HP FW0154, 0907, 0306 User Manual

Operating Instructions & Parts Manual

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product
described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in per­sonal injury and/or property damage! Retain instructions for future reference.

Pressure Booster Pumps

FW0154

0907

Supersedes

0306

Description

Pressure booster pumps increase water pressure from city mains or private water sys­tems. Applications include providing high water pressure for washing buildings, dairy
walls or floors, hog parlors, poultry houses, rinsing or spray cooling equipment, lawn
sprinkling and insecticide spraying. Stainless steel models can handle salt-water and
contaminated water in reverse osmosis filter and other aggressive water applications.

Unpacking

When unpacking the unit, inspect care­fully for any damage that may have
occurred during transit.

NOTE: Use pump with clear water
only.

Single-phase models are equipped with a capacitor start, thermal protected motor.
Three-phase models require separate overload protection.

H

Inlet I

Discharge J

G

D

Figure 1

A

C

F

B

E

IL0391

60 Hz Motor Driven Pump Dimensions (See Figure 1) • Chart A

Stainless

Steel Fitted

PB0508S031
PB0512S051
PB0516S071
PB0712S071
PB1014S101
PB1016S151
PB1914S201
PB2711S201
PB3506S201
PB2714S301
PB3508S301

-

-

-

-

Powder-Coated

Cast Iron Fitted

PB0508C031
PB0512C051
PB0516C071
PB0712C071
PB1014C101
PB1016C151
PB1914C201
PB2711C201
PB3506C201
PB2714C301
PB3508C301

-

-

-

-

Cast Iron

Fitted

PB0508A031†
PB0512A051†

PB0516A071
PB0712A071
PB1014A101
PB1016A151
PB1914A201
PB2711A201
PB3506A201
PB2714A301
PB3508A301
PB5504A201
PB5506A301
PB8504A201
PB8505A301

Dimensions In Inches Lbs. Ship

AB C DE F GH IJ

3-1/4

3-3/4
3-1/4
3-1/4
3-1/4
3-1/4
3-1/4
3-1/4
3-1/4
3-1/4
3-1/4
3-1/4
3-1/4
3-1/4
3-1/4
3-1/4

3-3/4

3-3/4

3-3/4

3-3/4

3-3/4

3-3/4

3-3/4

3-3/4

3-3/4

3-3/4

3-3/4

3-3/4

3-3/4

3-3/4

10-3/16
13-3/8
16-1/2
13-3/8
16-5/16
17-5/8
18-1/8
15-3/8
13-15/16
18-1/2
17-1/8
13-3/4
18-1/16
16-1/2
19-5/16

3-7/8
3-7/8
3-7/8
3-7/8
3-7/8
3-7/8
3-7/8
3-7/8
3-7/8
3-7/8
3-7/8
3-7/8
3-7/8
3-7/8
3-7/8

6-1/2
6-1/2
6-1/2
6-1/2
6-1/2
6-1/2
6-1/2
6-1/2
6-1/2
6-1/2
6-1/2
6-1/2
6-1/2
6-1/2
6-1/2

19-15/16
23-3/8
27
23-7/8
27-1/4
29-3/16
29-11/16
27-1/2
25-7/8
30-9/16
29-3/16
25-15/16
30-3/16
28-5/8
31-1/2

7-3/8
7-3/8
7-3/8
7-3/8
7-3/8
7-3/8
7-3/8
7-3/8
7-3/8
7-3/8
7-3/8
7-3/8
7-3/8
7-3/8
7-3/8

1-7/16
1-7/16
1-7/16
1-7/16
1-7/16
1-7/16
1-7/16
1-7/16
1-7/16
1-7/16
1-7/16

2-1/8
2-1/8
2-1/8
2-1/8

3/4
3/4
3/4
3/4
3/4
3/4
3/4

3/4
3/4
3/4
3/4
3/4
3/4
3/4

1

1

1

1

1

1

1

1

2

2

2

2

2

2

2

2

Wt.

35
38
43
42
48
51
51
52
51
54
53
57
57
58
58

50 Hz Motor Driven Pump Dimensions (See Figure 1) •58

PB0508Y031
PB0514Y051
PB0714Y071
PB1020Y101
PB1023Y101
PB2717Y201

­PB1021Y101
PB1920Y151

-

(*) NOTE: Figure 1, holes in mounting base are open slotted 3/8” wide x 1/2” long; dimension A & B are centerline from these
open slotted holes. These holes are suitable for 1/4 to 3/8” bolts.
Dimensions also apply to three phase models.
(†) Equipped with carrying handle. 132079 handle available as an option on other models. Add 1-3/8” to “G” if handle is included.

-

-

-

-

PB1023Z101

-

-

-

-

PB1922Z201

PB0508X031
PB0514X051
PB0714X071
PB1020X101
PB1023X101

-

PB3508X151

-

-

-

3-1/4
3-1/4
3-1/4
3-1/4
3-1/4
3-1/4
3-1/4
3-1/4
3-1/4
3-1/4

3-3/4
3-3/4
3-3/4
3-3/4
3-3/4
3-3/4
3-3/4
3-3/4
3-3/4
3-3/4

10-3/16
14-7/16
14-15/16
21-11/16
24-3/8
21-5/16
16-13/16
22-1/2
24-1/16
26-1/8

3-7/8
3-7/8
3-7/8
3-7/8
3-7/8
3-7/8
3-7/8
3-7/8
3-7/8
3-7/8

6-1/2
6-1/2
6-1/2
6-1/2
6-1/2
6-1/2
6-1/2
6-1/2
6-1/2
6-1/2

20-3/16
25-7/16
25-15/16
33-5/16
36
33-7/16
29-11/16
34-3/16
34-3/8
37-3/16

7-3/8
7-3/8
7-3/8
7-3/8
7-3/8
7-3/8
7-3/8
7-3/8
7-3/8
7-3/8

1-7/16
1-7/16
1-7/16
1-7/16
1-7/16
1-7/16
1-7/16
1-7/16
1-7/16
1-7/16

3/4
3/4
3/4
3/4
3/4

3/4
3/4
3/4

3/4
3/4
3/4
3/4
3/4

1

1

1

1
3/4
3/4
3/4

34
41
47
53
55
56
52
54
56
59

FLINT & WALLING, INC. • 95 North Oak St. • Kendallville, IN 46755 • www.flintandwalling.com

