Hayward KingShark 2 Troubleshooting Manual
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Hayward KingShark 2 Troubleshooting Manual

Commercial cleaner
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Commercial Cleaner
Troubleshooting Guide
© 2012 Hayward Industries Inc.

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Summary of Contents for Hayward KingShark 2

  • Page 1 Commercial Cleaner Troubleshooting Guide © 2012 Hayward Industries Inc.

  • Page 2: Table Of Contents

    Drive Belt Removal Page 12 Motor / Power Cord Voltage Testing Pages 33-35 Intake Removal Page 13 KingShark 2 / KingShark 2 Plus Tips Page 36 Drive Wheel Pages 14-17 Serial number locator Page 37-38 Mako Shark 2 and KingShark Troubleshooting...

  • Page 3: Safety Precautions

    Safety 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...

  • Page 4: Service Tools

    Service Tools 3/8“, 5/16“, 7/16“, 1/2" Wrench 5/32“, 1/4“ Allen Wrench 3/8“, 7/16“, 1/2“ 3/8“ Ratchet Snap Ring Pliers Flat Tip and Phillips Socket Screwdriver 3/8“ Socket 1/4“ Socket Needle Nose Pliers Small Flat Tip Extension Driver Screwdriver Page 2...

  • Page 5: Special Notes Pages

    Special Notes When disassembling the KingShark 2 and the KingShark 2 Plus, 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.
  • Page 6 230 VAC Supply to Master Control Panel When supplying 230 VAC instead of 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.

  • Page 7: Removal Of Hood Pages

    Removal of Hood 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.
  • Page 8 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. Page 6...

  • Page 9: Filter Removal Pages

    Filter Removal Step 6: Step 5: Pull and slide the filter assembly backwards and Pull up on the yellow quick release handle assembly. away from the cleaner. Page 7...
  • Page 10 Filter Removal Step 7: Lift the housing assembly off the tie rods Lift the cartridges up and off the Remove the push style clips / back plate. back plate. To clean the filters, spray with clean water. Back Plate Note : Never remove or adjust the 4 nuts Page 8...

  • Page 11: Power Cord Removal

    Power Cord Removal 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.

  • Page 12: Swivel Removal

    Swivel Removal Step 9: ” socket, remove the two 1/4" – Using a 7/16 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.

  • Page 13: Accessing The Impeller

    Accessing the Impeller 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.

  • Page 14: Drive Belt Removal

    Drive Belt Removal 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 the gear box assembly meets the front housing bell, since the larger support bracket is on the left side of the gearbox assembly.

  • Page 15: Intake Removal

    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. NOTE : When removing and reinstalling the Intake, be aware of the 2 plastic washers that seat between the Intake and the base plate.

  • Page 16: Drive Wheel Pages

    Drive Wheel Disassembly 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.
  • Page 17 Drive Wheel Disassembly Step 14: 1. Use the snap ring pliers to remove the 4 E-Clips from the L & R drive wheels. Remove the 4 plastic washers / spacers. from the drive wheels – Each set of screws indicate LEFT 2.
  • Page 18 Drive Wheel Disassembly Step 15: 3. Remove the Sun Gear 1. Remove the 4 Button Washers 2. Remove the Gear Ring 4. Remove the 4 Planetary Gears 5. Remove the Wheel Lock Page 16...
  • Page 19 Drive Wheel Reassembly 1. When reinstalling the drive wheels, make sure the Wheel Locks 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. Page 17 LEFT DRIVE WHEEL RIGHT DRIVE WHEEL...
  • Page 20 Motor Separation 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.

  • Page 21: Pump Housing / Gear Box Disassembly

    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. Gear Box Assembly Pump Housing Page 19...

  • Page 22: Solenoid Disassembly

    Solenoid Disassembly 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) .

  • Page 23: Bumper / Cable Assembly Removal

    Bumper / Cable Assembly Removal Step 19: 1. Remove the two 3/8” nuts (top), four flathead screws (center), and two pins (bottom). bar. 2. Slide the bumper from the arm sensor Note: Both the reversing arms and cable assembly can be turned over and be reused Page 21...

