Robotic Cleaner Troubleshooting Guide
Contents
1. No movement but impeller turns Drive motor pin or drive motor is broken possible due to overload during use To avoid repeat failure follow up with the customer for obstructions in the pool such as a ladder The Scanner will display a Drive Over Current signal if the machine has been caught on an obstruction Check for belt or roller obstruction e Check for broken impeller Check for missing roller tube bearing screws 2 per side gt No movement and no pump discharge Check with the scanner for communication failure see scanner section to diagnose e Check for impeller obstruction Check for broken blades Check electrical source for proper voltage range of 115 125v including extension cord if used Troubleshooting gt Debris falls from unit when removed from pool e Filter overload increase frequency of filter cleaning Large debris blocking intake Remove large debris from pool before using machine Drain flaps out of place on bottom lid Snap flaps back into place Avoid dropping or throwing machine into the pool C HAYWARD Page 43 Service Tools NE x M Power Driver not supplied Pin Removal Torx Drivers Tool T 10 amp T 25 not supplied Torx Bit T 20 not supplied Spanner Tool Belt Installation Tool Torque Driver HAYWARD Page 44 Power Supply On Off Switch Lighted Installati2. Pump Overcurrent 0 Times arr Pump Over Current Causes 1 Debris around the pump impeller Remove impeller and inspect for hair or grass around pump shaft 2 Defective pump motor Motor should turn smoothly by hand with only a slight resistance from the shaft seals Number of times the pump motor has realized an over load condition Unit will stop after 3 5 seconds in this condition DHAYWARD Page 33 Using The Scanner Tool Drive Over Current Causes Drive Overcurrent Unit caught under a ladder 0 Times 2 Debris caught in traction drive belt and or pulleys under side cover Riding or standing on unit during operation Defective wheel tube bearings or side cover idler bearings Defective drive motor ure o9 Number of times the drive motor has realized an over load condition Unit will stop after 3 5 seconds in this condition Number of times the water has contacted the sensor inside the motor box Continuous contact will stop operation of the unit Severe water damage will cause a Communication Failure when hooked to the scanner Water Detected 0 Times e HAYWARD Page 34 Testing Power Supply amp Flotation Cord _ Communication Failure Causes Damaged power supply check for 21 25 volts DC 2 Water inside power connection to motor box check seal at motor box and for breaks in flotation hose Damaged flotation cord check for ohms reading of 4 to 8 ohms Flotation cord test R
3. Troubleshooting z gt In Process Mapping As the unit encounters large changes in pool configuration it will revert to the mapping process for a few passes to adjust itself to the change in shape Mapping will take several passes and is undetectable from normal operation Navigation he unit navigates itself primarily by running in a diagonal direction at the water line This is the key to complete pool coverage Shutdown e The machine will shut down after 4 hours for the standard TigerShark TigerShark QC will shutdown after 90 minutes if the Quick Clean LED is illuminated or after 4 hours if Full Cycle is selected The power supply will continue to supply low voltage to the unit and the diagnostic memory will continue to record hours until the power switch is turned off Troubleshooting gt Will not climb walls Filter Too Dirty to Allow Proper Machine Performance Pool condition is unacceptable for cleaner use Sweep walls vacuum pool balance chemicals and algaecide to an acceptable swimming condition Resume use of TigerShark for pool maintenance as often as required Increase frequency of TigerShark filter cleaning especially during the initial use Filter may have to be cleaned 30 minutes to 3 hours in the first few cycles until the pool is in an acceptable condition Algae on pool walls Brush walls and chemically treat for algae Increase frequency of Tig
4. Note drive key in pulley and how it mates to the output shaft drive pin of the motor Main drive pulley motor output side only e HAYWARD Page 14 Carefully pull wheel tube Both drive tubes removed away from other side plate Roller will slide off track C HAYWARD Page 15 Removal Drive Track amp Idler Pulley Non drive Side Track idler pulleys 3 Note this side does not have a keyed drive pulley at the center pulley since it is opposite the motor drive end This pulley is simply an idler pulley similar to the ones to the left and right E y ocrew removal opposite side cover non drive side Side cover removed e HAYWARD Page 16 MUN 209040 pervo ntun jo pho uon edo NAIL iy Ld EL qom jaa ponas VO Fa PSO Pesta Eee o0 MM Nr iE uri NOUNALIY A Remove strain relief Plate removed showing cover plate strain relief system LA in AA u amp a Page 17 CO MEN o 95 Z2 o Amutu 3 9 8 1 n jo Dum eO Pe Dry we QUEM UA AI AU 6 Lg JOG T E CET uM ECT ma aa aa sp OPEC ERE Up 2098 JO INO UO eC m ale PE ERES Use spanner wrench and Threaded plug removed Torque driver to remove threaded plug securing power cord into motor assembly CCW removal Cas ERE PPPs ERG Page 18 Gently pull on cord to disconnect and remove from motor Note that plug has taper on bottom side to mate with rubber
