18220-1121

43000-0755
1/10/03
4:43 PM
Page 1
Model 18220-1121
Model 18220-1121
BALLAST PUPPY
Wakeboard Towboat Ballast Pump
FEATURES
Pump:
Impeller:
Seal:
Ports:
Motor:
Bronze
Jabsco Neoprene compound
Lip Type
1/2" Internal Pipe Threads
1" External Hose Barb
Equipped with Run-Dry Protection Device
(Patent Pending)
12 Volt DC
Permanent Magnet Type
Fully Enclosed
Stainless Steel Shaft
Ball Type Shaft Bearing
Reversible
Dimensions: 3-5/8" (93mm) high,
7-1/8" (182mm) long
4-3/4" (120mm) wide
Weight:
6 lb (2.7 kg)
Rating:
Motors meet USCG Electrical Regulation
183.410 and ISO 8846 MARINE for IGNITION
PROTECTION on gasoline powered vessels.
!
WARNING
Explosion hazard. Do not pump gasoline, solvents,
thinners or other flammable liquids. To do so can
cause an explosion resulting in injury or death.
!
WARNING
Explosion hazard. Do not operate with rivets
removed from motor case. Explosion resulting in
personal injury, death or property damage can
occur. Case openings must be sealed to avoid
explosion and maintain ignition protected rating.
!
WARNING
Sinking hazard. Do not exceed manufacturer's combined
maximum weight capacity and persons capacity as specified
in vessel's "Maximum Capacities" warning placard. To do so
can cause sinking that can result in loss of property and life.
APPLICATION
The Ballast Puppy is designed to pump water into
Wakeboard Liquid Ballast Tanks and when reversed will
also pump water out of them. It has a flow rate of 11
gallons per minute, so it can fill most ballast tanks in
about five minutes. It is equipped with a Run-Dry
Protection Device (patent pending) to automatically
shut-off the pump and protect the impeller from run-dry
damage should the pump be mistakenly left on after the
Ballast Tank is empty.
INSTALLATION
The pump must be mounted in a dry location – the motor
is not waterproof and must not be submerged.
SELECTION OF A COOL VENTILATED location will
generally extend pump motor life. The unit can be
mounted in any desired position. It is best to mount so
that water dripping from loose port connection will not
wet the motor. The pump head may be rotated 180° on
the motor to change the direction of flow.
PLUMBING CONNECTIONS
Pump ports have external 1" hose barb and internal 1/2"
pipe threads. Use hose that does not kink when bent and
with sufficient wall thickness to prevent collapse when
used on suction side of pump. Hoses should be routed
so that some water will be retained in pump body to wet
the impeller. Wetting the impeller aids in priming and
extends impeller life. Use a strainer on the intake hose
to stop trash and solids from going through the pump. All
hoses must have airtight connections to enable fast
priming.
PSI
2.1
4.3
6.5
8.7
Total Head
Feet Metres
5
10
15
20
1.5
3.0
4.6
6.1
Capacity
GPM
LPM
9.0
8.5
8.0
7.5
Table shows approximate Head-Flow for new pump.
34
32
30
28
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OPERATION
ELECTRICAL CONNECTIONS
!
WARNING
Explosion hazard. If pump is operated in an area
containing flammable vapors, motor wire leads must
be joined by insulated mechanical locking connectors.
Loose or inadequate wire connections can spark
resulting in an explosion. Property damage, injury
or death can occur.
NOTICE: To prevent motor damage, use only multistrand copper wire in size recommended. DO NOT use
ordinary lamp cord or other substitutes
The Ballast Puppy should be wired to the Polarity
Reversing Switch (provided) through an over-current
protected distribution panel fitted with a 20 amp breaker
or fuse. This circuit should be dedicated to the Ballast
Puppy and free of any other accessories. The Polarity
Reversing Switch requires that both positive and
negative conductors be run from the power source to the
switch as well as both positive and negative conductors
run from the pump to the switch. These conductors must
be sized to match the recommended wire size in the
Electrical Specification Chart for the total length of the
circuit (the sum of the length of all positive and negative
conductors). Use positive locking type wire connectors
(crimp type butt connectors) to complete all connections
at the pump and reversing switch. Use only quality
marine grade multi-strand copper wire of the proper size
as determined from the Electrical Specification Chart
below.
