Polaris PB4-60 Quick Start Manual
Polaris® Booster Pump PB4-60
Replacement Kits
WARNING
FOR YOUR SAFETY - This product must be installed and serviced by a contractor who is licensed and
qualified in pool equipment by the jurisdiction in which the product will be installed where such state or
local requirements exist. In the event no such state or local requirement exists, the maintainer must be
a professional with sufficient experience in pool equipment installation and maintenance so that all of
the instructions in this manual can be followed exactly. Improper installation and/or operation can create
dangerous electrical hazards, which can cause high voltages to run through the electrical system. Before
installing this product, read and follow all warning notices and instructions that accompany this product.
Failure to follow warning notices and instructions may result in property damage, personal injury, or death.
Improper installation and/or operation will void the warranty.
These instructions are to be used with the following Installation/Replacement Kits:
P17 -- Softube® Quick Connect Installation Kit
P19 -- 6’ Flexible Reinforced Pump Hose Installation Kit
P21 -- Pump Quick Connect Retainer
P61 -- 60 Hz, 3/4 HP Motor
P133 -- Softube Quick Connect with Retainers
R0445500 -- PB4-60 Ceramic Seal and Spring Replacement Kit
R0536300 -- PB4-60 Volute Replacement Kit
R0536400 -- PB4-60 Impeller Replacement Kit
R0536600 -- PB4-60 Backplate O-Ring Replacement Kit
R0536700 -- PB4-60 Backplate Replacement Kit
R0536800 -- PB4-60 Motor Bolts and Washers Replacement Kit
R0536900 -- PB4-60 Bolts, Washers, and Nuts Replacement Kit
R0537100 -- PB4-60 Booster Pump Base Replacement Kit
WARNING
If the information in these instructions is not followed exactly, an electrical re or shock hazard may result causing
property damage, personal injury or death.
This document gives instructions for replacing
the Volute, Impeller, Backplate, Base, Ceramic Seal,
Hose, O-Rings and Hardware on the PB4-60 Booster
Pump. The instructions must be followed exactly. These
instructions were written with safety as the priority.
Not following this procedure or taking shortcuts may
result in personal injury. Read through the instructions
completely before starting the procedure.
Before starting the procedure, use the parts list at
the back of these instructions to identify the parts that
are in your kit. If any parts are missing from the kit
please call your local Zodiac distributor for assistance.
For technical assistance please contact our Technical
Support Department at 800.822.7933.
H0332800 Rev A
1. Replace the Volute, Backplate O-Ring
and Drain Plug
WARNING
While servicing the pump, switch off the circuit
breakers at the power source. Severe personal
injury or death may occur if the pump starts while
your hand is inside the pump.
1. Turn off the pump. Switch off the circuit breaker
to the pump motor. If you are not replacing the
motor, do not disconnect the electrical wiring.
NOTE If you are replacing the motor, Zodiac Pool
Systems, Inc. strongly recommends that a
qualied service technician or electrician
properly disconnect the electrical wiring at the
pump motor.
Page 2
• Ceramic Face Seal
• Carbon Face/ Spring
2. Turn off any valves to prevent pool water from
reaching the pump. Drain the water from the pump
by removing the drain plug.
3. Using a 1/2” wrench, loosen the six (6) bolts
connecting the pump volute to the motor
backplate. Remove the bolts and washers and
either set aside to use in reassembly or use new
ones from the kit. See Figure 1.
Bolts
(Qty. 6)
Hex-Head
Motor Cover
Back
Plate
Volute
Figure 1. Remove the Volute
Motor
Body
4. Pull the volute from the backplate.
NOTE The impeller is a right-handed thread, therefore
turn the impeller counter-clockwise to unscrew.
4. Inspect the impeller for signs of rubbing and/or
damage and replace if necessary.
5. If you are replacing the mechanical seal do steps 6
through 10, if not, skip to step 11.
CAUTION
Do not damage the ceramic or carbon surfaces
of the seals. If surfaces are damaged, leaks will
occur.
6. Remove the carbon face seal half from the
impeller. Refer to Figure 2 and 3. This is a springloaded seal. Grasp the portion of the seal closest
to the impeller body and pull the seal off using a
twisting motion.
NOTE This is a two (2) part replacement process. The
mechanical seal must be replaced as a set.
7. Remove the four (4) 9/16” screws that secure the
backplate to the motor and remove the motor.
8. Place the backplate o-ring side down and force the
ceramic seal out using a screwdriver or drift pin.
NOTE At this point you have access to the inlet and
outlet of the impeller to remove any debris.
5. Remove the backplate o-ring and replace it with
the new o-ring making sure it is seated properly.
6. Install the new volute using six (6) bolts with six
(6) washers and six (6) nuts. Torque the bolts to
7±0.3 ft-lbs
7. If required, install the new drain plug. Torque to 8
to 10 in-lbs.
8. Turn on the lter pump and turn on the circuit
breaker to booster pump motor.
9. Once all the air has left the lter, close the
air release valve. (Follow the manufacturer’s
instructions for your lter.)
10. Turn on the booster pump and check the system
for proper normal operation.
2. Replace the Impeller and Mechanical
Ceramic/Spring Seal
1. To access the impeller and mechanical seal, follow
steps 1 though 4 of Section 1.
2. Remove the motor shaft cover on the back of the
motor by twisting the hex-head motor cover with
an adjustable wrench. See Figure 1. The motor
shaft will be exposed.
3. The impeller is connected to the motor shaft.
Hold the motor shaft with a ½” wrench while
unscrewing the impeller from the motor shaft with
your hand.
Carbon Seal Surface
• Backplate Seal
Figure 2. Replace the Mechanical Seal
Back Plate
Prongs
Impeller
Figure 3. Backplate, Impeller and Mechanical Seal
Location
Side of Seal
• Impeller Side of the
Mechanical Seal
Mechanical Seal
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