump and/or high water alarm
as an additional safeguard against flooding.
13. WARNING: The cord of this product contains
lead and/or di (2-ethylhexyl) phthalate (DEHP),
chemicals 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.)
14. People with pacemakers should consult their
physician(s) before use. Electromagnetic fields in
close proximity to heart pacemaker could cause
pacemaker interference or pacemaker failure.
15. 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.
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 fluids, especially not fuels, cleaning fluids, or other chemical products.

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Specifications
ITEM 68455 68476 68454
Float Switch Operation Height 8.4" ON / 4.0" OFF
Electrical Requirements 120 VAC / 60 Hz / 6.4 A 120 VAC / 60 Hz / 7.6 A 120 VAC / 60 Hz / 9.8 A
Power Cord Length 10 Feet
Maximum Capacity 2800 GPH 3000 GPH 3200 GPH
Maximum Delivery Height 22 Feet 25 Feet 28 Feet
Discharge Size 1.5" NPT (includes 1.25" Adaptor)
Maximum Water Temperature 77° F (25°C)
252728
Installation
The submersible motor pump must be installed
in a stationary position with either:
a. A fixed pipeline or
b. A flexible hose pipe.
Please note!
1. Do not install the pump by suspending it
unsupported from its delivery pipe or power cords.
The pump must be suspended from the
handle or be placed on the bottom of the shaft.
To ensure that the pump works properly,
keep the bottom of the shaft free from
sludge and dirt of all kinds.
2. If the water level sinks too low, any sludge in the
shaft will dry out and stop the pump from starting.
To help ensure the pump will start as required,
check the pump regularly with start-up tests.
Power Supply
1. The pump is equipped with a shock-proof
plug according to regulations. The pump
is designed to be connected to 120 VAC,
60 Hz, Ground Fault Circuit Interrupter
(GFCI) protected safety socket.
2. Make sure that the socket is sufficiently
secured and is in excellent condition.
3. When the plug is inserted into the socket
the pump will be on standby.
4. Connect the Pump Power Cord only through the
Float Switch Cord plug to prevent dry running.
WARNING! If either power cord or plug is damaged,
do not use the pump. The power cord or plug
may only be repaired by a certified electrician.
Areas of use
1. This pump is designed to pump clear water only.
2. This pump is designed for use as a basement pump.
When installed in a shaft, this pump provides
some protection from basement flooding.
3. This pump can also be used to transfer water
(e.g. household, farming, plumbing).

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Installation Instructions
1. Construct a basin that is at least 22" deep
and at least 14" in diameter.
at least 14″
diameter
at least 22" deep
Sump
Basin
Inlet Pipe
Figure A: Sump Basin
2. Position pump on solid surface so that the Float
Switch is away from the inlet pipe and at least 1"
away from all obstructions throughout its movement.
3. Fit a sump cover with a hole for the output pipe
and a hole for the power cords. Thread the
Power Cords through their holes, but do not plug
them in yet. Set the sump cover aside for now.
Note: The sump cover can also be
fitted with a vent pipe, if desired.
Float
Switch
Pump
Pump
Cord
Sump Cover Float
Switch
Cord
Figure B: Pump Position
4. Attach a discharge pipe to the Pump Outlet.
Note: Wrap all threaded connections
with PTFE thread seal tape.
5. To prevent needless cycling, install a check valve
onto the discharge pipe. This prevents water
from flowing back after the pump shuts off.
To discharge
(away from foundation)
GFCI-Protected
Receptacle
Pump
Cord
Float
Switch
Cord
Check
Valve
Pump
Outlet
1/8"
Air Bleed
Hole
Discharge
Pipe
Figure C: Outlet Pipe and Plug
6. IMPORTANT: Drill a 1/8" diameter air bleed hole
through the Discharge Pipe just above the lower Base
to prevent Pump ″airlock″. A small spray of water
out of this hole is normal while the Pump is running.
7. Install a gate valve or ball valve if
required by building codes.
8. The ON/OFF height can be changed
by adjusting the Float Switch.
9. Connect additional Discharge Pipe as needed
to direct the water discharge at least 3 feet
away from the foundation. Slope the discharge
pipe downward, away from the foundation.
The discharge should be kept as short as
possible with a minimum number of turns.
IMPORTANT: Do not exceed the
Maximum Delivery Height of the Pump.