Reversing
Switch
Orange
Black
+
When ready to add ballast, simply flip the switch to the
fill position and watch for indicators that the tank is full,
then switch the pump off. To reduce the ballast load, flip
the switch to the drain position and the pump will reverse
itself to pump liquid ballast back overboard. To fully
empty tank, just leave the pump in the drain position and
monitor the tank level so that the pump can be turned off
when the tank is empty. Alternatively, simply pay
attention to the sound made by the pump and when the
frequency changes (higher pitch) and it gets louder, that
is an indication the tank is empty and the pump should
be turned off. However, if for some reason attendants
become distracted and do not notice the change in pump
sound or that the tank is empty, the Jabsco Ballast
Puppy is equipped with an exclusive Run-Dry Protection
Device (patent pending) to prevent serious impeller
damage. This Run-Dry Protection Device senses the
absence of water and after a short period of sustained
run-dry operation will shut-off the pump before the
impeller is badly damaged. The delay in run-dry operation
before pump shutdown provides adequate time for initial
pump priming when filling the ballast tank.
The Ballast Puppy is designed for intermittent duty
cycles only. It is capable of filling most ballast tanks in
about 5 – 6 minutes and can be immediately reversed to
empty the tank if urgent de-ballasting is required.
However, after about twenty minutes of continuous
running the Run-Dry Protection Device will interrupt
power to the pump and cause the pump to shutdown.
The pump would then need to cool off for about twenty
minutes before normal operation will resume.
WIRING DIAGRAM
Overload
Protected
Distribution
Panel
The Ballast Puppy is reversible so it can both add liquid
ballast and then pump it back overboard when ready to
lighten the load. The stylish double throw reversing
switch (provided) is intended to be mounted in a
convenient, easily accessible location for quick and easy
ballast control. The pump can fill a typical forty gallon
tank in about 5 – 6 minutes.
The pump cannot run against a closed outlet as may be
encountered when installed in systems with valves to
regulate flow. Pressure for normal operation should not
exceed 20 feet of head (8.7 psi).
+
–
–
Battery
ELECTRICAL SPECIFICATIONS AND MINIMUM WIRE SIZE
AMP
VOLTAGE DRAW
12V DC
12
FUSE
SIZE
0'-10' (0 M-3 M)
10'-15' (3 M-4.6 M)
20
#16 (1.5 mm2)
#14 (2.5 mm2)
WIRE SIZE PER FEET OF RUN*
15'-25' (4.6 M-7.6 M) 25'-40' (7.6 M-12.2 M) 40'-60' (12.2 M-18.3 M)
#12 (4 mm2)
#10 (6 mm2)
#8 (10 mm2)
* Length of run is total distance from power source to pump and back to ground. Wire sizes listed are SAE gauge and metric millimetres .
2
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EXPLODED VIEW
MAINTENANCE
Check wires and connections to be sure corrosion is
not adding additional resistance to the motor circuit
and causing a low voltage condition at the motor. Low
voltage can inhibit motor from starting and/or reversing
and cause fuse to blow. Full voltage should be available
to prevent motor damage.
NOTICE: If pump is idle for extended periods, the impeller
may stick to the pump body, preventing motor rotation
and causing blown fuses. To correct, remove end cover
and impeller, clean body and impeller, then lubricate with
water or small amounts of grease before assembly.
If pump is to be in freezing temperatures, drain by
loosening end cover screws.
A Service Kit, or at least spare impellers, should be
carried aboard to be assured of pumping capability.
PARTS LIST
Key
1
2
3
4
5
6
7
8
9
Description
Screw Kit (End Cover)
(3 screws per kit)
End Cover
O-Ring*
Impeller*
Seal*
Body
Slinger
Motor
Screw, Pump to Motor (3/kit)
Rocker Switch
Service Kit
Qty.
Part
Number
1
91004-0090
1
1
1
1
1
1
1
2
1
18647-0000
18753-0660
6303-0003
18753-0384
18645-0000
6342-0000
18753-0696
98019-0020
18753-0095
90061-0006
* Parts Contained in Service Kit.
DISASSEMBLY
ASSEMBLY
1. Remove end cover screws, end cover and O-ring.
1. Lubricate seal with water and position it in seal bore
with lip, or hollowed-out side of seal, pointing
towards the impeller bore. With a 1/2" diameter
dowel, push the shaft seal into its bore until it contacts the bottom.
2. Withdraw impeller.
3. Loosen and remove two slotted hex screws, which
attach body to motor.
4. Tap body lightly between ports and remove body
from motor.
5. With a 1/2" diameter dowel, push against the shaft
seal from back (motor) side of the body to dislodge
it from the seal bore.
NOTE: Do not tamper with or dissemble motor.
2. Lubricate motor shaft and install body on motor.
3. Lubricate impeller bore and, aligning flat in impeller
with flat on motor shaft, install impeller with a rotary
motion.
