Merging Kit

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Tools Needed:

• Phillips screwdriver

• Needle nose pliers

• Small flathead screwdriver

Disassembly

1. Remove and discard the all-purpose bag,

head float, top cover(s), feed pipe/timer

blank assembly and sweep hose assembly.

2. Remove the four screws that secure the

frame to the base. Lift the frame off the base

at a 45-deg

ree angle, pull back and lift off.

Discard the base

. The rebuild kit contains a

pre-assembled base unit, so all items still

attached to the base can be discarded.

3. Familiarize yourself with the gears, bearings

and e-clips, and note their location on the

shafts before dismantling the frame (see

diagram below). Disengage the front and rear

belts by pushing the belt off the pulley while

turning the wheel.

4. Remove the hub caps, e-clips, wheels,

belts, axle blocks, transfer pulley/drive shaft

assembly, gears, bearings and turbine wheel.

These parts can be discarded.

5. If the frame has not already been notched,

file the fr

ame to provide proper clearance for

the feed pipe/timer blank assembly.

Assembly

1. Install the new axle blocks using lock washers

with screws. Tighten screws loosely to keep

them in place.

File Here

Frame

Lock

Washers

Axle Block

Assembly

Frame

Turbine Wheel

with Bearing

Bearing Shield

Bearing #1

(Shield side out)

Transfer Pulley/Drive

Shaft Assembly

Drive Gear

E-clip #2

Compound

Gear

E-clip #1

Notch for E-clip #1

Hub (Shortest)

Compound Gear Shaft

Bearing #2 (Shield side out)

E-clip #3

E-clip #4

Inner

Bearing

Axle Block

Bearing

Polaris 380 Factory Rebuild Kit

Summary of content (4 pages)

PAGE 1
Polaris 380 Factory Rebuild Kit Tools Needed: 5. If the frame has not already been notched, file the frame to provide proper clearance for the feed pipe/timer blank assembly. • Phillips screwdriver • Needle nose pliers • Small flathead screwdriver Frame Disassembly 1. Remove and discard the all-purpose bag, head float, top cover(s), feed pipe/timer blank assembly and sweep hose assembly. 2. Remove the four screws that secure the frame to the base.
PAGE 2
. Install bearings, shield side out. Insert compound gear shaft with inner bearing. Install new compound gear. Note: Gear may seem tight. 3. Once gear is installed attach e-clip. Push the compound gear shaft through, secure it to the other side with another e-clip. E-clips should snap into place. 12. Install feed pipe and o-ring. Reinstall the three feed pipe screws. Vacuum Tube Latch Base Weight 4. Place the longest hub of the new drive gear into the new turbine wheel. 5.
PAGE 3
Back Plate Hub Caps Stainless Steel E-clips (3) MaxTrax ® Tires (2) Double Side Wheels (2) Top Assembly Upper Turbine Housing Bearings Bearings Bearing Shields Head Float Small and Large Belt Kit Serial Number Transfer Pulley/Drive Shaft Assembly MaxTrax Tire Feed Pipe/Timer Blank Assembly Bearing All-Purpose Bag and Collar Tie Hub Cap Single Side Wheel O-Ring Lower Turbine Housing Base Weight Thrust Jet e Sw ep Hose Barb In-line Back-up V alve Base Assembly e Sw ep Hose Assembly
PAGE 4
Polaris 380 Factory Rebuild Kit Limited Warranty This limited warranty is extended to the original consumer purchaser of this Polaris 380 Rebuild Kit manufactured by Polaris Pool Systems, Inc., 2620 Commerce Way, California 92081-8438, USA. Polaris warrants the parts in this kit to be free of defects in material and workmanship. We do not cover tires, bottom plates, belts, or bearings which have been worn out by use. These are normal replacement items.