Commercial Cleaner Troubleshooting Guide
Contents
1. Step 18 1 Use a 7 16 wrench to remove the 4 retention nuts from the U bolts 2 Once the 4 retention nuts 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 cord that has the black lines indicates the right solenoid connection see insert picture photo 2 Bumper Cable Assembly Removal Step 19 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 Cable assembly s do not come pre tensioned from the manufacturer 1 2 Tension cables cable assembly are adjustable 2 plastic spacers Once the cable assembly is reinstalled push in 1 plastic spacer on the sensor bar The L amp R reversing arms BOTTOM should touch the inside of the drive wheels Release the sensor bar it should spring back to it s TOP Instructions for Reinstalling the Cable Assembly normal position if it doesn t tighten or loosen accordingly blue Note the proper location of the washers and spacer when reinstalling the L amp R reversing arms L side top R side top f Page 22 Master Control Panel 24 VDC relays Antenna Transformer Receiver Board AC to DC rectifier 24 VDC relays Relay Board Power out to cleaner Pa2. Page 15 Drive Wheel Disassembly a Step 15 1 Remove the 4 Button Washers 2 Remove the Gear Ring 3 Remove the Sun Gear 5 Remove the Wheel Lock O HAYWARD Page 16 Drive Wheel Reassembly 1 When reinstalling the drive wheels make sure the are installed in the correct direction and position The photo s below indicate the correct position and direction 2 The outside wheel plate screws must match the L or R indicator markings on the outside wheel plates HAYWARD LEFT DRIVE WHEEL RIGHT DRIVE WHEEL Page 17 le A Je Re E GS tees 4 a pe R A p gt 7 4 A o A d Ww 14 G al a l T A r ad Sa Vy L i Step 16 1 Use a 1 4 allen wrench to remove the 2 bolts and washers Once these are removed lift 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 3 Use a flat tip screw driver to remove the 4 impeller screws 4 Unscrew the 2 screws and 1 7 16 bolt to separate the motor from the housing bell Left View Right View Page 18 Pump Housing Gear Box Disassembly Step 17 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 Gear Box Assembly Pump Housing HAYWARD Page 19
3. Using DC Voltmeter check voltage between either the brown or blue wire to yellow 24 VDC should be present while pushing the REVERSE TURN button on the remote Note Voltage can vary between 22 28 VDC Vv AUO4 JOAVZ vz 461 pIeyw 478 480d PL yo Step 25 1 After testing the RELAY PCB Board Step 24 if the tests do not match the correct voltages then the RELAY PCB Board will need to 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 at the master control panel Repeat steps 24 amp 25 If steps 24 amp 25 pass the testing the motor and cord need to be test separately to determine which one needs to be replaced Voltage Check to Swivel Step 26 To verify voltage is passing through the power supply cord to the swivel 1 Power the system off 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 verify breaker is good ON switch is ON and all power is correct POWER END CONNECTION power cord Step 27 To verify voltage is getting through the swivel to the MOTOR Power the system off Disconnect the power end connection at the motor Power the system on and make sure the RUN light is o
4. Commercial Cleaner Troubleshooting Guide 2012 Hayward Industries Inc TABLE OF CONTENTS KingShark 2 and KingShark 2 Plus Safety Precautions Page 1 Motor Removal Page 18 Service Tools Page 2 Pump Housing Gear Box Disassembly Page 19 Special Notes Pages 3 4 Solenoid Disassembly Page 20 Removal of Hood Pages 5 6 Bumper Cable Assembly Removal Page 21 Filter Removal Pages 7 8 Cable Assembly Components Page 22 Power Cord Removal Page 9 Control Panel Components Pages 23 25 Swivel Removal Page 10 Control Panel Troubleshooting Pages 26 28 Accessing the Impeller Page 11 Control Panel Timer Relay PCB Testing Pages 29 31 Drive Belt Removal Page 12 Swivel Voltage Testing Page 32 Intake Removal Page 13 Motor Power Cord Voltage Testing Pages 33 35 Drive Wheel Pages 14 17 KingShark 2 KingShark 2 Plus Tips Page 36 Serial number locator Page 37 38 Mako Shark 2 and KingShark Troubleshooting begins on Page 39 HAYWARD HAYWARD Warning Risk of Injury Failure to follow the safety warnings below may result in severe injury death or property damage Always place the machine in the water before connecting it to the electrical supply Always connect the power supply to an approved GFCI ground fault circuit interrupter Do not handle machine while it is plugged into the electrical supply Do not use an extension cord Immediately remove the cleaner from the water after cleaning Never allow swimmers in t
