2"
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
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
Discard the base
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.
ree angle, pull back and lift off.
. The rebuild kit contains a
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.
2. Install bearings, shield side out. Insert
1/4"
Deflection
Base
Weight
Rear Jet Retainer
Vacuum Tube
Latch
30" Section
Polaris
Add Float
Flow ArrowMender Nut
compound gear shaft with inner bear
ing.
Install new compound gear. Note: Gear
y seem tight.
ma
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.
4. Place the longest hub of the new drive gear
into the new turbine wheel.
5. Push the drive shaft through the new turbine
bearing, turbine wheel, drive gear and install
single-wheel side wheel with bearing. Secure
with e-clip.
6. Lay the frame on the single-wheel side and
place the drive belts over the axle block
shafts. Install the new bearing shields.
7. Install the new double-wheel side wheels with
bearings, e-clips and the hub caps. Engage
each belt by pushing the belt onto the pulley
while turning the wheel. The small belt should
be on the inside of the transfer pulley and the
large belt on the outside with the belt divider
separating them.
8. Place the frame on the double-wheel side.
Push the axle blocks toward the outside
edge of the Polaris until the belts have 1/4"
tension and tighten the axle block screws.
12. Install feed pipe and o-ring. Reinstall the
eed pipe screws.
three f
13. From the back, slide top in and over vacuum
tube. Align top and base and snap into place.
IMPORTANT: Top should be secured by
the vacuum tube latch.
14. Slide on back plate and reinstall screws to
secure the thrust jet. You may have to create
tension on the thrust jet to line up the holes.
15. Attach new head float. pushing it forward as
close to the Polaris as possible.
16. Attach the new bag.
17. Attach sweep hose using the new
attachment clamp.
Replacement of In-line Back-up Valve
1. Remove any existing in-line back-up valve.
The replacement Polaris in-line back-up
valve and float should be installed 30” from
the cleaner.
9. Remove two back screws from new preassembled new body. Lift off back plate.
Push in vacuum tube latch to remove top.
10. Place lower turbine housing into base. Place
w base w
ne
against the v
Slide fr
11.
of the 3/4” screws into frame. Place upper
turbine housing cover on, then screw in the
th and final 3/4”
our
f
eight on rear jet retainer flush
acuum tube
ame onto ne
.
w base
w.
scre
Reinstall three
.
2. Install the new float as shown below. It may
be helpful to tr
im the end of the hose at an
angle so the hose can be pulled through the
float with needle nose pliers. Once the float
is installed, tr
im the hose square.
3. Attach the back-up valve to the hose with the
flow arrow pointing toward the cleaner.
Push the ne
4.
alve as possible.
v
w float as close to the bac
k-up
Serial Number
Upper Turbine
Housing
Hub Cap
MaxTrax
Tires (2)
Back Plate
Lower Turbine
Housing
Feed Pipe/Timer
Blank Assembly
Double Side
Wheels (2)
Single
Side Wheel
Small and Large
Belt Kit
Base Weight
Tr a
nsfer
Pulley/Drive
Shaft Assembly
To p Assembly
Base Assembly
Bearing
Shields
MaxTrax
Tire
Thrust
Jet
O-Ring
®
Head Float
All-Purpose Bag
and Collar Tie
Hub Caps
Stainless
Steel E-clips (3)
Bearings
Bearings
Bearing
In-line Back-up V alve
Sweep Hose
Assembly
Sweep Hose Barb
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.
We do not cover damage caused by improper installation of the parts in the Rebuild Kit. If you have a question
regarding your Polaris 380 Rebuild Kit or your Polaris 380 Automatic Swimming Pool Cleaner, please feel free
to call or wr
frame of your unit, when you contact us.
of purchase.
improper handling, improper usage, improper storage, winter freezing, abuse, improper installation, unsuitable
application of the unit, improper maintenance, lack of reasonable and necessary maintenance, damage in
transit or during installation, or damage from repairs/alterations made or attempted by anyone other than
Polaris or one of its Authorized Service Centers. Polaris will repair or replace, at its option, a part proved to be
defective within the warranty period and under the conditions of the warranty.
freight prepaid to the nearest Polaris Authorized Service Center or return it freight prepaid (after proper
authorization) to the plant of manufacture. Authorization to return a unit or parts to the plant of manufacture
must be obtained from the Polaris Customer Service Department. Check with your dealer for the local
procedure before exercising this warranty. If further directions or instructions should be required, contact the
Customer Service Department at 1-800-822-7933 (USA and Canada only) or (760) 599-9600. Be sure you
insure your shipments against loss or damage in transit.
any other expenses incurred in shipping the unit or parts to or from the factory or its Authorized Service
Centers, or damages during the installation of the repaired or replacement unit. The consumer must bear
these expenses.
Polaris Authorized Service Center. This warranty does not cover pattern removal, abrasion or markings on a
vinyl liner.
INCLUDING
PURPOSE, AND ALL SUCH OTHER WARRANTIES ARE DISCLAIMED EXCEPT TO THE EXTENT ANY
IMPLIED WARRANTY MAY BE IMPOSED BY STATE CONSUMER LAW. ANY SUCH IMPLIED WARRANTY
IMPOSED BY STATE CONSUMER LAW IS LIMITED IN DURATION TO ONE (1) YEAR FROM DATE OF
PURCHASE.
D
AMA
ANY DAMAGE RESULTING FROM THE USE OF THE POLARIS 380 AUTOMATIC SWIMMING POOL
CLEANER WITH A SUBSTANDARD POOL CIRCULATION SYSTEM.
incidental or consequential damages, so the above limitations may not apply.
apply to Polaris 380 Factory Rebuild Kits sold or installed in any other country.
ite us. Please provide the serial number, which can be located under the handle on the rear of the
The Polaris 380 Factory Rebuild Kit is warranted for a period of one year from date of purchase with proof
This limited warranty does not apply if the failure is caused or contributed to by any of the following:
In order to make a claim under this warranty, the consumer must deliver or ship the unit or warranty parts
Polaris is not responsible for the cost of removal of the unit or parts, damages during or due to removal,
This warranty does not cover repair or replacement of a unit or part except at our plant of manufacture or
THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,
ARRANTIES OF MERCHANT
THE IMPLIED
IN NO EVENT SHALL POLARIS BE LIABLE FOR INCIDENT
GES OF ANY NATURE OR KIND OR FOR DAMAGES TO PERSONS OR PROPERTY, INCLUDING
Some states do not allo
This limited warranty is valid only in the United States of America, Canada and Australia, and it does not
W
w limitations on ho
w long an implied w
ABILITY AND FITNESS FOR A PARTICULAR
AL OR CONSEQ
arranty lasts, or the exclusion or limitation of
UENTIAL
©
olaris Pools Systems, Inc. All rights reserved. TL-864 5/05
2005 P
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