DIY: How to Repair Your Polaris Booster Pump

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How To Repair Your Polaris PB4-60 Booster Pump

Before you begin to repair your Polaris Booster Pump you must be certain there is no electrical current running to it. If you are unsure if there is electrical current running to your Booster Pump then stop. Do not attempt to repair it and call a professional.

Items you will need:

  • 1/4″ Socket & Driver
  • 1/2″ Wrench
  • 9/16″ Open-Ended Wrench
  • Pliers Or Crescent Wrench With At Least 1″ Opening
  • PS-1000 Replacement Shaft Seal
  • 1″ PVC Pipe Coupler
  • Hammer or Mallet
  • Good Lubricant
  • Clean Towel
  • P40 Shaft O-Ring (As Needed)
  • P95 Seal Plate O-Ring (As Needed)
For Your Information:
When repairing a Polaris Booster Pump you must always replace the Shaft Seal Assembly. Otherwise your Booster Pump will leak water when reassembled. We recommend using a U.S. Seal replacement seal part number PS-1000.

Disassembling Polaris Booster Pump

Step 1 : Remove Wiring

1To disconnect the wiring running to the Booster Pump you will first need to remove the wiring cover. When facing the rear of the Booster Pump; the wiring cover is located to the right. There are two small hex-head screws holding the wiring cover in place. They are best removed with a 1/4″ socket. After the cover is removed you will need to disconnect the wiring. Again if you don’t already know how to do this then please do not attempt and call a professional.

PB4-60 Back view
PB4-60 Removing wiring cover
PB4-60 Wiring
Step 2 : Remove Volute

2Next you need to remove the volute. The volute is the part of the impeller casing that has a discharge port which is located up top. The volute is held on with six 1/2″ hex-head bolts. After removing the six bolts; the volute should pop right off by applying pressure to the discharge port with your palm.

PB4-60 Volute bolts
PB4-60 Volute removed
PB4-60 Volute and bolts
Step 3 : Remove Impeller

3The impeller is the disk-shaped object attached to motor shaft. The impeller is what actually provides the pumping action allowing your PB4-60 to work. To remove the impeller, you will first need to remove the shaft access cover on the back center of the booster pump. The shaft access cover is about two inches in diameter and has a 1″ hex-head on it. This hex-head is not threaded. You only need to turn it approximately 1/4 turn counter clockwise and you will be able to pull the shaft access cover out. With the shaft access cover removed you will need to use an open-ended 9/16″ wrench to hold the rear end of the motor shaft in place so you can unscrew the impeller. Holding the shaft in place, you can unscrew the impeller by hand by turning it counter clockwise. Lastly remove the seal plate o-ring on the lip of the bracket just outside of where the impeller was. Set the seal plate o-ring to the side and be sure not to lose it.

PB4-60 Remove shaft-access cover
PB4-60 Shaft-access cover removed.
PB4-60 Holding shaft in place
PB4-60 Removed impeller
PB4-60 Remove seal plate o-ring
PB4-60 Seal plate o-ring
Step 4 : Remove Motor Bracket

4First, you will need to remove the four hex-head bolts holding the bracket to the motor. The top two bolts are shorter than the bottom two bolts because the bottom bolts also attach to the pump stand. The bolts can be removed using a 9/16″ wrench. With the bolts removed the bracket will slide right off. The motor is now detached from the bracket and pump base.

PB4-60 Remove bracket bolts
PB4-60 Four bracket bolts
PB4-60 Removed pump base
PB4-60 Bracket off
PB4-60 Motor, bracket and pump stand
PB4-60 Bracket notch
Step 5 : Remove Old Shaft Seal

5Before we can replace the old shaft-seal assembly we must remove it. You will first need to place the bracket on a flat surface facing down. From above you can see the spring side of the shaft-seal assembly which looks like a silver ring around the opening. This is where you will need to apply pressure to remove shaft seal. Be careful not to scratch or damage the bracket. Next, you will need to remove the porcelain half of the shaft-seal assembly from the Impeller. Place the Impeller face down on a flat surface. You should be able to remove the porcelain shaft seal by hand. Once again, be careful not to scratch or damage the Impeller.

PB4-60 Spring-side shaft seal
PB4-60 Remove spring-side shaft seal
PB4-60 Spring-side shaft seal removed
PB4-60 Remove porcelain shaft seal
PB4-60 Porcelain shaft seal removed
PB4-60 Shaft seal assembly complete

Reassembling Polaris Booster Pump

Step 1 : Spring-Side Shaft Seal

1Now we need to put your new shaft seal assembly in place. We recommend using the U.S. Seal PS-1000 shaft seal because it is more readily available than the Polaris P55 Shaft Seal,  and it is also cheaper and just as high a quality. First, we need to put the spring side of the shaft seal into the bracket. Place the bracket on a flat surface face up and be sure to clean the seal-seat counter-bore with your towel before setting the shaft seal into position. With the shaft seal in position, you will need to apply even pressure to it. Take your 1″ PVC pipe coupler and place it around the shaft seal with it resting on the lip of the shaft seal. Tap the PVC pipe coupler lightly with either a mallet or the side of a hammer until the shaft seal is firmly in place.