5. First two numbers of a serial number LETTER ae Februar a B ebruary October 30 MAKOSHARK2 D April M December 50 KINGSHARK E Ma 70 KINGSHARK2 A 90 KINGSHARK2 PLUS G July a pe DE A bottom side of Gear Box Assembly Serial Number Locations after March 2010 Currently we are using the 17 digit serial number 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 HAYWARD Page 38 HAYWARD Mako 2 amp King Shark Troubleshooting TABLE OF CONTENTS Filter Removal Handle Removal Filter Housing Removal Hood Removal Cord Assembly Removal Drive Belt Removal Gearbox Assembly Removal Impeller and Motor Removal Pump Housing and Base Disassembly Troubleshooting Page 40 Page 41 Page 42 Page 43 Page 44 Page 45 Page 46 Pages 47 48 Pages 49 52 Pages 53 54 Page 39 Filter Removal Step 1 Remove both clips from the rear Step 2 Remove the back cover from the of the unit filter housing Step 3 Remove filter elements Handle Removal HAYWARD Page 41 Filter Housing Removal Step 1 Slide Ring Adapter off the housing and remove the two screws to remove the ring adapter from cord Hood Removal Step 1 Remove the bolt from the handle Step 2 Remove the handle riser riser using 7 1
6. Step 8 1 Using a flat tip screwdriver and 3 8 wrench remove 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 silicone rubber sealant and replace the o ring HI LH AY A Wy iA p b Page 9 Swivel Removal Step 9 EL Using a 7 16 socket remove the two 1 4 Remove the four screws connecting the power 20 X 1 1 4 hex head bolts from the swivel cord to the motor end mounting bracket Note Make sure to use RTV 162 Silicone Rubber Sealant when reconnecting the power cord and replace the o ring aaa iba ad ate 0 K k eee Pe x HAYWARD Page 10 Step 10 1 Use a 7 16 socket to remove the two plastic bolts and impeller access plate from the pump housing 2 After removing the impeller access plate this will allow you to inspect the impeller and check for debris or damage inside the impeller area 2 Page 11 aN A LAN J GED al ae FOR PR NU FF A p L f 4 a mm a d 7 fr Yn rn N CD JIVE DEIL MelrrOoVa VU Lg ZIL ENZ IIIJ V UA lt Step 11 1 Remove right side drive belt 2 Remove left side drive belt Note When putting the drive belts back on put the LEFT side on first then the RIGHT side This will prevent possible torque damage where
7. 115 VAC to the 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 cord to a dedicated 10 15 amp breaker The master control panel draws roughly 3 amps 06414 CHINA Jumper configured for 240 VAC ONLY move the E9 connection Page 4 Step 1 Step 2 Remove the two 1 4 20 X 3 4 SS bolts from both Pull the cartridge handle quick release sides of the cleaner using a 7 16 socket UP and then pull the cartridge assembly back and away from the cleaner Note 1 bolt and 2 plastic washers per side Removal of Hood Step 3 Step 4 Unscrew the filter retainer knob using a slide the hood cover over the swivel assembly 5 32 Allen Wrench j j ET ETE oa H I IS rm L F n F at Ej ao Ft th CELL ew E i a E pa B ht E E 2 oe Filter Removal ae a Step 5 Step 6 Pull up on the yellow quick release handle assembly Pull and slide the filter assembly backwards and away from the cleaner HAYWARD Page 7 Filter Removal nn SS Step 7 Lift the housing assembly off the tie rods Lift the cartridges up and off the back plate back plate Remove the push style clips To clean the filters spray with clean water Back Plate Power Cord Removal
8. 6 socket 4 Hl f a 2 ag Step 3 Remove the hat riser Step 4 Lift the body off Page 43 Step 1 Remove the bolt from the pump Step 2 Remove the 4 screws housing using a 7 16 socket from the motor Note When replacing the cord assembly clean surface thoroughly and use new o ring and RIV 162 White Silicone for a water tight seal Page 44 Drive Belt Removal a Step 1 Looking at the cleaner from the rear remove the RIGHT drive belt from the rear wheel and then the front wheel Step 2 Remove the LEFT belt HAYWARD Gear Box Assembly Removal Step 1 Remove the five bolts from the rear of the gear box assembly using a 7 16 socket Step 2 Pull the gear box away from the pump housing HAYWARD Page 46 Impeller and Motor Removal es Step 1 Pull the impeller from the Step 2 Pull the impeller drive collar impeller drive collar from the motor shaft HAYWARD Page 47 Impeller and Motor Removal Step 3 Remove the 3 motor screws Step 4 Slide the motor away from the pump housing Page 48 Pump Housing and 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 the base Page 49 Pump Housing and Base Disassembly Step 4 Remove the snap ring fr