1

132934

PRESSURE ADDED - PSI 10 20 40 60 80 100 120 140 160 180 200

Stainless

Steel Fitted

PB0512S051 PB0512C051 PB0512A051• 1/2 12 9.8 9.2 8.2 7.3 6.3 5.2 3.5 131
PB0516S071 PB0516C071 PB0516A071 3/4 16 9.9 9.5 8.7 8.0 7.3 6.5 5.8 4.8 3.5 175
PB0712S071 PB0712C071 PB0712A071• 3/4 12 14.0 13.4 12.2 10.9 9.5 7.9 6.0 3.6 152
PB1014S101 PB1014C101 PB1014A101 1 14 * * 14.5 13.4 12.3 11.2 9.8 8.3 6.3 3.3 185
PB1016S151 PB1016C151 PB1016A151 1-1/2 16 * * 14.7 13.8 12.9 11.9 10.8 9.7 8.2 6.6 4.3 211
PB1914S201 PB1914C201 PB1914A201 2 14 27.5 27.0 25.7 24.2 22.6 20.8 18.7 16.2 13.0 7.8 190
PB3506S201 PB3506C201 PB3506A201 2 6 41.5 41.1 40.5 34.2 23.3 90
PB2711S201 PB2711C201 PB2711A201 2 11 * * 31.3 29.3 26.8 23.8 19.8 13.0 150
PB3508S301 PB3508C301 PB3508A301 3 8 41.5 41.1 40.9 40.0 34.2 26.4 10.0 120
PB2714S301 PB2714C301 PB2714A301 3 14 * * 32.2 30.6 28.9 27.0 24.8 22.0 18.4 12.2 190

--

--

--

--

† Example: If PB0508A031 pump is connected to supply line of sufficient capacity, carrying water at 40 PSI, and the output of the pump is held to 7.3 GPM by a

gate valve, the pump will add 40 PSI to line pressure for a total output pressure of 80 PSI.

* Operation of pump in this range may result in reduced pump life and/or motor damage.

To keep pump and seal lubricated, a minimum flow of 1.5 GPM must always be maintained through the pump.

Motor voltage: Single Phase 1/3 - 2 HP - 115/230; 3 HP - 230V 60 Hz.
Three Phase 1/2 - 2 HP - 208-230/460, 50/60Hz.
Three Phase 3 HP - 208-230/460, 60 HZ
For three phase models, use suffix “3” on the model no. Example: PB0512A053

• Handle included with these models only.

Powder-

Coated Cast

Iron Fitted

PB0508C031 PB0508A031• 1/3 8 9.5 8.7 7.3 5.8 3.5 87

Cast Iron

Fitted

PB5504A201 2 4 77.6 71.5
PB5506A301 3 6 77.8 74.4
PB8504A201 2 4 105.8 90.0
PB8505A301 3 5 108.8 98.8

HP Stage Output - Gallons per Minute

52.5

65.0

47.0

60.0

31.9

51.1

25.0 60

Max.

Press.

PSI

55
83
49

Suction

Pipe

Pipe Tap

Tap

NPT

3/4” 3/4”

1” 1”

2” 2”

Disch.

NPT

PERFORMANCE SPECIFICATIONS

Single Phase Motor Data 60HZ Chart C

Single Phase† 60 Hz 3450 RPM Capacitor Start

HP

1/3
1/2
3/4

1

1-1/2

2
3

Motor

Voltage

115/230
115/230
115/230
115/230
115/230
115/230

230

Factory

Connected

Motor

Voltage

115V
115V
115V
230V
230V
230V
230V

Service Factor Motor

Amps

Locked Rotor Motor

Amps

115V 230V 115V 230V

8.6

13.0

14.0

18.0

21.0

25.0

-

4.3

6.5

7.0

9.0

10.5

12.5

13.5

26.0

36.0

52.0

78.0

98.0

116.0

-

13.0

18.0

26.0

39.0

49.0

58.0

53.0

Code Letter

K
K
K

L

J
H
D

Single Phase Motor Data 50HZ

Single Phase† 50 Hz 2850 RPM Capacitor Start

1/2
3/4

1

1-1/2

2

115/230
115/230
115/230
115/230

230

115V
115V
230V
230V
230V

†Thermal overload protector - automatic reset

10.0

14.4

16.4

23.6

-

5.0

7.2

8.2

11.8

13.2

48.0

64.0

72.0

104.0

-

24.0

32.0

36.0

52.0

55.0

M

L
K
K
H

FLINT & WALLING, INC. • 95 North Oak St. • Kendallville, IN 46755 • www.flintandwalling.com

2

Three Phase Motor Data Chart D

Three Phase† 60/50 Hz 3450/2850 RPM Capacitor Start

HP

3/4

1

1-1/2

2

3✝✝

Motor

Voltage

208-230/460
208-230/460
208-230/460
208-230/460
208-230/460

Factory

Connected

Motor

Voltage

230V
230V
230V
230V
230V

Service Factor Motor

Amps

Locked Rotor Motor

Amps

230V 460V 230V 460V

3.5

4.5

5.7

7.4

9.8

1.75

2.25

2.85

3.70

4.90

19.0

26.9

33.5

44.0

48.0

13.5

16.8

22.0

24.0

9.5

Code Letter

K
K
K
K
D

✝✝3 HP, 3 Phase motor operable on 60Hz only.

Material Construction Chart E

Component Standard Models* Stainless Steel Models

Motor Rear access - Nema 56J face Rear access - Nema 56J face

Bearings Ball-ball, permanently lubricated Ball-ball, permanently lubricated

Impellers Noryl with 304 stainless steel bearing insert Noryl with 304 stainless steel bearing insert

Diffuser Noryl Noryl

Diffuser plates Delrin Delrin

Pump shaft 416 Stainless steel 304 Stainless steel

Pump shaft coupling 316 Stainless steel 316 Stainless steel

Pump shell 304 Stainless steel 304 Stainless steel

Discharge & inlet casting Cast iron 304 Stainless steel

O-Rings Buna-N Viton

Seal composition Carbon-silicon carbide, stainless steel spring

and Buna-N

*Models with powder coated inlet & discharge also available.

