Hayward KingShark 2 Plus Page 21 Troubleshooting Manual Download | Manualshive

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Pump Housing / Gear Box Disassembly

Gear Box Assembly

Pump Housing

1. Use a 7/16" socket to remove the 3 bolts from the pump housing. Pull the pump housing from the

gear box assembly.

2. After removing the 3 - 7/16" bolts, note the length and location of each bolt for reinstallation.

1.

2.

Step 17:

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Summary of Contents for KingShark 2 Plus

Page 1: ...Commercial Cleaner Troubleshooting Guide 2012 Hayward Industries Inc...

Page 2: ...Pump Housing Gear Box Disassembly Page 19 Solenoid Disassembly Page 20 Bumper Cable Assembly Removal Page 21 Cable Assembly Components Page 22 Control Panel Components Pages 23 25 Control Panel Troubl...

Page 3: ...m the pool immediately after each use will enhance the cleaner s life 150 minutes of operation in a 30 x 60 pool should be sufficient with no more than a few twists in the cord which should be straigh...

Page 4: ...2 3 8 5 16 7 16 1 2 Wrench Snap Ring Pliers Needle Nose Pliers Flat Tip and Phillips Screwdriver Small Flat Tip Screwdriver 3 8 Ratchet 3 8 Socket Extension 1 4 Socket Driver 3 8 7 16 1 2 Socket 5 32...

Page 5: ...ong electrical cord 2 RCX400388 3 4 h p w o swivel 3 RCX4011 3 4 h p w swivel Page 3 The remote has a maximum communication line to the antenna of 150 1 Different pigtail connections 2 KingShark 2 Plu...

Page 6: ...Master control panel the following jumper cable switch must be moved 1 Move the jumper wire connection E9 to E7 230 VAC connection on the RELAY BOARD just above the transformer 2 Hard wire the power c...

Page 7: ...e two 1 4 20 X 3 4 SS bolts from both sides of the cleaner using a 7 16 socket Pull the cartridge handle quick release UP and then pull the cartridge assembly back and away from the cleaner Note 1 bol...

Page 8: ...Step 3 Unscrew the filter retainer knob using a 5 32 Allen Wrench Step 4 Slide the hood cover over the swivel assembly Removal of Hood Page 6...

Page 9: ...Filter Removal Step 5 Pull up on the yellow quick release handle assembly Step 6 Page 7 Pull and slide the filter assembly backwards and away from the cleaner...

Page 10: ...ove the push style clips Back Plate Note Never remove or adjust the 4 nuts To clean the filters spray with clean water Page 8 Lift the housing assembly off the tie rods back plate Lift the cartridges...

Page 11: ...the swivel cord clamp 2 Using a Phillips screwdriver remove the four screws connecting the power end to the swivel 3 When reconnecting the power end to the swivel or motor make sure to use RTV 162 si...

Page 12: ...4 20 X 1 1 4 hex head bolts from the swivel mounting bracket Remove the four screws connecting the power cord to the motor end Note Make sure to use RTV 162 Silicone Rubber Sealant when reconnecting t...

Page 13: ...to remove the two plastic bolts and impeller access plate from the pump housing Step 10 1 2 After removing the impeller access plate this will allow you to inspect the impeller and check for debris or...

Page 14: ...lts back on put the LEFT side on first then the RIGHT side This will prevent possible torque damage where the gear box assembly meets the front housing bell since the larger support bracket is on the...

Page 15: ...f the 2 plastic washers that seat between the Intake and the base plate 2 Page 13 1 Unscrew the 4 screws holding the intake to the base plate also remove the SS wire baffle 2 Remove the intake stabili...

Page 16: ...nap rings from the wheels pull the front wheels from the base plate and remove the drive wheels from the gear box assembly Note There is one SS washer on each side of the gear arm 1 Front Wheels 2 Dri...

Page 17: ...R drive wheels Remove the 4 plastic washers spacers 2 Remove the 2 indicator screws from the drive wheels Each set of screws indicate LEFT drive wheel specific or RIGHT drive wheel specific Below the...