4. Install O-ring, end cover and screws.
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Page 4
DIMENSIONAL DRAWING
Inches (Millimetres)
ONE YEAR LIMITED WARRANTY
A. LIMITED WARRANTY:
Jabsco warrants that at the time of shipment, the products
manufactured by Jabsco and sold hereunder shall be in
conformity with applicable written specifications and descriptions
referred to or set forth herein, free from defects in material and
workmanship, merchantable, and suitable for a particular
purpose, provided such is implied by State law under the
circumstances of this sale.
2.
ITT SHALL NOT BE LIABLE FOR ANY LOSS, DAMAGE,
SPECIAL OR CONSEQUENTIAL DAMAGE OF ANY KIND,
WHETHER BASED UPON WARRANTY, CONTRACT,
NEGLIGENCE, OR STRICT LIABILITY ARISING IN
CONNECTION WITH THE SALE, USE, OR REPAIR OF THE
PRODUCT.
3.
THE MAXIMUM LIABILITY OF ITT IN CONNECTION WITH THIS
WARRANTY SHALL NOT IN ANY CASE EXCEED THE
CONTRACT PRICE FOR THE PRODUCT CLAIMED TO BE
DEFECTIVE OR UNSUITABLE.
4.
This warranty does not extend to any product manufactured by
Jabsco which has been subjected to misuse, neglect, accident,
improper installation, or use in violation of instructions furnished
by Jabsco.
5.
This warranty does not extend to or apply to any unit which has
been repaired or altered at any place other than Jabsco’s factory,
or by persons not expressly approved by Jabsco, nor to any unit
the serial number, model number, or identification of which has
been removed, defaced or changed.
6.
Components manufactured by any supplier other than Jabsco
shall bear only that warranty made by the manufacturer of that
product.
7.
This warranty applies to products defined as “consumer products”
by the Consumer Product Warranties Act as from time to time
amended.
B. WARRANTY ADJUSTMENT:
1.
Jabsco agrees to repair or furnish a replacement for, but not to
remove or install, any product or component thereof which, within
one (1) year from date of purchase, shall upon test and
examination by Jabsco prove defective within the above warranty.
Receipt verifying purchase date is required to obtain adjustment.
2.
Buyer shall notify Jabsco of any defect within this warranty no
later than ninety (90) days after the defect is discovered.
3.
No product will be accepted for return or replacement without the
prior written authorization of Jabsco. Upon such authorization,
and in accordance with instructions from Jabsco, the product will
be returned to Jabsco, shipping charges prepaid by Buyer.
Products returned to Jabsco will be addressed as follows:
JABSCO
20 Icon
Foothill Ranch, California 92610-3000
Or to such alternate locations as may be designated
on the product, its container, or this sheet.
Repair or replacement made under this warranty
will be shipped prepaid to Buyer.
C. EXCLUSIONS FROM WARRANTY AND
LIMITATION OF LIABILITY:
1.
The foregoing warranty is limited solely as set forth herein and
applies only for the period designated above.
U.S.A.
Jabsco
20 Icon
Foothill Ranch, CA 92610-3000
Tel: 949.609.5106
Fax: 949.859.1254
© Copyright 2003, ITT Industries
UNITED KINGDOM
Jabsco
Bingley Road, Hoddesdon
Hertfordshire EN11 OBU
Tel: +44 (0) 1992 450145
Fax: +44 (0) 1992 467132
Printed in U.S.A.
D. CONSUMER RIGHTS:
This warranty gives you specific legal rights, and you may have
other rights which vary from state to state. Some states do not
allow exclusion or limitation of damages.
STANDARD WARRANTY: If the products manufactured and sold
hereunder are not Consumer Products, the warranty extended to
Buyer shall be as set forth in subparagraphs (A), (B), and (C), EXCEPT
THAT ALL EXPRESS OR IMPLIED WARRANTIES OR
MERCHANTABILITY OR SUITABILITY FOR ANY PARTICULAR
PURPOSE ARE EXCLUDED.
CANADA
Fluid Products Canada
55 Royal Road
Guelph, Ontario N1H 1T1
Tel: (519) 821.1900
Fax: (519) 821.2569
JAPAN
NHK Jabsco Company Ltd.
3-21-10, Shin-Yokohama
Kohoku-Ku, Yokohama, 222
Tel: 045.475.8906
Fax: 045.475.8908
All Rights Reserved
GERMANY
Jabsco GmbH
Oststrasse 28
22840 Norderstedt
Tel: +49-40-53 53 73 -0
Fax: +49-40-53 53 73 -11
Form: 43000-0755
Rev. 1/2003