Carbon-silicon carbide, stainless steel spring
and Viton

Minimum Wire Size Chart (Gauge) Chart F

Motor

HP

1/3 115/230 1 14/14 14/14 14/14 12/14 12/14 15/15

1/2 115/230 1 12/14 12/14 12/14 12/14 10/14 20/15

3/4 115/230 1 12/14 12/14 10/14 10/12 8/12 20/15

1 115/230 1 10/14 10/14 10/12 8/12 6/10 30/15

1

/2 115/230 1 10/12 8/12 6/12 */10 */10 30/20

1

2 115/230 1 10/12 8/12 6/12 */10 */10 30/20

3 230 1 10 10 10 10 8 30

3/4 230/460 3 14/14 14/14 14/14 14/14 14/14 15/15

1 230/460 3 14/14 14/14 14/14 14/14 12/14 15/15

11/2 230/460 3 14/14 14/14 14/14 12/14 12/14 15/15

2 230/460 3 14/14 14/14 14/14 12/14 10/12 15/15

3 230/460 3 14/14 14/14 14/14 12/14 10/12 15/15

(*) Not economical to run in 115V, use 230V.

Volts Phase

FLINT & WALLING, INC. • 95 North Oak St. • Kendallville, IN 46755 • www.flintandwalling.com

0-50 50-100 100-150 150-200 200-300

Distance In Feet From Motor To Service Panel

Breaker Size

(Amps)

Wire Size

3

General Safety Information

Carefully read and follow all safety instructions in
this manual and on pump. Keep safety labels in good

condition. Replace missing or damaged safety labels.

9. Do not insert finger or any object into pump or motor
openings.

10. Secure the discharge line before starting the pump. An
unsecured discharge line will whip, possibly causing per­sonal injury and/or property damage or puncture.

symbol on the pump or in the manual, look for one of the
following signal words and be alert to the potential for per­sonal injury or property damage.

personal injury, death or major property damage if ignored.

personal injury or death, if ignored.

personal injury, product or property damage if ignored.

This is a SAFETY ALERT SYMBOL. When you see this

Warns of hazards that WILL cause serious

!

Warns of hazards that CAN cause serious

Warns of hazards that MAY cause minor

IMPORTANT: Indicates factors concerned with operation,
installation, assembly or maintenance which could result in
damage to the machine or equipment if ignored.
NOTE: Indicates special instructions which are important but
are not related to hazards.

!

Hazardous volt­age. Can shock,
burn or cause
death. Ground

pump before con­necting to power
supply.

Follow wiring instructions in this manual when connect-

ing to power lines.

!

performing any work on or near the motor or its connected
load.

Do not use to pump flammable or explosive fluids
such as gasoline, fuel oil, kerosene, etc. Do not use in flam­mable and/or explosive atmospheres.

Hazardous pressure! Install pressure relief valve in
discharge pipe. Release all pressure on system before work­ing on any component.

Wire motor for correct voltage. See
“Electrical” section and Motor Data Charts
C&D of this manual, and motor nameplate.

Ground motor before connecting to
power supply.

Meet United States National Electrical
Code and local codes for all wiring.

Do not handle a pump or pump motor
with wet hands or when standing on a wet
or damp surface or in water.

Always disconnect power source before

1. Make workshop child proof - use padlocks, master
switches; remove starter keys.

2. Wear safety glasses when working with pumps.

3. Wear a face shield and proper apparel when pumping
hazardous chemicals.

4. Keep work area clean, uncluttered and properly lighted;
replace all unused tools and equipment.

5. Provide guarding around moving parts.

6. Keep visitors at a safe distance from the work area.

7. Periodically inspect pump and system components.

8. Protect electrical cord. Replace or repair damaged or
worn cords immediately.

FLINT & WALLING, INC. • 95 North Oak St. • Kendallville, IN 46755 • www.flintandwalling.com

engine. They are designed to operate at high temperatures.

!

the State of California to cause cancer and birth defects or
other reproductive harm.

!

been investigated for use in swimming pool areas.
NOTE: Pumps with the “CSA-CUS” mark are tested to UL stan­dard UL778 and certified to CSA standard C22.2 No. 108.

Do not touch an operating motor or

This product contains chemicals known to

Risk of Electric Shock. This pump has not

Pre-Installation

HANDLING

1. Use handle supplied to lift pump.

2. Avoid impact on pump or motor. In particular, avoid
impact on discharge end of pump or rear motor access
cover.

LOCATION

!

age and/or personal injury might result from an inoperative
or leaking pump due to power outages, discharge line block­age, or any other reason, a backup system(s) should be used.

1. Locate pump as close to the fluid source as possible, keep­ing the inlet pipe short as possible.

2. Place unit where the pump and piping are protected from
the weather and extremes of heat, humidity and below
freezing temperatures.

3. Mount unit in a dry location that is easily accessible for
inspection and maintenance. If a dry location is not avail­able, mount it on a foundation well above the wet floor.

4. Allow ample clearance around unit for free air circulation.

SUCTION LIMITATIONS

1. Units are non self-priming.

2. Pressure booster pumps are not recommended for suction
lift applications.

PIPING

1. Use galvanized piping, rigid plastic or other suitable pipe
that will not collapse under suction or rupture due to pres­sure.

forced industrial type that is rated higher than the shutoff
pressure of the system. Ordinary garden hose will collapse
and starve the pump of water.

2. The diameter of the inlet and discharge pipe should be
no smaller than the corresponding ports of the pump (See
Figure 1). Smaller pipe will reduce the capacity of the
pump. Increase pipe size on long runs.

3. Avoid air pockets in inlet piping or air will accumulate at
high points, making priming difficult.

4. Use pipe compound on all joints and connections. Use
Teflon tape or plastic joint stik, on plastic pipe. Draw all
pipe up tightly.

IMPORTANT: The entire system must be air and water tight
for efficient/proper operation.

4

In any installation where property dam-

If hose is used, make sure it is the rein-

Installation

PUMP INSTALLATION
IMPORTANT: Pump is built to handle

clear water only; it is not designed to
handle water containing sand, silt or
other abrasives.

1.Refer to Figures 6, 7, and 8 for typi­cal installations.

No Sags

Sags Allow Air Pockets

No Air Leaks In
Inlet Pipe

If Air Flows
Water
Won’t

Pipe Joint Compound
Will Damage Plastic

IL0419

piping when assembling and when
installed. Failure to do so may cause
piping to break, pump to fail, motor
bearing failures, etc.

