Pacific hydrostar Pacific Hydrostar Portable Utility Pump... Installation manual

PORTABLE UTILITY PUMP
65836
SET UP AND OPERATING INSTRUCTIONS
Distributed exclusively by Harbor Freight Tools®.
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our website at: http://www.harborfreight.com
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
Copyright©2008 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.
For technical questions or replacement parts, please call 1-800-444-3353.

SKU 65836 For technical questions, please call 1-800-444-3353. Page 2
SAVE THIS MANUAL
Keep this manual for the safety warn-
ings and precautions, assembly, operat-
ing, 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.
IMPORTANT SAFETY
INFORMATION
In this manual, on the labeling,
and all other information provid-
ed with this product:
This is the safety alert
symbol. It is used to alert
you to potential personal
injury hazards. Obey all
safety messages that
follow this symbol to avoid
possible injury or death.
DANGER indicates
a hazardous
situation which, if not
avoided, will result in death or
serious injury.
WARNING
indicates a
hazardous situation which, if
not avoided, could result in
death or serious injury.
CAUTION, used
with the safety
alert symbol, indicates a
hazardous situation which, if
not avoided, could result in
minor or moderate injury.
NOTICE is used to
address practices
not related to personal injury.
CAUTION, without
the safety alert
symbol, is used to address
practices not related to
personal injury.
General Power Tool Safety
Warnings
WARNING Read all safety
warnings and instructions.
Failure to follow the warnings and
instructions may result in electric
shock, re and/or serious injury.
Save all warnings and
instructions for future reference.
The term ″power tool″ in the
warnings refers to your mains-
operated (corded) power tool or
battery-operated (cordless) power
tool.
Work area safety1.
Keep work area clean and well lit.a.
Cluttered or dark areas invite acci-
dents.
Do not operate power tools inb.
explosive atmospheres, such as in
the presence of ammable liquids,
gases or dust. Power tools create
sparks which may ignite the dust or
fumes.
Keep children and bystandersc.
away while operating a power tool.
Distractions can cause you to lose
control.
Electrical safety2.
Power tool plugs must match thea.
outlet. Never modify the plug in
any way. Do not use any adapter

SKU 65836 For technical questions, please call 1-800-444-3353. Page 3
plugs with grounded power tools.
Unmodied plugs and matching out-
lets will reduce risk of electric shock.
Avoid body contact with groundedb.
surfaces such as pipes, radiators,
ranges and refrigerators. There is
an increased risk of electric shock if
your body is grounded.
Do not expose power tools to rainc.
or wet conditions. Water entering
a power tool will increase the risk of
electric shock.
Do not abuse the cord. Never used.
the cord for carrying, pulling or
unplugging the power tool. Keep
cord away from heat, oil, sharp
edges or moving parts. Damaged
or entangled cords increase the risk
of electric shock.
When operating a power tool out-e.
doors, use an extension cord suit-
able for outdoor use. Use of a cord
suitable for outdoor use reduces the
risk of electric shock.
If operating a power tool in a dampf.
location is unavoidable, use a
Ground Fault Circuit Interrupter
(GFCI) protected supply. Use of
a GFCI reduces the risk of electric
shock.
Personal safety3.
Stay alert, watch what you are do-a.
ing and use common sense when
operating a power tool. Do not use
a power tool while you are tired
or under the inuence of drugs,
alcohol or medication. A moment
of inattention while operating power
tools may result in serious personal
injury.
Use personal protective equip-b.
ment. Always wear eye protection.
Safety equipment such as dust mask,
non-skid safety shoes, hard hat, or
hearing protection used for appropri-
ate conditions will reduce personal
injuries.
Prevent unintentional starting.c.
Ensure the switch is in the off-po-
sition before connecting to power
source and/or battery pack, pick-
ing up or carrying the tool. Carry-
ing power tools with your nger on
the switch or energizing power tools
that have the switch on invites acci-
dents.
Remove any adjusting key ord.
wrench before turning the power
tool on. A wrench or a key left at-
tached to a rotating part of the power
tool may result in personal injury.
Do not overreach. Keep propere.
footing and balance at all times.
This enables better control of the
power tool in unexpected situations.
Dress properly. Do not wear loosef.
clothing or jewelry. Keep your
hair, clothing and gloves away
from moving parts. Loose clothes,
jewelry or long hair can be caught in
moving parts.
If devices are provided for the con-g.
nection of dust extraction and col-
lection facilities, ensure these are
connected and properly used. Use
of these devices can reduce dust-re-
lated hazards.
Only use safety equipment thath.
has been approved by an appropri-
ate standards agency. Unapproved
safety equipment may not provide
adequate protection. Eye protection
must be ANSI-approved and breath-
ing protection must be NIOSH-ap-