9. ad HAYWARD Page 27 Step 22 To verify 115 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 meter lead into the black port and the other lead into the white or green port 115 VAC or should be present 115 VAC 24 VDC Master Control Panel ES a RS ee Step 23 Timer PCB Testing On RELAY PCB at REMOTE J4 Using 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 should read 0 VDC Do the same test procedure on the push LEFT TURN button on the remote voltmeter should read 0 VDC LEFT ee RIGHT nev D ON OFF Gy Aquavacsystems com Z Copyright c 2006 HAYWARD Page 29 Step 24 RELAY PCB Testing On RELAY PCB at J3 BAGH F Yellow wire is the common wire to both solenoids Blue wire is the LEFT Turn solenoid Brown wire is the RIGHT Turn solenoid Using DC Voltmeter check voltage between the yellow wire and the 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 the RIGHT TURN button on the remote
10. gage 3 Sensor Bar Cable screws are loose 4 Sensor Bar Cable is broken 5 Drive Wheel is broken Check Sensor Bar regularly and keep the sensor bar level at all times Loss of vacuuming action 1 Filter may be clogged slowing the flow of water 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 outlet Check Fuses and breakers Verify power switch is on 2 Object lodged in the impeller 3 Unit runs for a short distance and stops Check for over load of the electrical circuit or faulty motor DO NOT USE EXTENSION CORDS 4 Motor runs but machine becomes or is motionless Gear box could be worn or drive pin could be sheared Machine tips over 1 Filters are dirty 2 Sensor Bar set too high 3 Tipping in certain situation can be prevented by purchasing a float and installing per instructions Disconnecting and removing the unit from the pool immediately after each use will enhance the life of the cleaner 4 hours operation ina 50 x 100 pool should be sufficient with not more than a few twists in the cord which should be straightened out after each use HAYWARD Page 36 Q E D Serial numbers for the Commercial Units can be found in the three locations indicated below
11. ge 23 Master Control Panel Timer Board Back Side of Front Panel 4 gt pee p gt m UJ Display ribbon cable y Power On Off Switch Fuse Power Indicator Light Auto Turn On Off HAYWARD Switch Page 24 Master Control Panel Step 20 Power cord MUST be plugged If you supply power to the master control panel and you into a grounded electrical have no display this is NORMAL outlet equipped with a Ground Fault Circuit Interrupter Unless you have the Cannon Plug power cord from the GFCI swivel connected to the 2 center ports the display will be blank This will prevent any shocking hazards that may occur with the power connection at the master control panel Master Control Panel ee Step 21 Make sure power is ON Put one meter lead on L1 connection and one lead on L2 115 VAC should be present 2 Put meter lead on the on off switch and one lead to ground 115 VAC should be present 1 24 o Potter amp Brumfield r9ASTOUTZ A 24VDI FORM POWER AUTO TURN ON OFF ON OFF EN WARNING Lo RISK OF ELECTRIC SHOCK CONTROL BOX PLUG MUST BE PLUGGED INTO G F C I RECEPTACLE HAYWARD Master Control Panel Correct power to Master Control Panel and NO display Check for a blown fuse Twist the fuse left and pull out for access Slo Blo 1 amp 250VP Do a continuity check on the fuse to verify if fuse is good or b
12. he pool while the cleaner is operating Never allow plug or power supply unit to enter pool Keep the power supply unit a safe distance from the pool edge and water e Keep the power supply unit dry and away from rain or other water spray Disconnecting and removing the unit from 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 straightened out after each use Page 1 Wrench 5 32 1 4 Allen Wrench Snap Ring Pliers Flat Tip and Phillips 3 8 Ratchet 3 8 7 16 1 2 Screwdriver 7 Socket 3 8 Socket 1 4 Socket Needle Nose Pliers Extension Driver Small Flat Tip 9 Screwdriver Page 2 Special Notes When disassembling the KingShark 2 and the KingShark 2 Plus the ONLY DIFFERENCES between the two cleaners are as follows KingShark 2 KingShark 2 Plus 1 Standard 3 prong electrical cord 1 Different pigtail connections 2 RCX400388 3 4 h p w o swivel 2 KingShark 2 Plus has a remote 3 RCX4011 3 4 h p w swivel 3 KingShark 2 Plus has a cannon plug for the control panel 4 KingShark 2 Plus has solenoids which control left and right movement from the remote 5 RCX4020 3 4 h p The remote has a maximum communication line to the antenna of 150 HAYWARD Page 3 When supplying 230 VAC instead of