Support pump and

2. If the pump is used as part of a per­manent installation, bolt to a rigid
foundation.

!

nents that are rated for maximum pres­sure pump can produce when used in
boosting system or any other system.
Do not exceed the total maximum
pressure boost as listed per model in
Performance Charts B.

Use only compo-

PRESSURE BOOST SYSTEMS

1. On pressure boost systems, locate
the pump so that there will always
be a positive supply of water to the
pump (See Figures 6, 7 and 8).

2. For service convenience, install a
gate valve and union in the inlet
and discharge line.

valve or other restricting type of valve
that will seriously restrict the pumps
discharge capacity.

Do not use a globe

3. Install a check valve as shown in
Figure 6. Be sure check valve flow
arrows point in the direction of
water flow.

4. Whenever dirt, sand or debris is
present in the supply water, install a
strainer or filter on the inlet side of
the pump (See Figure 7).

NOTE: For heavy amounts of sedi­ment, install a trap filter on the inlet
side of the pump (See Figure 5).
NOTE: Pressure gauges installed
before and after the filter will show
pressure differential indicating the
need for filter replacement or clean­ing.

If Air Pockets Form,
Water Won’t Flow

Figure 2 - No Air Pockets in Inlet Pipe

Mount pump in correct position or pump failure will result.

Correct

IL0418

Use Teflon Tape

Figure 3 - Inlet Pipe Must Not Leak

Incorrect

Figure 4A Figure 4B

SAND AND SEDIMENT TRAP FILTER

Standard Pressure
Tank - 42 Gallon Or
Larger

Outlet

Inlet

Sand Settles To The Bottom

Figure 5

Clean Out

IL0421

IMPORTANT: Clean all filters and strainers on a regular schedule.

IL0420

IL0315

FLINT & WALLING, INC. • 95 North Oak St. • Kendallville, IN 46755 • www.flintandwalling.com

5

Installation (Continued)

5. A pressure gauge installed in the

inlet pipe close to the inlet port, (See
Figure 6) will show if enough water
is being supplied to the pump. See
Operation Section - Priming, Pressure
Boost Installations.

6. On installations that are using noz­zles for mist spraying, install a filter
in the discharge plumbing to prevent
the nozzles from becoming plugged.
Multiple filters should be plumbed in
parallel.

!

relief valve on any installation where
pump pressure can exceed the pressure
tank’s maximum working pressure or
on systems where the discharge line
can be shut off or obstructed. Extreme
over pressure can result in personal
injury or property damage.

waterproof and is not intended to
be used in showers, saunas or other
potentially wet locations. The motor
is designed to be used in a clean dry
location with access to an adequate
supply of cooling air. Ambient tem­perature around the motor should
not exceed 104ºF (40ºC). For outdoor
installations, motor must be protected
by a cover that does not block airflow
to and around the motor. This unit is
not weatherproof nor is it able to be
submersed in water or any other liq­uid.

To avoid dangerous or fatal elec­trical shock, turn off power to motor
before working on electrical connec­tions.

Supply voltage must be within ±
10% of nameplate voltage. Incorrect
voltage can cause fire or seriously
damage motor and voids warranty. If
in doubt, consult a licensed electrician.

Install a pressure

This unit is not

Pump used to boost incoming city pressure (automatic operation).

Street Supply

Check
Valve

Gate/Ball
Valve
(Normally
open)

Union

IL0422

Figure 6

Union

Pressure
Gauge

Check Valve

Service Tee

Inlet

Outlet

Pressure
Switch

Drain

Gate/Ball
Valve
(Normally
open)

To size tank
properly - Match
drawdown of
tank to capacity
of pump

Pressure Switch

Main Power Box

Fuse
Box or
Switch

Union

Pressure
Gauge

Pressure
Relief
Valve

IMPORTANT: A contained air pressure tank and pressure switch is required to
keep the pump from rapid cycling and prevent the motor from over heating.
Install the tank and switch on the house side of system.

Pump used to boost water pressure in mist spray applications (automatic opera­tion).

Fuse Box
or Switch

Pressure Gauge

Thermostat

Gate/Ball Valve

From Water Source

Line Filter
Pressure
Relief
Valve

Solenoid
Valve

Gate/Ball Valve
(Normally open)

Use wire size specified in wiring
Chart F. If possible, connect pump
to a separate branch circuit with no
other appliances on it. If motor wiring
diagram differs from diagram shown
below, follow diagram on motor.

FLINT & WALLING, INC. • 95 North Oak St. • Kendallville, IN 46755 • www.flintandwalling.com

To Nozzles

Figure 7

To Drain

IL0423

NOTE: Install solenoid valve on discharge side of pump.
IMPORTANT: Clean all filters and strainers on a regular schedule.

6

Installation (Continued)

!

Hazardous
voltage. Can
shock, burn or
cause death.

Ground pump
before connecting
to power supply.

pump impeller is critical on three phase
motors. See Motor Rotation under
Operation section and Figure 12.

WIRING

1. Install, ground, wire and maintain
this pump in accordance with your
local electrical code and all other
codes and ordinances that apply.
Consult your local building inspector
for local code information.

2. Ground the pump permanently using
a wire of size and type specified
by local or United States National
Electrical Code. Do not ground to

a gas supply line.

3.Connect ground wire first. Connect

to ground first, then to green ground­ing terminal provided on the motor
frame, identified as GRD. Ground con­nection MUST be made to this termi­nal. Do not connect motor to electrical
power supply until unit is permanently
grounded; otherwise serious or fatal
electrical shock hazard may be caused.

4. Connect the other end of the ground
wire to a properly grounded service
panel or to a control panel ground
bar if it is connected to the power
supply ground.

IMPORTANT: Check local and/or
United States National Electric Codes
for proper grounding information.

the power supply conforms to the elec­trical specifications of the motor sup-

plied. See Motor Data Charts.

Ground motor
before connecting to
electrical power sup­ply.

Failure to ground
motor can cause
severe or fatal electri­cal shock hazard.

Do not ground to
a gas supply line.

Proper rotation of

Make certain that

Pump used to boost incoming pressure from a wall hydrant (manual operation).

