Polaris 3900 Sport Service Manual Download | Manualshive

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POLARIS® 3900 SPORT

TEARDOWN

WORKBOOK

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Summary of Contents for 3900 Sport

Page 1: ...POLARIS 3900 SPORT TEARDOWN WORKBOOK ...

Page 2: ......

Page 3: ... service or repairs Keep all electrical equipment at least 10 feet 3m from inside wall of pool or spa Connect equipment only to a receptacle cord models or circuit hardwired protected by a ground fault circuit interrupter GFCI Use only copper conductors and supply wires suitable for the specific device Replace damaged power cord s immediately and use only identical replacement parts Do not bury po...

Page 4: ...822 7933 Regional Extension_________________ www ZodiacPoolSystems com Instructor __________________________________________________ ext _______ Sales person ________________________________________________ ext _______ Service Manager ____________________________________________ ext _______ Notes ...

Page 5: ...TOM HOUSING REMOVAL 7 WATER MANAGEMENT REMOVAL 8 WHEEL REMOVAL 9 GEAR BOX ASSEMBLY 10 TOP ASSEMBLY 11 DRIVE TRAIN 11 16 PRODUCT BREAKDOWN 17 COMPONENT PARTS 18 REASSEMBLY AXLE ASSEMBLY 19 GEAR BOX 20 WHEELS CHAIN 21 23 TOP ASSEMBLY 24 WATER MANAGEMENT 25 BOTTOM SWEEP HOSE 26 BAG QUICK DISCONNECT 27 ...

Page 6: ...6 4 Remove Sweep hose by twisting nut to release from hose Remove bag by twisting collar Press logo buttons to remove Quick Disconnect BAG AND SWEEP HOSE REMOVAL DISASSEMBLY ...

Page 7: ...7 5 Remove 3 screws from bottom of cleaner Remove Bottom Housing BOTTOM HOUSING REMOVAL Locate 3 screws labeled A and remove DISASSEMBLY ...

Page 8: ...8 6 Remove Water management System and Rear Housing Locate 4 screws labeled B and remove Remove Gearbox and single side wheel GEAR BOX REMOVAL DISASSEMBLY ...

Page 9: ...9 7 Pry hubcap with flat blade screw driver for removal Un thread screw to remove wheel Pull wheel from gearbox shaft GEAR BOX REMOVAL DISASSEMBLY ...

Page 10: ...10 8 Gearbox Assembly Part 39 200 GEAR BOX COMPONENTS Notes DISASSEMBLY ...

Page 11: ...11 9 Locate and remove 2 screws in order to remove the Top Remove Top Top Assembly Part 39 003 includes float TOP ASSEMBLY REMOVAL DISASSEMBLY ...

Page 12: ...12 10 Pry hubcap off double side wheels with flat blade screw driver Un thread screw to remove wheel Remove wheel DRIVE TRAIN REMOVAL DISASSEMBLY ...

Page 13: ...13 11 Remove wheel sprocket cover to expose chain Remove chain from rear wheel sprocket Remove Sprocket and note bearing placement DRIVE TRAIN REMOVAL DISASSEMBLY ...

Page 14: ...14 12 Press bearing out with screw driver and inspect Reinstall bearing with open face into Sprocket Press against closed face of bearing DRIVE TRAIN REMOVAL DISASSEMBLY ...

Page 15: ...15 13 Sprocket Assembles and chain Drivetrain Locate and remove wheel spac ers from 2 wheel side axles Locate and remove 2 screws at the base of the feed pipe DRIVE TRAIN REMOVAL DISASSEMBLY ...

Page 16: ...16 14 Remove the Vacuum Tube Feed pipe assembly Locate and remove the 2 screws that attach each axle to the frame Frame assembly with Chain tensioner DRIVE TRAIN REMOVAL DISASSEMBLY ...

Page 17: ...17 15 Product Breakdown COMPONENTS Notes ...

Page 18: ...18 16 PART NUMBERS ...

Page 19: ...Assemble axle blocks with star washers and screws Turn frame upside down and install axle blocks to frame Brass Inserts Brass Inserts Drop gearbox into place with brass inserts pointing up REASSEMBLY ASSEMBLY ...

Page 20: ...20 18 Attach gearbox with 4 screws in pockets labeled B Install wheel spacers on double side wheel axle blocks Attach Vacuum tube Feed pipe Assembly to frame with 3 screws REASSEMBLY ASSEMBLY ...

Page 21: ...21 19 Install Wheel Sprockets on double side axle Wrap chain around front axle sprocket and through tensioner as shown REASSEMBLY ASSEMBLY ...

Page 22: ...22 20 Use the diagram on the Vacuum tube to assist with wrap configuration Install the 2 sprocket covers Locate double side wheel noting one bearing in the outer cavity of each wheel REASSEMBLY ASSEMBLY ...

Page 23: ...23 21 Align wheels into sprockets and attach with locking screw Attach single side wheel with the same locking screw Locking screw REASSEMBLY ASSEMBLY ...

Page 24: ...24 22 Replace top assembly with 2 screws Inspect o ring on Water management System Snap rear housing to Water management System REASSEMBLY ASSEMBLY ...

Page 25: ...25 23 Attach Water management System with 3 screws Align bottom housing REASSEMBLY ASSEMBLY ...

Page 26: ...26 24 Snap hub caps on all wheels Attach bottom housing with 3 screws Attach sweep hose install nut first then thread back onto sweep hose REASSEMBLY ASSEMBLY ...

Page 27: ...27 25 Note the serial number location under the canopy Press bag into vacuum tube Install quick disconnect REASSEMBLY ASSEMBLY ...

Page 28: ...28 26 Notes ...

Page 29: ...29 26 Notes ...

Page 30: ...DVS 3900 JUN 2015 ...

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