US Seal PS-1000 Shaft seal assembly
PB4-60 Clean bracket
Shaft seal and PVC coupler
PB4-60 Placing spring-side shaft seal
PB4-60 Tap lightly with hammer
PB4-60 Spring-side shaft seal in place
Step 2 : Porcelain Shaft Seal

2Now for the porcelain side of the shaft seal assembly. When handling the porcelain side of the shaft seal, be sure to never touch the white-porcelain face with your fingers. Any dirt or oils on the porcelain face will cause the shaft seal to wear out prematurely. You will want to set the porcelain seal gently into position touching only the black sides of the seal. The seal will slide into position much easier with the smallest amount of lubrication applied to only the black sides of the seal. We do mean a very small amount, and be sure not to get any lubrication on the porcelain face of the seal. With the seal in position, place a clean towel over it and apply even pressure to slide it firmly into place.

PB4-60 Place the porcelain-side seal
PB4-60 Cover porcelain seal with towel
PB4-60 Apply pressure to porcelain seal
Step 3 : Shaft O-Ring & Bracket

3Before you replace the bracket, you may need to first change the shaft O-ring. Inspect the shaft o-ring for signs of wear. A new O-ring’s outer edge is rounded, where as a worn O-ring will look flat. If your O-ring appears to be worn you will need to replace it. Remove the old O-ring and replace it with the new one. Be sure to lubricate the new O-ring as well or it will be difficult to put the bracket back on. Next, we’ll need to place the bracket back on. Be sure the notch on the bracket is located on the top side of the booster pump. You should put the shorter, top bolts back on first. The longer, bottom bolts go back through the pump stand.

PB4-60 Shaft O-Ring P40
PB4-60 New Shaft O-Ring
PB4-60 New Shaft O-Ring
PB4-60 Bracket notch
PB4-60 Bracket top bolts
PB4-60 Bracket bottom bolts
Step 4 : Impeller & O-Ring

4To put the Impeller back on, you will once again need to secure the shaft with a open-ended 9/16″ wrench. With the shaft held in place, screw the Impeller back on by hand by turning it clockwise. The Impeller only needs to be hand tight. With the Impeller back in place, you will need to put the seal plate O-ring back on. You may need to replace the P95 seal plate O-ring. Inspect the seal plate O-ring for signs of wear. Good O-ring edges are rounded and worn O-rings are not. If your O-ring is worn you will need to replace it. Lubricate the seal plate O-ring before you put it back on.

PB4-60 Hold shaft in place
PB4-60 Tighten impeller
PB4-60 Inspect old o-ring
PB4-60 Lubricate seal plate o-ring
PB4-60 Place seal plate o-ring on lip
PB4-60 Seal plate o-ring in place.
Step 5 : Volute

5First make sure the seal plate O-ring is in place before putting the Volute back on. With the Volute back in place, bolt it back on with the six 1/2″ bolts, then replace the shaft access cover which only needs to be hand tight. Now all you need to do is re-wire your booster pump, replace the wiring cover and plumb your booster pump.

PB4-60 Place volute back on
PB4-60 Bolt volute back on
PB4-60 Put shaft access cover back on
Finished

Your Polaris Booster Pump should now be fully assembled, installed and working great.

Shop for all PB4-60 parts discussed here:

Shop Now At PoolSupplySales.com
P5 – VoluteOnly $47.94+ Free Shipping…Learn MoreBuy Now
P15 – ImpellerOnly $23.35+ Free Shipping…Learn MoreBuy Now
PS1000 – Shaft SealOnly $9.00+ Free Shipping…Learn MoreBuy Now
P95 – Bracket O-RingOnly $11.34+ Free Shipping…Learn MoreBuy Now
P10 – BracketOnly $47.94+ Free Shipping…Learn MoreBuy Now
P40 – Shaft O-RingOnly $4.32+ Free Shipping…Learn MoreBuy Now
B625 – 3/4 HP AO Smith MotorOnly $231.97+ Free Shipping…Learn MoreBuy Now
P70 – Pump StandOnly $41.44+ Free Shipping…Learn MoreBuy Now
As with any do-it-yourself project, unfamiliarity with the tools and process can be dangerous. These DIY Instructions should be construed as theoretical advice. Any use of these instructions is at your own risk. Pool Supply Sales, will not be held responsible for any injury or property damage due to the misuse or misunderstanding of these instructions.

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