Page 18: ...Drive Wheel Disassembly 2 Remove the Gear Ring 3 Remove the Sun Gear 1 Remove the 4 Button Washers Step 15 4 Remove the 4 Planetary Gears 5 Remove the Wheel Lock Page 16...

Page 19: ...eel Locks are installed in the correct direction and position The photo s below indicate the correct position and direction LEFT DRIVE WHEEL RIGHT DRIVE WHEEL 2 The outside wheel plate screws must mat...

Page 20: ...ift the motor from the base plate 2 Use a 1 2 socket to remove the 5 bolts and washers that hold the motor to the pump housing 1 2 3 Use a flat tip screw driver to remove the 4 impeller screws 4 Unscr...

Page 21: ...embly Pump Housing 1 Use a 7 16 socket to remove the 3 bolts from the pump housing Pull the pump housing from the gear box assembly 2 After removing the 3 7 16 bolts note the length and location of ea...

Page 22: ...s are removed the solenoids can be set aside To separate the solenoids from the motor pull and separate at the quick connection at the solenoid Note Solenoids are marked left L and right R The power c...

Page 23: ...val 1 Remove the two 3 8 nuts top four flathead screws center and two pins bottom 2 Slide the bumper from the arm sensor bar 1 Step 19 Page 21 Note Both the reversing arms and cable assembly can be tu...

Page 24: ...1 Tension cables cable assembly are adjustable Once the cable assembly is reinstalled push in should touch the inside of the drive wheels Cable assembly s do not come pre tensioned from the manufactu...

Page 25: ...Master Control Panel Relay Board Transformer Receiver Board 24 VDC relays 24 VDC relays Power out to cleaner Relay Board Receiver Board Antenna Page 23 Incoming power supply AC to DC rectifier...

Page 26: ...ter Control Panel Fuse Power Indicator Light Auto Turn On Off Switch Power On Off Switch Note Ribbon cable disconnects at the Timer Board Timer Board Page 24 Back Side of Front Panel Display ribbon ca...

Page 27: ...upter If you supply power to the master control panel and you have no display this is NORMAL Unless you have the Cannon Plug power cord from the swivel connected to the 2 center ports the display will...

Page 28: ...l Panel but NO display 1 2 Put meter lead on the on off switch and one lead to ground 115 VAC should be present 1 2 NOTE Check voltage on LEFT connection of switch Make sure power is ON Put one meter...

Page 29: ...el Correct power to Master Control Panel and NO display Check for a blown fuse Twist the fuse left and pull out for access Page 27 Slo Blo 1 amp 250VP Do a continuity check on the fuse to verify if fu...

Page 30: ...VAC is being supplied through the female cannon plug receiver install a jumper wire into the 2 center ports Power the unit on and press the Start button until RUN is on the display Then stick one met...

Page 31: ...25 on Page 32 Page 29 Using RED lead of DC voltmeter at green wire on J4 and BLACK lead of DC voltmeter at COM E12 Voltmeter should read 24 VDC Now push RIGHT TURN button on the remote voltmeter shoul...

Page 32: ...e blue wire 24 VDC should be present while pushing the LEFT TURN button on the remote Using DC Voltmeter check voltage between the yellow wire and the brown wire 24 VDC should be present while pushing...

Page 33: ...be replaced 2 If the problem still exists after replacing the RELAY PCB Board remove the cannon plug from the master control panel Insert the jumper wire into the 2 center ports of the connector plug...

Page 34: ...2 Disconnect the power end connection at the swivel 3 Power the system ON and make sure the RUN light is illuminated 4 Put meter leads on the black and white ports 115 VAC should be present If not ve...

Page 35: ...verify voltage is getting through the swivel to the MOTOR 1 Power the system off 2 Disconnect the power end connection at the motor 3 Power the system on and make sure the RUN light is on the display...

Page 36: ...Ohm Check at Motor Step 28 Ohm meter 0 9 ohms 1 3 ohms for 115 VAC 4 3 ohms 6 3 ohms for 240 VAC Page 34...