Hose Adapter

Wall Hydrant

Pressure Gauge

Pressure
Relief Valve

Hose Adapter

High Pressure Reinforced Hose

Service Tee

Inlet

Outlet

IL0424

Spray
Nozzle

High Pressure Reinforced Hose

Figure 8

L1

Y
E
L
L
O

W

230 Volts

Single Phase

Line

A

B

W

G

H

R

I

A

T

Y

E

R

T

E

A

D

N

IL0180

115 Volts

Single Phase

Line

L1

A

Y

W
E
L
L

O
W

G

H

R

I

A

T

Y

E

L2 L2

B

R

T

E

A

D

N

NOTE: Dual voltage motors, change the red and

gray wire to the voltage required.

Figure 9 - Wiring Diagram for Single Phase 1/3 - 2 HP
Motors

230 Volts

Single Phase

Line

L1 L2

AB

Y

E

L

L

O
W

NOTE: Single voltage (230V) motor, and can not be connected to 115V.

Figure 10 - Wiring Diagram for Single Phase 3 HP Motors

G
R
A
Y

IL0181

FLINT & WALLING, INC. • 95 North Oak St. • Kendallville, IN 46755 • www.flintandwalling.com

7

Installation (Continued)

5.Specific Wiring Procedure (Refer to Figures 9, 10, & 11
and Minimum Wire Size Chart).

a. Select the voltage you are to use, either 115V or 230V

single phase, 230V or 460V three phase.

b. The 1/3, 1/2 and 3/4 HP single phase pumps are factory

connected for 115V at the motor. The 1, 1
HP pumps are factory connected for 230V at the motor.
Three phase models are factory connected for 230V at
the motor.

c. If the motor wiring must be changed to conform to your

specific voltage requirements then the motor, pressure
switch or other controls should be rewired to conform
to one of the wiring diagrams (either 115V or 230V,
single phase; 230V or 460V, three phase). Single phase 3
HP motors are 230V only and cannot be wired for 115V
service.

d. The motor wiring diagrams are Figures 9, 10, & 11 and

also are located on the motor label of the pump.

6. Remove the rear access cover of the motor.

7. Make the wiring change and replace the rear access cover.

!

or operating pump. Failure to do so can result in personal
injury.

Replace rear access cover before starting

IMPORTANT: Do not use an extension cord or splice wires.
Joints should be made in an approved junction box. If the
above information or the following wiring diagrams are con­fusing, consult a licensed electrician.

8. All units are not supplied with pressure switches, float
devices, on/off switches, or the like (control devices).
Controls should be wired in at this time, utilizing whatever
instructions come with the controls. All units supplied
with cords, will run whenever cord is plugged into power
and will turn off whenever cord is disconnected from
power.

MOTOR PROTECTION

All single phase motors have built in thermal protection for
all voltages. The overload protects the motor against burn­out from overload of low voltage, high voltage and other
causes. The device is automatic and resets itself once the
temperature has dropped to a safe point. Frequent tripping
of the device indicates trouble in the motor or power lines
and immediate attention is needed.

!

touch the motor before disconnecting the main electrical
supply switch. The thermal device may have opened the
electrical circuit.

Never examine, make wiring changes or

Three phase motors do not have a built in thermal protec­tion. It is recommended that a properly sized magnetic or
manual starter (both with properly sized heaters) be used
with all three phase motors. Install starters following instruc­tions of the starter manufacturer. See Motor Rotation under
Operation Section for changing rotation on three phase
motors.
All motors (single and three phase) should be equipped
with a correctly fused disconnect switch to provide protec­tion. Consult local or United States National Electric Codes
for proper fuse protection based on motor data chart (See
Charts C, D and Wire chart F).

1

/2, 2 and 3

Low Voltage 230V High Voltage 460V

456

7

1

L

1

1 - Tan 4 - Yellow 7 - Purple

2 - Red 5 - Black 8 - Gray

3 - Orange 6 - Blue 9 - White

CONNECTION FOR 3 PHASE, 9 LEADS. IF YOUR 3 PHASE
LEADS ARE COLOR CODED, MATCH NUMBER ABOVE TO THE
CORRESPONDING COLOR.
NOTE: To reverse rotation, interchange any two incoming lines
(Power) leads.

Figure 11 - Wiring Diagram for Three Phase Motors

8

2

L

2

9

3

L

3

IL0182

4

7

1

L

1

5

8

2

L

2

6

9

3

L

3

Operation

ing. Do not run dry, or against a closed discharge. Do not
pump dirty water or abrasive liquids. To do so will cause
pump failure and will void the warranty.

VALVES

The inlet valve should be in the full open position and the
discharge valve should be partially open, permitting some
back pressure to be exerted against the pump when starting
up. Open valve after start up is completed.

PRIMING
NOTE: Before starting the pump it is absolutely necessary
that both the pump and the inlet pipe be completely
filled with water.

PRESSURE BOOST INSTALLATIONS
Priming is automatic when pump is connected to a pressure
source such as a hydrant or city main (See Figures 6, 7 & 8).

1. Open valves or nozzle on inlet and discharge side of pump.

2. To relieve trapped air, allow water supply to run a mini­mum of 30 seconds before starting the pump.

IMPORTANT: An adequate flow of water going into the
pump is required so that the pumps impellers and shaft seal
do not run dry and fail.

3. If you installed a pressure gauge at the pump inlet, a read­ing of 2 psi minimum should show whenever the pump is
in operation (See Figures 6, 7 & 8).

This reading insures that there is an ample supply of water
into the pump inlet housing.

Unit must be full of fluid before operat-

FLINT & WALLING, INC. • 95 North Oak St. • Kendallville, IN 46755 • www.flintandwalling.com

8

Operation (Continued)

MOTOR/PUMP ROTATION

1. Single phase models are one (1) rotation only (counter­clockwise when facing the pump end) and cannot be
reversed.

2. Proper rotation of pump impeller is critical for three phase
pumps. Pump motor should turn counterclockwise (CCW)
when facing pump end. Momentarily “bump” (apply
power for less than a second) the motor to check for
proper rotation. To change rotation on three phase units,
interchange any two (2) incoming line (power) leads.

Do not go over recommended maximum
operating pressure (see Specifications), while maintaining
minimum flow of 1.5 GPM thru the pump. Do not restrict
the inlet line to the pump.
If driver (electric motor) is overloaded, a valve can be
installed in the discharge line to increase the back pressure
and reduce driver loading.

START - UP PROCEDURE

Once the preceding instructions have been completed, the
pump can be started.

1. During the first few hours of operation, inspect the pump,

piping and any auxiliary equipment used in connection
with the unit.