5. aid of a pair of needle nose pliers Pull post slightly till taught then push down on tab until it locks into post Spraying the post with soap and water sparingly will aid in assembly Foam roller HAYWARD Page 30 Using The Scanner Tool Power switch on Initializing Please wait Startup Screen Scanner Setup Scanner male end Power cord to cleaner C HAYWARD Page 31 Scanner Tool Using The icc Motor ON Time 4 Haire Power ON Time 12 Hours The combined total number of hours the unit has spent with the power switch on Includes both hours accumulated in Motor On Time and hours inactive after the cleaning cycle has been completed Number of hours the unit has spent in the 4 hour cleaning cycle mode Total Cycles Run The total number of times the power switch 28 Cycles was turned on to run the unit This will not necessarily represent the complete cleaning cycles run Page 32 Using The Scanner Tool Out of Water Causes Out of Water 1 Attempting to run the unit out of the water pool 0 Times 2 Air trapped in the filter after placing the unit in the water 3 Bench testing in manufacture or repair 4 Machine climbing too high above the waterline 5 Low voltage at power source 6 Low voltage from use of an extension cord 7 Worn or defective pump motor drawing less than 1 amp at 24 volts The number of times the unit has realized a low load on the pump motor
6. Robotic Cleaner Troubleshooting Guide es Table of Contents s 3 a cm p punu C TigerShark amp TigerShark QC Important safety instructions Page 1 Service Tools Page 2 Filter Removal Cleaning and Drain Flaps Pages 4 6 Handle Removal Page Venturi Removal Page 8 Bottom Lid Disassembly Pages 9 10 Side Cover Removal Pages 11 12 Drive Track and Idlers Pages 13 16 Power Cord and Motor Box Pages 17 27 Wheel Tube Brush and Bearings Pages 28 30 Using the Scanner Tool Pages 31 34 Power Supply and Flotation Cord Testing Page 35 Basic Operation Pages 36 3 Troubleshooting Pages 38 43 HAYWARD Table of Contents Continued SharkVAC amp E Vac Service Tools Page 44 Power Supply Page 45 Filter Removal Pages 46 47 Filter Replacement Page 48 Wheel and Tire Removal Page 49 Side Cover Removal Page 50 Drive Track and Idlers Page 51 Main Drive Pulley Removal Page 52 Wheel Tube Removal Page 53 Wheel Tube Brush Page 54 Power Cord Removal Pages 55 60 Motor Box Removal Pages 61 62 Power Supply and Flotation Cord Testing Page 63 Troubleshooting Pages 64 68 Safety 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 around fault circuit interrupter Do not handle machine w
7. While holding connector firmly depress as possible Carefully insert pin removal tool button on pin removal tool to remove into power cord connector electrical connector pin from housing HAYWARD Page 57 Power cord electrical pins Connector seals and washers removed removed from connector Note that white wire goes on tab side of connector 7 RE ESRAFA ESES HAY WARD Page 58 Note the order of the seals and washers Remember to mate the taper of the seal and threaded plug Pd mr t Connector must be installed with tab on connector placed in mating hole of motor assembly The white wire must be inserted on the tab side of the connector Use the Torque driver and spanner wrench to install and tighten the threaded plug Tighten the threaded plug until you feel the Torque wrench click or slip Cas ERE PPPs ERG Page 59 Power Cord Removal B ms Gently route power Power cord removed cord out from unit HAYWARD Page 60 When removing motor assembly without complete removal of side cover gently separate motor output shaft from keyed drive gear using a Screwdriver The drive gear will remain in place Be sure to remove all 4 motor securing screws rarer WV Page 61 m EE n Rotate motor slightly to remove drive output shaft from side of unit then lift out motor assembly Output shaft key on motor mates with drive gear Note The
8. aning heads toys etc o HAYWARD Page 66 Troubleshooting gt No movement but impeller turns Drive motor pin or drive motor is broken possible due to overload during use To avoid repeat failure follow up with the customer for obstructions in the pool such as a ladder e Check for belt or roller obstruction e Check for broken impeller Check for missing roller tube bearing screws 2 per side gt No movement and no pump discharge e Check for impeller obstruction e Check for broken blades Check electrical source for proper voltage range of 115 125v including extension cord if used HAYWARD Page 67 Troubleshooting e gt Debris falls from unit when removed from pool e Filter overload increase frequency of filter cleaning e Large debris blocking intake Remove large debris from pool before using machine Drain flaps out of place on bottom lid Snap flaps back into place Avoid dropping or throwing machine into the pool C HAYWARD Page 68