SKU 65836 For technical questions, please call 1-800-444-3353. Page 4
proved for the specic hazards in the
work area.
Power tool use and care4.
Do not force the power tool. Usea.
the correct power tool for your ap-
plication. The correct power tool will
do the job better and safer at the rate
for which it was designed.
Do not use the power tool if theb.
switch does not turn it on and off.
Any power tool that cannot be con-
trolled with the switch is dangerous
and must be repaired.
Disconnect the plug from thec.
power source and/or the battery
pack from the power tool before
making any adjustments, chang-
ing accessories, or storing power
tools. Such preventive safety mea-
sures reduce the risk of starting the
power tool accidentally.
Store idle power tools out of thed.
reach of children and do not allow
persons unfamiliar with the power
tool or these instructions to oper-
ate the power tool. Power tools are
dangerous in the hands of untrained
users.
Maintain power tools. Check fore.
misalignment or binding of moving
parts, breakage of parts and any
other condition that may affect the
power tool’s operation. If dam-
aged, have the power tool repaired
before use. Many accidents are
caused by poorly maintained power
tools.
Keep cutting tools sharp andf.
clean. Properly maintained cutting
tools with sharp cutting edges are
less likely to bind and are easier to
control.
Use the power tool, accessoriesg.
and tool bits etc. in accordance
with these instructions, taking into
account the working conditions
and the work to be performed. Use
of the power tool for operations differ-
ent from those intended could result
in a hazardous situation.
Service6.
Have your power tool serviced bya.
a qualied repair person using
only identical replacement parts.
This will ensure that the safety of the
power tool is maintained.
Portable Pump Safety Warnings
Maintain labels and nameplates on1.
the tool. These carry important safety
information. If unreadable or miss-
ing, contact Harbor Freight Tools for a
replacement.
Avoid unintentional starting. Prepare2.
to begin work before turning on the
tool.
Do not leave the tool unattended3.
when it is plugged into an electrical
outlet. Turn off the tool, and unplug it
from its electrical outlet before leav-
ing.
This product is not a toy. Keep it out4.
of reach of children.
People with pacemakers should5.
consult their physician(s) before use.
Electromagnetic elds in close prox-
imity to heart pacemaker could cause
pacemaker interference or pacemak-
er failure. In addition, people with
pacemakers should:
• Avoid operating alone.
• Do not use with power switch locked
on.

SKU 65836 For technical questions, please call 1-800-444-3353. Page 5
• Properly maintain and inspect to
avoid electrical shock.
• Any power cord must be properly
grounded. Ground Fault Circuit Inter-
rupter (GFCI) should also be imple-
mented – it prevents sustained elec-
trical shock.
WARNING: Handling the cord on6.
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. (Califor-
nia Health & Safety Code § 25249.5,
et seq.)
WARNING: The brass components7.
of this product contain lead, a chemi-
cal known to the State of California
to cause birth defects (or other repro-
ductive harm). (California Health &
Safety code § 25249.5, et seq.)
The warnings, precautions, and in-8.
structions discussed in this instruction
manual cannot cover all possible con-
ditions 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.
SAVE THESE
INSTRUCTIONS.
GROUNDING
TO PREVENT
ELECTRIC SHOCK
AND DEATH FROM
INCORRECT GROUNDING
WIRE CONNECTION:
Check with a qualied
electrician if you are in doubt
as to whether the outlet is
properly grounded. Do not
modify the power cord plug
provided with the tool. Never
remove the grounding prong
from the plug. Do not use the
tool if the power cord or plug
is damaged. If damaged, have
it repaired by a service facility
before use. If the plug will not
t the outlet, have a proper
outlet installed by a qualied
electrician.
Grounded Tools: Tools with Three
Prong Plugs
Tools marked with “Grounding Re-1.
quired” have a three wire cord and
three prong grounding plug. The
plug must be connected to a properly
grounded outlet. If the tool should
electrically malfunction or break
down, grounding provides a low
resistance path to carry electricity
away from the user, reducing the risk