2. Check for leaks, excessive vibration or unusual noises.

IL0539

Figure 12 - Correct Motor/Pump Rotation (all units)

NOTE: See rotation arrow on inlet casting.

Maintenance

Disconnect power supply and depressur­ize system before servicing pump or removing any compo­nent.

ROUTINE

Pump should be checked routinely for proper operation.
Replace or clean all filters and line strainers on a regular
basis.

DRAINING

This pump cannot be completely drained because of internal
design. Most of the liquid can be drained by tilting the dis­charge forward after removing discharge casting; or, the liq­uid can be drained through the inlet port. Store in heated
areas.

CLEANING

If used for spraying insecticides, pump should be thoroughly
flushed with clean water after using.

LUBRICATION

The motor has prelubricated bearings. No lubrication is
required.

SERVICING THREE-PHASE UNITS

Loctite (thread sealer) is used on the threads between the
motor shaft and the pump shaft coupling. When reassem-

bling, reapply thread sealer.

PUMP DISASSEMBLY

To disassemble the pump, refer to the exploded parts view,
Figures 17 & 18 Tools Required

• Block of wood (2” x 4” x 12”)
Piece of 3/4” pipe (12” to 24” long)

• Pipe wrench

• Strap wrench

• 1/4” Dowel rod (about 24” long)

• 9/16” Open end wrench

• 3/8” Open end wrench

1. To stabilize pump during disassembly, place block of wood
underneath pump barrel.

2. Thread pipe into pump inlet port. This acts as a handle.

3. Using the pipe wrench, remove the discharge head, turn­ing CCW (counter clockwise).

4. With the strap wrench, loosen the barrel, turning CCW
(counter clockwise). DO NOT use pipe wrench on pump
barrel.

5. Holding the impeller stack in place, position pump in
upright position, standing unit on the motor end cover.

6. Use the 1/4” dowel rod to hold the stages down and in
place on the pump shaft. Remove pump barrel.

7. Slide the stages off the pump shaft onto the 1/4” dowel
rod. Leave stages on rod and carefully set aside.

NOTE: There may be some small .010” shim washers located
next to the pump shaft coupling. Keep these shims for re­assembly.

8. Through the side opening of the mounting frame, hold
the motor shaft with 9/16” wrench. Remove the shaft and
coupling from the motor using the 3/8” wrench on the hex
shaped pump shaft.

NOTE: If the hex shaft comes free, leaving the coupling
attached to the motor, use vise grips to free the coupling.

MECHANICAL SEAL REPLACEMENT

1. Follow instructions under “Pump Disassembly”.

2. Remove the mechanical seal assembly.
a. The rotary portion of the seal assembly (carbon ring,

Buna-N gasket and spring will slide easily off the end of
shaft).

b. Using two (2) screwdrivers, pry the ceramic seal and rub-

ber gasket from the recess of the mounting ring (See
Figure 14).

The precision lapped faces of the mechan­ical seal are easily damaged. Handle the replacement seal
carefully. Short seal life will result if seal faces (ceramic &
carbon) are nicked, scratched or dirty.

3. Clean the seal cavity of the mounting ring and the motor

thoroughly.

4. Wet outer edge of rubber cup on ceramic seat with liquid

soap solution. Use sparingly (one drop only).

FLINT & WALLING, INC. • 95 North Oak St. • Kendallville, IN 46755 • www.flintandwalling.com

9

Maintenance (Continued)

NOTE: Liquid soap solution - one drop of liquid soap com-

bined with one teaspoonful of water.

5. With thumb pressure, press ceramic seal half firmly and
squarely into seal cavity. Polished face of ceramic seat
is up. If seal will not seat correctly, remove, placing seal
face up on bench. Reclean cavity. Seal should now seat
correctly (See Figure 14).

6. If seal does not seat correctly after recleaning cavity,
place a cardboard washer over polished seal face and
carefully press into place using a piece of standard clean
3/4” pipe as a press (See Figure 15).

IMPORTANT: Do not scratch seal face.

7. Dispose of cardboard washer and recheck seal face to
be sure it is free of dirt, foreign particles, scratches and
grease.

8. Inspect shaft to be sure it is free of nicks and scratches.

9. Apply liquid soap solution sparingly (one drop is suffi­cient) to inside diameter of rubber rotating member.

10. Slide rotating seal member (carbon face down toward
ceramic face) and spring over the shaft.

IMPORTANT: Do not nick or scratch carbon face of seal
when handling.

MOTOR REPLACEMENT

The motor can be replaced with any standard Nema 56J jet
pump motor (of proper HP for each pump) by referring to
the following instructions.

1. Follow steps as outlined under Rotary Seal Replacement
and Pump Disassembly.

2. Remove cap screws that connect the motor to the
mounting ring and pull motor away.

3. Replace motor with standard Nema 56J jet pump motor
by positioning motor against the mounting frame and
assembling with four (4) cap screws.

IMPORTANT: Because damage to the shaft seal can occur in
disassembly, a new seal will be necessary.

PUMP REASSEMBLY

Before reassembling the pump, carefully inspect the com­ponent parts of the cartridge (stage) assembly, looking for
damage, wear or heat distortion. Pay careful attention to
spacing direction of components, and location of shims.
Refer to Figure 16 for proper facing and parts arrangement.
If damage to Stage components is evident, a complete car­tridge assembly or individual stage assemblies are available
for replacement (See Replacement Parts List).

1. Reassembly should follow the reverse order of the disas-

sembly procedure with special care given to replacement
of the rotary seal.

2. Check top and bottom of o-rings for damage. It is recom-

mended that new o-rings be used.

3. Do not use pipe compound of Teflon tape on barrel

threads. The o-rings will prevent pump from leaking.

4. After pump is reassembled, tighten the discharge head to

a torque of 45-50 ft/lbs. If torque wrench is not available,
tighten firmly but avoid distortion or damage to plastic
internal parts.

5. After reassembly, apply power momentarily to unit (15 to

30 seconds). The pump and motor should rotate freely or
with a light rubbing.