9. emove cord from motor box and check ohm s reading between each pin and wire end 4 to 8 ohm s is acceptable ET Circuit failure between power supply and and the PCB printed circuit board in the motor assembly box DC voltage test on power supply 21 to 25 volts dc is acceptable The power supply is not repairable and must be replaced if defective Insert voltage probes in pin terminal 1 and 2 and turn on power supply to test Page 35 Troubleshooting SS 1 ji po gt Startup Machine will seguence between pump and drive motor for up to 1 minute During this time the microprocessor is sampling motors for proper electrical load gt Mapping Sequence e At about 2 minutes the machine will begin mapping the immediate section of the pool e Wall climbing will be every other floor pass and the time on the wall climb will be random The pattern is not permanently imbedded and will be reconfigured with each use of the cleaner gt Wall Climbing Once in the cleaning cycle the machine will typically perform a wall climb every other floor pass and vary the amount of time on the wall e At random the machine will perform a free fall from the wall to aid in random navigation The startup of each 4 hour cycle may require up to 30 minutes as the machine measures the pool configuration before climbing the walls completely to the water line C HAYWARD Page 36
10. erShark use and filter maintenance D E or sand filter leak The primary pool filter may leak diatomaceous earth or fine sand that can overload the filter Service and inspect the pool filter system vacuum the pool and resume use of the TigerShark for pool maintenance HAYWARD Page 38 Troubleshooting eS E p gt Will not climb walls Pool design or configuration e The pool bottom corner design may be too sharp Some pool designs feature a sharp 90 degree bottom corner A guideline for the best machine performance is a corner radius similar in contour to a basketball In a clean pool the machine symptom will be movement to the wall with repeated bumping and infrequent climbing The PVC rollers can be replaced with foam rollers only if a dirty pool condition is ruled out e Clean vinyl or tile pool surface is too slick Replace the PVC rollers with foam rollers only if a dirty pool condition is ruled out Machine problem e Broken impeller Inspect and replace it if required Inspect for tears that may allow objects to pass through and entangle or damage the impeller e Defective pump motor can be identified by a slow or non rotating impeller Replace the motor box assembly Troubleshooting caa WA z apm 3 ma l v a gt Will not climb walls Confusion on normal operation The startup of each 4 hour cycle may require up to 30 minutes as the
11. hile 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 the 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 Keep the power supply unit dry and away from rain or other water spray Page 1 Service Tools P EU J ro mm Pin Removal Tool Torque Driver FU Torx Bit opanner Tool Torx Driver Scanner C HAYWARD Page 2 Power Supply _ On Off Switch Lighted Quick Clean LED QC Models Only Power Cord Full Cycle Button and LED QC Models Only Flotation Power Cord Connector HAYWARD Page 3 1 IA 9 9 9 4 V 9 w em COUPTTUTTTUTTTTTTYTYYS o MlM 1 a s Bottom lid removed providing access to filter cartridge assembly Page 4 Filter Removal Note the drain flaps one per side Not required to remove for filter cleaning but visually inspect when filter is removed Filter cartridge removed Page 5 Filter Removal m m at t War we MONTE i T Ww m E aln Filter cartridge assembly Filter elements removed Note Elements can be cleaned by gently spraying with a garden hose Be careful not to use high pressure or this may damage the element Spring cleanup f
12. ilter elements For temporary use in heavy spring cleaning HAYWARD Page 6 o amp ig basas Handle removal Handle removed 1 screw each end Note Handle is watertight If water is heard sloshing around in handle it must be replaced HAYWARD Page 7 Rotate CCW amp lift out Removed access to impeller Page 8 Bottom Lid Disassembl Bottom lid assembly Pull up Inlet cover removed to remove inlet cover HAYWARD Bottom Lid Disassemb amm a Inlet flaps check for Inlet flaps removed free movement for inspection OHAYWARD Motor output shaft Motor assembly Power cord Power cord end Drive end Note Use Torx bit and power driver for removal ri Bottom view with bottom lid screws each end to remove and filter assembly removed for side plate removal drive side Power cord end 7 screws e HAYWARD Page 11 Side Cover Removal Screw removal Note that drive side or motor output side is side opposite of where power cord enters unit Side cover removed D HAYWARD Page 12 Drive Track amp Idler Pulley Removal Drive Side Drive track removed Check for missing broken drive cogs on inner loop of belt and also for cracks in belt Track idler pulley 2 side Bearings should rotate smoothly and freely Note that flange faces inward e HAYWARD Page 13 Main Drive Pulley Remova