Page 37: ...start button until Run is displayed 1 2 Put one meter lead into the white port and one meter lead into the black port at the swivel connector end where it connects to the swivel 115 VAC should be pre...

Page 38: ...er through the unit Clean the filters 2 Suction area may be obstructed by large debris Unplug power cord and remove obstruction No apparent power 1 Electrical outlet may be dead Check electrical GFCI...

Page 39: ...d in the three locations indicated below First two numbers of a serial number 10 MAKOSHARK 30 MAKOSHARK2 50 KINGSHARK 70 KINGSHARK2 90 KINGSHARK2 PLUS LETTER A January B February C March D April E May...

Page 40: ...mber sequence used on Hayward products This will be located on the gear box assembly and on the motor Example Model Serial RC9860DCC 21121102005246000 2112 location made 11 year made 02 month made Pag...

Page 41: ...e Removal Page 41 Filter Housing Removal Page 42 Hood Removal Page 43 Cord Assembly Removal Page 44 Drive Belt Removal Page 45 Gearbox Assembly Removal Page 46 Impeller and Motor Removal Pages 47 48 P...

Page 42: ...the unit Note Elements can be cleaned by gently spraying with a garden hose Be careful not to use high pressure as this may cause damage to the elements Step 3 Remove filter elements Step 1 Step 2 Rem...

Page 43: ...Handle Removal Step 1 Use a flat head screwdriver on both ends of the handle pin to unscrew and remove Page 41...

Page 44: ...Slide Ring Adapter off the housing and remove the two screws to remove the ring adapter from cord Lift the filter housing from the cleaner Filter Housing Removal Step 1 Step 2 Page 42...

Page 45: ...Hood Removal Remove the bolt from the handle riser using 7 16 socket Remove the handle riser Remove the hat riser Lift the body off Step 1 Step 2 Step 3 Step 4 Page 43...

Page 46: ...sing using a 7 16 socket Remove the 4 screws from the motor Pull the plug away from the motor Note When replacing the cord assembly clean surface thoroughly and use new o ring and RTV 162 White Silico...

Page 47: ...e LEFT belt Note Look at the cleaner from the rear and note that the gear box has a Support on the left side of the unit Left Right Note When installing the drive belts install the left belt first and...

Page 48: ...Step 1 Remove the five bolts from the rear of the gear box assembly using a 7 16 socket Gear Box Assembly Removal 1 2 3 4 5 Step 2 Pull the gear box away from the pump housing Gear Box Page 46...

Page 49: ...Impeller and Motor Removal Pull the impeller from the impeller drive collar Pull the impeller drive collar from the motor shaft Step 1 Step 2 Page 47...

Page 50: ...Impeller and Motor Removal Step 3 Remove the 3 motor screws Step 4 Slide the motor away from the pump housing 1 2 3 Page 48...

Page 51: ...Base Disassembly Step 1 Remove the 2 blue intake blades by pulling them from the slide Step 2 Remove the two bolts from the bottom of the unit using a 1 2 socket Step 3 Remove the pump housing from t...

Page 52: ...heel Step 5 Slide the wheel off of the axle Step 6 Repeat the 2 previous steps on the opposite side of the base Note Sensor Bar and Reversing Arms are both reversible As they become worn they can be t...

Page 53: ...ing and Base Disassembly Remove the 2 flat head screws from the sensor bar This will allow removal of the sensor bar from the base Pull the 2 cotter pins at the opposite end of the cables Step 7 Step...

Page 54: ...located on either side of the reversing arm to allow smooth movement Pump Housing and Base Disassembly Washer locations Page 52 Note The steps to disassemble reassemble the drive wheels are identical...

Page 55: ...ing or sensing wall 2 Turns or hesitates on pool drain C Sensor Bar adjustments required if machine turns in circles or twists cord 1 Sensor Bar not level or too high possible hitting hood OR 2 Thread...

Page 56: ...r at the electrical outlet 2 Object lodged in impeller 3 A short in the motor check the ground fault interrupter 4 Unit runs for a short distance and stops Check for overload of the electrical circuit...

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