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Operation
After reading these instructions,
consider the following points before starting the pump:
1. Verify that the pump rests on the floor of the shaft,
if it is not suspended by the handle.
2. Verify that the delivery pipe is properly connected.
3. Verify that the electrical connection is
120 VAC, 60 Hz, and GFCI-protected.
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.
7. Verify that the power cords do not have
excess slack in the Sump Basin to prevent
it from interfering with the Float Switch.
Secure them to the Discharge Pipe if needed.
8. Dry the floor and your hands,
then plug the Float Switch Cord into
a grounded, GFCI-protected receptacle.
9. Plug the Pump Cord into the back of the Float Switch
Cord’s plug. The pump will then be on standby.
GFCI-Protected
Receptacle
Pump
Cord
Float
Switch
Cord
Figure D: Outlet Pipe and Plug
10. After connecting power to the pump and
periodically afterwards, test the pump:
a. Fill the basin to above the Float Switch Operation
ON Height. The pump should start pumping.
b. The pump should pump the water down
to below its Float Switch Operation OFF
Height and then stop pumping.
c. If the water drains back into the basin and
restarts the pump, make sure the check
valve is properly installed and working.
Also make sure that all pipe connections are tight.
Note: It is the owner’s responsibility to ensure the
float switch is properly connected to the pump and can
operate properly and freely without obstructions.
Maintenance
TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION:
Unplug the Pump from its electrical outlet and ALLOW TO COOL FOR AT LEAST 2 HOURS
before performing any inspection, maintenance, or cleaning procedures.
If the pump is moved during operation, flush it out with clean water after every use.
1. Before each use, inspect the general condition
of the Pump. Check for cracked or broken parts,
damaged electrical wiring, clogged Impeller
Cover, Impeller, Discharge Pipes, leaks and
loose connections, and any other condition that
may affect safe operation. If abnormal noise or
vibration occurs, have the problem corrected before
further use.Do not use damaged equipment.
2. Keep the Sump Basin clean. Clean out thesump
basin regularly and keep the cover in place
to keep it clean. Sand and other debris can
interfere with pump operation, can block the air
bleed hole, or can cause premature wear.
3. Clean out the air bleed hole periodically.
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. Remove the Sump Basin Cover.
2. Clean sludge and debris from the bottom of the shaft.
3. Rinse the housing off with clean water.
4. Clean fibers from inside the pump housing
with a pressure washer (not included).

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5. If the pump housing cannot be cleaned from
the outside, it must be thoroughly cleaned.
Unplug the power cord before maintenance.
Dismantle the bottom part of the pump as follows:
a. Remove the Screws at the bottom of the Base.
b. Remove the Volute to expose the Impeller.
c. Clean the impeller with clean water.
d. To prevent damage, do not rest the pump on
the impeller or pry against the impeller.
e. Reassemble in reverse order.
6. Make sure the float switch can operate
freely, without obstructions.
7. Replace the Sump Basin Cover.
Cold Weather Storage
In cold weather, when the Pump is not in use,
protect the interior of the Pump from freezing by
draining the water and pumping a permanent-type
automobile anti-freeze containing a rust inhibitor
through the system. A 50% mixture with water is
recommended. Be sure to flush the system with a
neutralizing liquid prior to re-use of the Pump.
WARNING! The oil inside some pump types
can be harmful to the environment. Check state
environmental laws before disposing of any pump oil.
Troubleshooting
Problem Possible Causes Possible Solutions
Pump runs, but
will not deliver
any water.
Disconnect power cords immediately
to prevent damage from running dry.
1. Pump “airlock”. Impeller
trapped in an air bubble.
2. Shut-off valve closed (if installed).
3. Filter (if installed) and/or
impeller clogged.
4. Check valve (optional) stuck
or installed backwards.
Disconnect power cords immediately
to prevent damage from running dry.
1. Drill a 1/8" diameter air bleed hole through the Discharge Pipe
just above the Lower Base. Make sure air bleed hole is clear.
2. Open valve.
3. Remove filter and/or volute. Clean out dirt and debris
from filter and/or impeller. Replace filter and/or volute.
4. Examine and correct check valve.
Pump won’t
start or run.
1. Check power connections
and circuits/fuses.
2. Float Switch failed.
3. Filter (if installed) and/or
impeller clogged.
4. Defective motor.
1. Consult with an electrician.
2. Replace Float Switch.
3. Remove filter and/or volute. Clean out dirt and debris
from filter and/or impeller. Replace filter and/or volute.
4. Have a qualified service technician repair or replace.
Excessive noise
or vibration.
1. Debris in impeller.
2. Discharge pipe restricted.
3. Worn bearings.
1. Remove volute. Clean impeller. Reinstall volute.
2. Clean Pump and discharge pipe. Straighten flexible hose.
3. Have a qualified service technician repair or replace.
Pump starts
and stops too
frequently.
1. Water temperature too high.
2. Back flow of water from discharge pipe.
3. Extension cord used.
1. Do not exceed 77° F (25°C) water temperature.
2. Install or inspect check valve (optional).
3. Eliminate use of extension cord. Have licensed electrician
install GFCI-protected outlet if needed.
Pump does
not shut off
automatically.
DISCONNECT POWER CORDS FIRST
TO PREVENT SERIOUS INJURY.
1. Pump Cord not connected through
Float Switch Cord plug.
2. Float Switch stuck.
3. Check valve not installed or
functioning properly.
4. Defective Float Switch.
DISCONNECT POWER CORDS FIRST
TO PREVENT SERIOUS INJURY.
1. Plug Pump Cord into back of Float Switch Cord plug.
2. Check for free movement of Float Switch. Clear
debris away from beneath Float Switch.
3. Ensure check valve is properly installed and in working order.
4. Unplug Pump. Have qualified technician
check Pump for proper operation.
Follow all safety precautions whenever diagnosing or servicing the tool.
Disconnect power supply before service.

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Part Description Qty.
1 Pump Cord 1
2 Handle 1
3 Motor 1
4 Impeller 1
5 Gasket 1
6 Volute 1
7 Screw 7
8 Adaptor 1
9 Float Switch 1
10 Float Switch Cord 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 and Assembly Diagram
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.

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 verifies 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 specific 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 • 1-888-866-5797