13. machine measures the pool configuration before climbing the walls completely to the water line During the 4 hour cycle the machine will randomly re measure the pool configuration or release itself from the wall The machine will not climb the walls during this 15 30 minute cycle gt Climbs Too High Falls off Wall at Waterline Blows Air Bubbles Through the Exit Venturi Above average traction in a clean pool Install the Restrictor Plate Kit RCX11206 in the venturi Inspect bottom lid filter plate gasket and replace if torn or missing e Set handle position at an angle machine should never operate with the handle in the center or straight position e Check water chemical balance Troubleshooting uana X am n ii Runs only a few seconds or minutes Make sure the machine is submerged in the water An out of water detection within a few minutes will cause the machine to stop if not completely submerged e Check electrical source for proper voltage e f using an extension cord test for proper voltage An extension cord is not recommended e Check for missing or broken impeller blades e Check for pump impeller obstruction e Check pump impeller for hard rotation and pump motor binding gt Cord twisting e Alternate handle position with each use Be sure machine is not getting caught on obstructions in the pool such as raised drains in floor cleaning heads toys etc Troubleshooting a
14. motor assembly is a sealed unit and cannot be serviced only replaced It does not contain oil and is water cooled The impeller can be replaced Impeller removal CO HAYWARD Page 62 Testing Power Supply 4 Flotation Cord icc m Communication Failure Causes Damaged power supply check for 21 25 volts DC 2 Water inside power connection to motor box check seal at motor bor and for breaks in flotation hose 3 Damaged flotation cord check for ohms reading Flotation cord test Remove cord from motor box and check ohm s reading between each pin and wire end 4 to 8 ohm s is acceptable of 4 to 8 ohms Insert voltage probes in pin terminal 1 and 2 and turn on power supply to test DC voltage test on power supply 21 to 25 volts dc is acceptable The power supply is not repairable and must be replaced HAYWARD roo 7 j Page 63 mme Troubleshooting Startup e Machine will sequence between pump and drive motor for up to 1 minute During this time the microprocessor is sampling motors for proper electrical load Mapping Sequence e At about 2 minutes the machine will begin mapping the immediate section of the pool e The pattern is not permanently imbedded and will be reconfigured with each use of the cleaner gt In Process Mapping As the unit encounters large changes in pool configuration it will revert to the mapping process f
15. on and Care Instructions Power Cord Flotation Power Cord Connector Press Dome Button Lift to remove Filter Bucket to lift Dome for filter removal Housing Filter Bucket Housing Page 46 M YTS aw Open filter doors by pushing the tabs toward the outside and then pulling up Note Elements can be cleaned by gently spraying with a garden hose Be careful not to use high pressure or this may damage the element Spring cleanup filter elements For temporary use in heavy spring cleaning i 7 LJ AA r1 A y n rm m e ERN Y E JA PL Page 47 Filter Replacement Hold both cartridges toward center Push down cover and press tab towards fan to lock cartridges in place DW HAYWARD Make sure cover snaps in place Page 48 Remove wheel cap to access Screw Unscrew T25 screw holding wheel on axel EL AA de eee Remove wheel from axel Notice how wheel and axel mate Q HAYWARD Page 49 Power cord Motor assembly Impeller Motor output shaft Drive end Fu 4 T20 screws each side to remove for side plate removal Top view with bottom lid and filter assembly removed Drive side view with cover removed J m NEL UR HE E EB mi L UL E owe H ILWAMWELA FED ai NNGUSE T ME Wa m 4 ee 4M Ml ill TD eee Ct Check for missing broken drive cogs on inner loop of belt and also for cracks in belt Track idler pulleys Bearings should rotate smo