13. n the display Put meter leads on the white and black ports you should get 115 VAC ROM Old motor New motor Power end connection Page 33 Step 28 Ohm meter 0 9 ohms 1 3 ohms for 115 VAC 4 3 ohms 6 3 ohms for 240 VAC WARNING DISCONNECT PLUG FROM POWER SOURCE BEFORE REMOVING THIS PLUG Page 34 Cord Inspection Step 29 Undo the power connection at the swivel Remember to replace the o ring and to use RTV 162 silicone rubber sealant when reconnecting the swivel connector end 1 Make sure the cannon plug is connected Power the unit on Press the start button until is displayed 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 present 2 OHAYWARD CONNEC Page 35 KingShark 2 KingShark 2 Plus Tips Sensor Bar adjustments and other minor repairs Make all adjustments in 14 increments A Raise Sensor Bar if machine 1 Fails to climb out of deep end 2 Turns or hesitates on pool drain 3 Turns away from curved wall too soon B Lower Sensor Bar if 1 Tips over before tripping 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 possibly hitting the hood 2 Thread on reversing arm is worn or stripped not allowing reversing mechanism to disen
14. om the front wheel 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 turned over to use the other side This will extend the life of the part Page 50 Pump Housing and Base Disassembly Step 7 Remove the 2 flat head screws from the sensor bar This will allow removal of the sensor bar from the base HAYWARD Page 51 Pump Housing and Base Disassembly oo ES Step 9 Remove the two bolts from the reversing arms using a 5 16 socket Washer locations HAYWARD Page 52 Troubleshooting Sensor Bar adjustments and other minor repairs make all adjustments in 1 4 increments A Raise Sensor Bar if machine 1 Fails to climb out of the deep end 2 Turns or hesitates on pool drain 3 Turns away from curved wall too soon B Lower Sensor Bar if 1 Tips over before tripping 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 on reversing arm RC1 703 is worn or stripped not allowing reversing mechanism to disengage 3 Sensor Bar cable screws are loose 4 Sensor Bar cable is broken 5 Drive wheel is broken D Remember this basic rule Check Sensor Bar regularly and kee
15. p the Sensor Bar level at ALL times Troubleshooting Loss of vacuuming action A Filter may be clogged slowing the flow of water through the unit Clean the filters B Suction area may be obstructed by large object No apparent power A lf the machine does not move Verify power at the electrical outlet Object lodged in impeller Ashort in the motor check the ground fault interrupter Unit runs for a short distance and stops Check for overload of the electrical circuit or faulty motor DO NOT use extension cords 5 Motor runs but machine becomes or is motionless Gear box could be worn or drive pin could be sheared RS D Machine tips over A Filter loaded with sand or debris B Sensor Bar is set too high
16. the gear box assembly meets the front housing bell since the larger support bracket is on the left side of the gearbox assembly Intake Removal Step 12 1 Unscrew the 4 screws holding the intake to the base plate also remove the SS wire baffle 2 Remove the intake stabilizer from the intake The stabilizer prevents large debris from entering the cleaner l 7 2 oo CORRE p eee ae to NOTE When removing and reinstalling the Intake be aware of the 2 plastic washers that seat between the Intake and the base plate HAYWARD Page 13 Step 13 1 Using the snap ring pliers remove the snap ring from the front wheels and the rear drive wheels 2 After removing the snap rings from the wheels pull the front wheels from the base plate and remove the drive wheels from the gear box assembly 1 Front Wheels 2 Drive Wheels side of the gear arm Note There is one 1 8 SS Key on each rear drive wheel It is important the key is installed into the wheel prior to inserting the shaft Drive Wheel Disassembly Step 14 1 Use the snap ring pliers to remove the 4 E Clips from the L amp 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 2 indicator screws the letter L or R will be molded into the wheel
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