Figure 13 - Remove Mechanical Seal Figure 14 - Press In Seal

3/4” Pipe
Press Carefully

Cardboard
Washer
Protects Seal
Face

Seal Cavity

IL0554

Figure 15 - If Necessary, Press With
Cardboard And Pipe

Seal

FLINT & WALLING, INC. • 95 North Oak St. • Kendallville, IN 46755 • www.flintandwalling.com

10

Troubleshooting Chart

Symptom Possible Cause(s) Corrective Action

Pump won’t
start or run
at full speed

Pump oper­ates, but
delivers little
or no water

1. Blown fuse or open circuit breaker 1. Replace fuse or close circuit breaker. See wire size chart for
proper break/fuse size

2. Power supply in OFF position 2. Turn power on

3. Incorrect voltage at motor (check volt-

age with motor running)

4. Loose, broken or incorrect wiring 4. Rewire any incorrect circuits. Tighten connections, replace

5. Defective motor 5. Replace motor

6. Pump hydraulic components clogged/

worn/damaged

1. Manual or solenoid valves plumbed

into system restricting flow

2. In-line filter restricting flow 2. Check all in-line filters to be sure they are not plugged or

3. Low line voltage 3. See low line voltage corrective action (above)

3. Low voltage

a. Voltage must be within ± 10% of motor rated voltage.

Check incoming voltage. Contact power company

b. Make certain that voltage of motor matches voltage of

power supply. See motor name plate and motor wiring
diagrams

c. Check wire size from main switch to pump. See wire

size chart for correct wire size

defective wires

6. Replace worn parts or entire pump. Clean parts if required

1. a Check all valves on pump inlet and discharge sides of
system to be sure they are opened properly to allow
flow to and from the pump

b. Bleed trapped air in pump which keeps water from

reaching the pump. (Normally
due to closed valve in discharge plumbing)

restricted

4. Inadequate water supply to booster
pump

5. Undersized piping 5. Replace undersized piping

6. Leak on inlet side of system 6. Make sure connections are tight. Repair leaks as necessary

7. Inadequate, defective or plugged foot
valve and/or strainer

8. Worn or defective pump parts or
pump.

9. Suction lift too great 9. Pump should be operated under

10. Pump not primed 10. Prime pump - Make certain inlet pipe is drawn up tight and

11. Incorrect rotation, motor running
backwards

Excessive
noise while
pump in

Pump leaks 1. Worn mechanical seal (leaks at shaft) 1. Replace shaft (rotary) seal

1. Pump not secured to firm foundation 1. Secure properly

2. Piping not supported 2. Make necessary adjustments

3. Restricted inlet line 3. Clean or correct

4. Cavitation (noise like marbles in pump) 4. a. Reduce speed on direct drive

5. Worn motor bearings 5. Replace bearings or motor

2. Worn o-ring seals 2. Replace o-ring seals, located inside both ends of the stainless

4. Check pressure on inlet side of booster to be sure positive
pressure is maintained to the booster pump

7. Clean, repair or replace as needed

8. Replace worn parts or entire plugged impeller Clean parts if

flooded suction only

pump and pipe are full of water

11. Reverse motor rotation can occur on three phase units. To
correct, interchange any two incoming power leads.

b. Increase inlet pipe size

c. Too viscous (material being pumped too thick

steel shell

FLINT & WALLING, INC. • 95 North Oak St. • Kendallville, IN 46755 • www.flintandwalling.com

11

Booster Pump Parts Drawing

1A 1

10A

10

ITEM NO. DESCRIPTION

1 Motor

1A †Governor

1B †Switch Motor

2 Seal, Rotary
3 Barrel
4 Discharge Head

4A Discharge Bearing

5 O-ring (2)

6A Plate, Diffuser

6B Impeller
6C Diffuser

6D Diffuser Bearing

6E Shim as Required

7 Shaft and Coupling Assembly
8 Mounting Ring
9 Hex Head Bolts (4)

10 †MotorAccess Cover

10A †Screws, Access Cover (2)

*See note below parts included in cartridge assembly.

†ODP Motor Only

1B

9

2

5

7

6A

6E

6D

8

6A

5

4A

4

6B

6C

3

IL0593

Internal Parts Detail

IL0308

Figure 16 - Cartridge Assembly Includes Discharge Bearing, Shaft & Coupling Assembly, Diffuser Plate, Impellers, Diffuser
Bearings, Diffusers and O-rings

NOTE: Illustration shows only two stages. Pump has multiple stages. Individual parts are not available separately.

FLINT & WALLING, INC. • 95 North Oak St. • Kendallville, IN 46755 • www.flintandwalling.com

12

PRESSURE BOOSTER PUMP REPAIR PARTS

(For Pricing Refer To Repair Parts Price List)

Replacement Motors

9

10

IL0565

FORM NO. FW0045

SUPERSEDES 0206

PAGE 4-7A REPAIR PARTS

0907

ITEM REPLACEMENT MOTORS QTY CAST IRON

ODP NEMA J 1/3 HP
ODP NEMA J 1/2 HP 96J105 96J105 96S105 96J305 96J305 96S305
ODP NEMA J 3/4 HP 96J107 96J107 96S107 96J307 96J307 96S307

9

ODP NEMA J 1 HP 96J110 96J110 96S110 96J310 96J310 96S310
ODP NEMA J 1-1/2 HP 96J115 96J115 96S115 96J315 96J315 96S315
ODP NEMA J 2 HP 96J120 96J120 96S120 96J320 96J320 96S320
ODP NEMA J 3 HP 96J630 96J630 96S630 96J330 96J330 96S330

10 Motor Cover w/Screws 1 136132R 136132R 136132R 136132R 136132R 136132R

* Screws, Motor Cover 2 136133 136133 136133 136133 136133 136133

ODP NEMA J 1/3 HP
ODP NEMA J 1/2 HP 96J005 96J005 96S005 96J305 96J305 96S305
ODP NEMA J 3/4 HP 96J007 96J007 96S007 96J307 96J307 96S307

9

ODP NEMA J 1 HP 96J010 96J010 96S010 96J310 96J310 96S310
ODP NEMA J 1-1/2 HP 96J015 96J015 96S015 96J315 96J315 96S315
ODP NEMA J 2 HP 96J820 96J820 96S820 96J320 96J320 96S320

10 Motor Cover w/Screws 1 136132R 136132R 136132R 136132R 136132R 136132R

* Screws, Motor Cover 2 136133 136133 136133 136133 136133 136133

TEFC NEMA J 1/2 HP
TEFC NEMA J 3/4 HP 021008 021008 021012 021012
TEFC NEMA J 1 HP 021009 021009 020688 020688

9

TEFC NEMA J 1-1/2 HP 020692 020692 020647 020647
TEFC NEMA J 2 HP 020693 020693 020689 020689
TEFC NEMA J 3 HP 021010 021010 020690 020690