16. or a few passes to adjust itself to the change in shape Mapping will take several passes and is undetectable from normal operation o HAYWARD Page 64 Troubleshooting e i gt Navigation The unit navigates itself primarily by running in a diagonal direction at the water line This is the key to complete pool coverage Shutdown e The machine will shut down after 2 hours The power supply will continue to supply low voltage to the unit and the diagnostic memory will continue to record hours until the power switch is turned off Cleaner flips upside down and continues to run e The machine should correct itself and flip upright Check for water in handle Replace if necessary e Replace motor C HAYWARD Page 65 mme Troubleshooting 2 m Runs only a few seconds or minutes Make sure the machine is submerged in the water An out of water detection within a few minutes will cause the machine to stop if not completely submerged e Check electrical source for proper voltage e f using an extension cord test for proper voltage An extension cord is not recommended e Check for missing or broken impeller blades e Check for pump impeller obstruction e Check pump impeller for hard rotation and pump motor binding Cord twisting Be sure machine is not getting caught on obstructions in the pool such as raised drains in floor cle
17. othly and freely Note that flange faces inward COHAYW AED HAYWARD Page 51 Note drive key in pulley and how it mates to the output shaft drive pin of the motor Main drive pulley motor output side only oO HAYWARD Page 52 Carefully pull wheel tube away from wheel axels I mE NE a E EM NES GENES NS Eu H if i ara Bras E i age 53 Wheel Tube Brus Removal Brush replacement can be done leaving the machine assembled or otart in the center of the brush and put broken down Unsnap the tabs that run the post through the hole in the tab length wise of the brush with the aid of a pair of needle nose pliers Pull post slightly till taught then push down on tab until it locks into post Spraying the post with soap and water sparingly will aid in assembly C HAYWARD Page 54 poerpouineun 7 jo n6 VOTE SESEL IT 1 pu de a Par ada T WA NOU NJI iv F Use spanner wrench and Torque driver to remove threaded plug nr u E BH NH ETATE OE r J H p kh ATIF i LJ W LL aa Pee eF Page 55 Gently pull on cord to disconnect and remove from motor Note that plug has taper on bottom side to mate with rubber seal taper Note Any time seal is removed it is recommended to replace special rubber seal Cas ERE PPPs ERG Page 56 Power Cord Removal Push wires up into connector as far
18. seal taper Note Any time seal is removed it is recommended to replace special rubber seal WHA Rio AA Page 19 b Carefully insert pin removal tool into power cord connector Push wires up into connector as far as possible Power Cord amp Motor Box Removal While holding connector firmly depress button on pin removal tool to remove electrical connector pin from housing Page 20 Power Cord amp Motor Box Removal Power cord electrical pins Connector seals and removed from connector Note that white washers removed wire goes on tab side of connector e HAYWARD Page 21 Connector must be installed with tab on Note the order of the seals and washers connector placed in mating hole of motor Remember to mate the taper of the seal assembly The white wire must be inserted and threaded plug on the tab side of the connector Use the Torque driver and spanner wrench to install and tighten the threaded plug Tighten the threaded plug until you feel the Torque wrench click or slip B m E uL EL a UH ER LW ALLE FR oo i N LZ EB EIRE PP EE Page 22 Power Cord amp Motor Box Removal Gently route power Power cord removed cord out from unit HAYWARD Page 23 Power Cord amp Motor Box Removal Location of motor screws when side cover is not removed It is possible to remove motor assembly without removal of side cover However the 7 side cover screws mus
19. t be loosened on the motor drive side Remove 4 motor assembly screws 2 from each end QHAYWARD Page 24 Power Cord amp gently separate motor output shaft from keyed drive gear using a screwdriver The drive gear will remain in place Be sure to remove all 4 motor securing screws 2 each side and loosen side cover screws before attempting this MWAWWARTY HAYWARD Page 25 Power Cord amp Motor Box Removal EE GL Rotate motor slightly to remove drive output shaft from side of unit then lift out motor assembly r LE n A 1i i dir Jy H AL IAYWAHRL Page 26 Power Cord amp Motor Box Removal Output shaft key on motor mates with drive gear Motor assembly removed Note The motor assembly is a sealed unit and cannot be serviced only replaced It does not contain oil and is water cooled The impeller can be replaced Impeller removal e HAYWARD Page 27 Remove wheel tube from machine Remove 2 small phillips screws securing roller bearing to tube Bearings should rotate smoothly and freely Bearing assembly will slip off tube D HAYWARD Page 28 Wheel Tube Brush Brush replacement can be done leaving the machine assembled or broken down Unsnap the tabs these run length wise of the brush C HAYWARD Page 29 Wheel Tube Brush Start in the center of the brush and put the post through the hole in the tab with the
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