SKU 65836 For technical questions, please call 1-800-444-3353. Page 6
of electric shock. (See 3-Prong Plug
and Outlet.)
The grounding prong in the plug is2.
connected through the green wire in-
side the cord to the grounding system
in the tool. The green wire in the cord
must be the only wire connected to
the tool’s grounding system and must
never be attached to an electrically
“live” terminal. (See 3-Prong Plug
and Outlet.)
The tool must be plugged into an3.
appropriate outlet, properly installed
and grounded in accordance with all
codes and ordinances. The plug and
outlet should look like those in the
preceding illustration. (See 3-Prong
Plug and Outlet.)
Double Insulated Tools: Tools
with Two Prong Plugs
Tools marked “Double Insulated” do1.
not require grounding. They have
a special double insulation system
which satises OSHA requirements
and complies with the applicable
standards of Underwriters Labora-
tories, Inc., the Canadian Standard
Association, and the National Electri-
cal Code. (See Outlets for 2-Prong
Plug.)
Double insulated tools may be used2.
in either of the 120 volt outlets shown
in the preceding illustration. (See
Outlets for 2-Prong Plug.)
Extension Cords
Grounded1. tools require a three wire
extension cord. Double Insulated
tools can use either a two or three
wire extension cord.
As the distance from the supply outlet2.
increases, you must use a heavier
gauge extension cord. Using exten-
sion cords with inadequately sized
wire causes a serious drop in voltage,
resulting in loss of power and pos-
sible tool damage.
(See Table A.)
The smaller the gauge number of the3.
wire, the greater the capacity of the
cord. For example, a 14 gauge cord
can carry a higher current than a 16
gauge cord. (See Table A.)
When using more than one exten-4.
sion cord to make up the total length,
make sure each cord contains at
least the minimum wire size required.
(See Table A.)
If you are using one extension cord5.
for more than one tool, add the
nameplate amperes and use the sum
to determine the required minimum
cord size. (See Table A.)
If you are using an extension cord6.
outdoors, make sure it is marked with
the sufx “W-A” (“W” in Canada) to
indicate it is acceptable for outdoor
use.
Make sure the extension cord is prop-7.
erly wired and in good electrical con-

SKU 65836 For technical questions, please call 1-800-444-3353. Page 7
dition. Always replace a damaged
extension cord or have it repaired by
a qualied electrician before using it.
Protect the extension cords from8.
sharp objects, excessive heat, and
damp or wet areas.
RECOMMENDED MINIMUM WIRE
GAUGE FOR EXTENSION CORDS*
(120/240 VOLT)
NAMEPLATE
AMPERES
(at full load)
EXTENSION CORD
LENGTH
25’ 50’ 75’
100’ 150’
0 – 2.0 18 18 18 18 16
2.1 – 3.4 18 18 18 16 14
3.5 – 5.0 18 18 16 14 12
5.1 – 7.0 18 16 14 12 12
7.1 – 12.0 18 14 12 10 -
12.1 – 16.0 14 12 10 - -
16.1 – 20.0 12 10 - - -
TABLE A
* Based on limiting the line
voltage drop to ve volts at
150% of the rated amperes.
Symbology
Double Insulated
Canadian Standards Association
Underwriters Laboratories, Inc.
V~ Volts Alternating Current
AAmperes
n0xxxx/min. No Load Revolutions per Minute
(RPM)