  • Page 24: Cable Assembly Components

    Instructions for Reinstalling the Cable Assembly Cable assembly’s do not come pre-tensioned from the manufacturer Back to front view - TOP 1. Tension cables / cable assembly are adjustable. 2 plastic spacers Once the cable assembly is reinstalled, push in 1 plastic spacer on the sensor bar.
  • Page 25 Master Control Panel Relay Board / Receiver Board 24 VDC relays Antenna Transformer Receiver Board AC to DC rectifier 24 VDC relays Relay Board Power out to cleaner Incoming power supply Page 23...
  • Page 26 Master Control Panel Timer Board (Back Side of Front Panel) Display ribbon cable Note: Ribbon cable disconnects at the Timer Board Fuse Powe On / Off Switch Power Indicator Light Auto Turn On / Off Switch Page 24...
  • Page 27 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 Unless you have the Cannon Plug power cord from the Ground Fault Circuit Interrupter swivel connected to the 2 center ports, the display will be...
  • Page 28 Master Control Panel Step 21: Correct power to Master Control Panel but NO display Make sure power is ON. Put one meter lead on L1 connection and one lead on L2, 115 VAC should be present. Put meter lead on the on/off switch and one lead to ground, 115 VAC should be present. NOTE: Check voltage on LEFT connection of switch Page 26...
  • Page 29 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 bad Page 27...
  • Page 30 Master Control Panel Cannon Plug 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 “RUN“ until is on the display. Then, stick one meter lead into the black port and the other lead into the white or green port.
  • Page 31 Master Control Panel Step 23: Timer PCB Testing On RELAY PCB at REMOTE J4 - 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 should read 0 VDC –...
  • Page 32 Master Control Panel Step 24: RELAY PCB Testing On RELAY PCB at J3 (B A G H 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.
  • Page 33 Master Control Panel 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.
  • Page 34 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 swive Power the system ON and make sure the light is illuminated.
  • Page 35 Voltage Check to Motor Step 27: To 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 light is on the display 4.
  • 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 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.

  • Page 38: Kingshark 2 / Kingshark 2 Plus Tips

    KingShark 2 / KingShark 2 Plus Tips Sensor Bar adjustments and other minor repairs (Make all adjustments in ¼" increments) A. Raise Sensor Bar if machine: 1. Fails to climb out of deep end. 2. Turns or hesitates on pool drain.
  • Page 39 Serial Number Locations – March 2010 & prior Serial numbers for the Commercial Units can be found in the three locations indicated below A=January J=September First two numbers of a serial number: LETTER: B=February K=October 10 = MAKOSHARK C=March L=November 30 = MAKOSHARK2 M=December D=April...
  • Page 40 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...
  • Page 41 Mako 2 & King Shark Troubleshooting TABLE OF CONTENTS Filter Removal Page 40 Handle 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 Pump Housing and Base Disassembly...
  • Page 42 Filter Removal Step 1: Remove both clips from the rear Step 2: Remove the back cover from the of the unit. filter housing. Note: Elements can be cleaned by gently spraying with a garden hose. Be careful not to use high Step 3: Remove filter elements.
  • 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 Filter Housing Removal Slide Ring Adapter off the housing and remove the two screws to remove the ring Step 1: adapter from cord. Step 2: Lift the filter housing from the cleaner. Page 42...
  • Page 45 Hood Removal Step 1: Remove the bolt from the handle Step 2: Remove the handle riser. riser using 7/16” socket. Step 3: Remove the hat riser. Step 4: Lift the body off. Page 43...
  • Page 46 Cord Assembly Removal Step 1: Remove the bolt from the pump Remove the 4 screws Step 2: housing using a 7/16" socket. from the motor. Step 3: 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 Silicone for a water tight seal.
  • Page 47 Drive Belt Removal 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. Note: Look at the cleaner from the rear and note that the gear box has a Support on the left side of the unit.
  • Page 48 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. Gear Box Page 46...
  • Page 49 Impeller and Motor Removal Step 1: Pull the impeller from the Pull the impeller drive collar Step 2: impeller drive collar. from the motor shaft. 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. Page 48...
  • Page 51 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...
  • Page 52 Pump Housing and Base Disassembly Step 4: Remove the snap ring from 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.
  • Page 53 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. Step 8: Pull the 2 cotter pins at the opposite end of the cables. Page 51...
  • Page 54 Pump Housing and Base Disassembly Remove the two bolts from the reversing arms using a 5/16” socket. Step 9: Note: There are washers located on either side of the Washer locations reversing arm to allow smooth movement. Note: The steps to disassemble & reassemble the drive wheels are identical to those of the KingShark II and KingShark II Plus.

  • Page 55: Troubleshooting

    Troubleshooting Sensor Bar adjustments and other minor repairs (make all adjustments in ¼” 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.
  • Page 56 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. If the machine does not move: 1.

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