* Not Shown

1

1

1

96J103 96J103 96S103

96J003 96J003 96S003

POWDER

COATED

SINGLE PHASE 60 HZ THREE PHASE 60 HZ

SINGLE PHASE 50 HZ THREE PHASE 60/50 HZ

SINGLE PHASE 60/50 HZ THREE PHASE 60/50 HZ

020691 020691 021011 021011

STAINLESS

STEEL

CAST IRON

POWDER

COATED

STAINLESS

STEEL

FLINT & WALLING, INC. • 95 North Oak St. • Kendallville, IN 46755 • www.flintandwalling.com

13

FORM NO. FW0046
0907
SUPERSEDES 0206
PAGE 4-8A REPAIR PARTS

PRESSURE BOOSTER PUMP REPAIR PARTS

(For Pricing Refer To Repair Parts Price List)

10

8

9

3

6

7

1

4

2

IL0565

ITEM DESCRIPTION QTY CAST IRON

5 - 7 - 10 - 19 GPM,

60 HZ & 50 HZ

27 - 35 GPM,

60 HZ & 50 HZ

55 - 85 GPM,

60 HZ & 50 HZ

ALL SERIES

60 HZ & 50 HZ

(†) Buna N - Carbon/Silicon Carbide (‡) Viton - Carbon/Silicon Carbide (■) Buna N (▲) Viton (*) Not Shown
(8) 132079 Handle available as an option

MATERIAL

ITEM DESCRIPTION MATERIAL PART NUMBER

5 Cartridge Assembly ‡

6 Shaft & Coupling Assembly

7 Barrel/Shell CI, PC & SS 135162 132003 138448 132003 134997 135815

MATERIAL

ITEM DESCRIPTION MATERIAL PART NUMBER

5 Cartridge Assembly ‡

60 HZ MODELS

6 Shaft & Coupling Assembly

7 Barrel/Shell CI, PC & SS 137223 135628 136630 136627 136633

MATERIAL CAST IRON CI PB5504XX PB5506XX PB8504XX PB8505XX

ITEM DESCRIPTION MATERIAL PART NUMBER

5 Cartridge Assembly ‡ CI 022293 022294 022295 022296
6 Shaft & Coupling Assembly CI 022289 022287 022288 022287
7 Barrel/Shell CI, PC & SS 022291 022292 138151 022290

MATERIAL

ITEM DESCRIPTION MATERIAL PART NUMBER

5 Cartridge Assembly ‡

6 Shaft & Coupling Assembly

7 Barrel CI, PC & SS 135162 138151 138151 135098 020279 135912

MATERIAL

50 HZ MODELS

ITEM DESCRIPTION MATERIAL PART NUMBER

5 Cartridge Assembly ‡

6 Shaft & Coupling Assembly

7 Barrel CI, PC & SS 020094 138947 136633 021016 139436

(‡) Cartridge assembly includes: impellers, diffusers and shaft & coupling assembly. Components not available individually. Sold as assembly only.

1 Discharge Head 3/4” NPT 1 132000 136905 136640
2 Mounting Ring 3/4” NPT 1 132002 136904 136639

1 Discharge Head 1” NPT 1 136635 137796 139166
2 Mounting Ring 1” NPT 1 136634 137794 139100

1 Discharge Head 2” NPT 1 021585 - ­2 Mounting Ring 2” NPT 1 021584 - -

3 Seal, Rotary w/Spring 1 131100 † 131100 † 136682 ‡

O-Ring 2 131925 ■ 131925 ■ 136607 ▲

4

* Hex Head Cap Screws 3/8” x 3/4” 4 121106 121106 121106

CAST IRON CI PB0508AXXX PB0512AXXX PB0516AXXX PB0712AXXX PB1014AXXX PB1016AXXX
POWDER COATED PC PB0508CXXX PB0512CXXX PB0516CXXX PB0712AXXX PB1014CXXX PB1016CXXX
STAINLESS STEEL SS PB0508SXXX PB0512SXXX PB0516SXXX PB0712SXXX PB1014SXXX PB1016SXXX

CI & PC 135163 132939 138447 134097 134998 135814

SS 136683 138450 136684 136685 136686

CI & PC 135161 133336 138446 133336 134996 135813

SS 138938 136636 138449 136636 136637 136638

CAST IRON CI PB1914AXXX PB2711AXXX PB2714AXXX PB3506AXXX PB3508AXXX
POWDER COATED PC PB1914CXXX PB2711CXXX PB2714CXXX PB3506CXXX PB3508CXXX
STAINLESS STEEL SS PB1914SXXX PB2711SXXX PB2714SXXX PB3506SXXX PB3508SXXX

CI & PC 137222 135627 136629 136626 136632
SS 139162 139163 138946 139164 139165
CI & PC 137221 136624 136628 136625 136631
SS 139159 139157 137535 139156 139158

CAST IRON CI PB0508XXXX PB0514XXXX PB0714XXXX PB1020XXXX PB1022XXXX PB1023XXXX

POWDER COATED PC PB0508ZXXX PB0514ZXXX PB0714ZXXX PB1020ZXXX PB1022ZXXX PB1023ZXXX

STAINLESS STEEL SS PB0508YXXX PB0514YXXX PB0714YXXX PB1020YXXX PB1022YXXX PB1023YXXX

CI & PC 135163 138150 021032 135907 135911
SS 138682 021033 138683 020280 138684
CI & PC 135161 138149 138149 135906 020278 135910
SS 138938 138444 138444 138154 020278 137103

CAST IRON CI PB1920XXXX PB2717XXXX PB3508XXXX PB3514XXXXT

POWDER COATED PC PB1920ZXXX PB2717ZXXX PB3508ZXXX PB3514ZXXXT PB1922ZXXX

STAINLESS STEEL SS PB1920YXXX PB2717YXXX PB3508YXXX PB3514YXXXT

CI & PC 020982 020980 136632 021017 139435
SS 020095 138949 139165 021026 *
CI & PC 020971 020916 136631 021015 139434
SS 020093 138948 139158 021020 021425

4

POWDER

COATED

STAINLESS

STEEL

See

replacement

motors.

ITEMS 9 & 10

FLINT & WALLING, INC. • 95 North Oak St. • Kendallville, IN 46755 • www.flintandwalling.com

14