SKU 65836 For technical questions, please call 1-800-444-3353. Page 8
SPECIFICATIONS
Electrical Requirements 115 V~ / 60 Hz / 8.4 A
Pumping Capacity 1500 GPH Max.
Inlet & Outlet Size 1” x 11.5 TPI
(Standard Hose Size)
Pump Lift Capacity 120 Feet
UNPACKING
When unpacking, check to make sure
that the item is intact and undamaged. If
any parts are missing or broken, please
call Harbor Freight Tools at the number
shown on the cover of this manual as soon
as possible.
List of contents
Description Q’ty
Portable Utility Pump 1
Basket Filter 1
INSTRUCTIONS FOR
PUTTING INTO USE
Read the ENTIRE IMPORTANT
SAFETY INFORMATION
section at the beginning of this
manual including all text under
subheadings therein before set
up or use of this product.
TO PREVENT
SERIOUS INJURY
FROM ACCIDENTAL
OPERATION:
Turn the Power Switch of the
tool to its “OFF” position and
unplug the tool from its
electrical outlet before
assembling or making any
adjustments to the tool.
Note: For additional information regarding
the parts listed in the following pages,
refer to the Assembly Diagram near
the end of this manual.
Assembly
Inlet and outlet hoses (not included)1.
must be attached to pump prior to
use.
Attach inlet and outlet hoses to Hose2.
Fittings (3) on Pup Facing (2). Stan-
dard garden hose tting will work.
Attach the Accessory Basket Filter3.
included with the Pump to the inlet
end of the inlet hose. The strainer will
prevent foreign material from entering
the pump and damaging or jamming
it.
Mounting
Pump should be rmly mounted on a 1.
stabile base prior to use.
The pump and its electrical connec-2.
tions should be mounted so that they
remain dry. Water may damage the
pump if it enters any electrical com-
ponent.
Functions
This pump is useful for pumping1.
clean water. Do not use for dirty wa-
ter containing large particulates.
OPERATING INSTRUCTIONS
Read the ENTIRE IMPORTANT
SAFETY INFORMATION
section at the beginning of this
manual including all text under
subheadings therein before set
up or use of this product.

SKU 65836 For technical questions, please call 1-800-444-3353. Page 9
Tool Set Up
TO PREVENT
SERIOUS INJURY
FROM ACCIDENTAL
OPERATION:
Turn the Power Switch of the
tool to its “OFF” position and
unplug the tool from its
electrical outlet before
performing any inspection,
maintenance, or cleaning
procedures.
This pump operates immediately1.
when plugged in. Do not plug in this
pump when dry. Always prime pump
before plugging in.
Work Piece and Work Area Set Up
Designate a work area that is clean1.
and well-lit. The work area must not
allow access by children or pets to
prevent injury and distraction.
Route the power cord along a safe2.
route to reach the work area without
creating a tripping hazard or exposing
the power cord to possible damage.
The power cord must reach the work
area with enough extra length to al-
low free movement while working.
There must not be hazardous ob-3.
jects, such as utility lines or foreign
objects, nearby that will present a
hazard while working.
Protect yourself and others from4.
risk of electrical shock. Always wear
insulated boots and gloves. Stay out
of water or wet surfaces. Protect the
pump and its power cord from mois-
ture.
Never operate this tool in explosive5.
atmospheres.
General Operating Instructions
Attach inlet and outlet hoses (not1.
included) to pump. Standard garden
hoses will work.
Attach accessory Basket Filter to inlet2.
end of inlet hose.
Place basket lter end of inlet hose in 3.
water to be pumped.
Rout outlet hose so that pumped wa-4.
ter will run off appropriately.
Remove Priming Plug (4) by turn-5.
ing counterclockwise. Fill pump with
clean water. Replace Priming Plug by
turning clockwise.
Plug in Power Cord (22). Pump will6.
operate immediately. It will take a
few minutes for pump to prime and
remove air from inlet hose. Water
will then ow through the hoses and
pump.
Do not allow the Basket Filter to be-7.
come clogged. Check it periodically
to be sure that clear water can enter
the inlet hose.
Do not allow the pump to run dry.8.
Running dry, the pump will overheat,
and impeller and seals will be dam-
aged.
To prevent accidents, turn off the tool9.
and disconnect its power supply after
use. Clean, then store the tool in-
doors out of children’s reach.

SKU 65836 For technical questions, please call 1-800-444-3353. Page 10
MAINTENANCE AND
SERVICING
Procedures not specically
explained in this manual
must be performed only by a
qualied technician.
TO PREVENT
SERIOUS INJURY
FROM ACCIDENTAL
OPERATION:
Unplug the tool from its
electrical outlet before
performing any inspection,
maintenance, or cleaning
procedures.
TO PREVENT SERIOUS
INJURY FROM TOOL
FAILURE:
Do not use damaged
equipment. If abnormal noise
or vibration occurs, have the
problem corrected before
further use.
Cleaning, Maintenance, and
Lubrication
BEFORE EACH USE,1. inspect the
general condition of the tool. Check
for loose screws, misalignment or
binding of moving parts, cracked or
broken parts, damaged electrical wir-
ing, and any other condition that may
affect its safe operation.
AFTER USE,2. clean external surfaces
of the tool with clean cloth.
CARBON BRUSH MAINTENANCE.3.
The carbon brushes may require
maintenance when the motor perfor-
mance of the tool decreases or stops
working completely. To maintain the brushes:
Remove the brush cap on each sidea.
of the motor housing.
Remove the carbon brushes fromb.
the housing. Keep track of which
orientation the old carbon brush-
es were in to prevent needless
wear if they will be reinstalled.
If either carbon brush is worn downc.
by more than 1/2, replace both car-
bon brushes.
To clean old carbon brushes befored.
reusing them, rub the contact areas
with a pencil eraser.
Reinsert the old carbon brushes ine.
the same orientation to reduce wear.
When installing the carbon brushes,f.
make sure the carbon portions of the
carbon brushes contact the motor
armature, and that the springs face
away from the motor. Also, make
sure the springs operate freely.
Replace the brush caps. Do not overtighten.g.
Note: New carbon brushes tend to spark
when rst used until they wear and
conform to the motor’s armature.
WARNING! If the supply
cord of this power tool is
damaged, it must be replaced
only by a qualied service
technician.
Carbon Brush
Carbon Brush Cap
Carbon Brush Holder

SKU 65836 For technical questions, please call 1-800-444-3353. Page 11
Troubleshooting
Problem Possible Causes Likely Solutions
Tool will not start No power at outlet.1.
Cord not connected.2.
Worn out or damaged Carbon3.
Brushes.
Check power at outlet.1.
Check that cord is plugged in.2.
Replace Carbon Brushes.3.
Pump operates
but does not
pump water
Pump is not primed.1.
Basket Filter is clogged.2.
All water has been pumped out.3.
Impeller is worn out or jammed4.
Prime pump, see instructions page 9.1.
Check and clean basket lter.2.
Turn off pump and complete mop up by3.
hand.
Repair or replace Impeller as needed.4.
Follow all safety precautions whenever diagnosing or servicing the
tool. Disconnect power supply before service.
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
Part Description Qty.
1 Rubber Foot 3
2 Pump Facing 1
3 Hose Fitting 2
4 Priming Plug 1
5 Pump Gasket 1
6 Impeller 1
7 Pump Impeller Fitting 1
8 Pump Seal Gasket 1
9 Pump Back Wall 1
10 Bearing 600 1
11 Armature 1
12 Bearing 608 1
13 Screw m 4 x 60 2
14 Stator 1
PARTS LIST
Part Description Qty.
15 Pump Housing 1
16 Carbon Brush Cap 2
17 Carbon Brush 2
18 Carbon Brush Holder 2
19 Screw 2
20 Spring Washer m6 4
21 Screw m6 x 20 6
22 Power Cord 1
23 Grounding Screw 1
24 Cable Clamp 1
25 Cable Box 1
26 Screw m4 x 10 2
27 Cable Clip 1
28 Basket Filter (not shown) 1
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.

SKU 65836 For technical questions, please call 1-800-444-3353. Page 12
ASSEMBLY DIAGRAM