Hayward Navigator Pro Troubleshooting Manual
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Hayward Navigator Pro Troubleshooting Manual

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See also: Owner's Manual , Manual
Navigator Pro, Pool Vac XL
Navigator, Pool Vac Ultra Troubleshooting Guide
© 2010 Hayward Pool Products

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Summary of Contents for Hayward Navigator Pro

  • Page 1 Navigator Pro, Pool Vac XL Navigator, Pool Vac Ultra Troubleshooting Guide © 2010 Hayward Pool Products...
  • Page 2 Table of Contents Safety Precautions Page 1 Overview & Pre-Installation Check List Pages 2-5 Installation & Operation Tips Pages 6-10 Major Components Pages 11-14 Disassembly & Parts Replacement Pages 15-34 Troubleshooting Pages 35-47...

  • Page 3: Safety Precautions

    Safety Precautions • Use only the “In Line Flow Gauge” provided to check the system vacuum (or suction). • Never use your hand to verify the amount of vacuum at the skimmer or dedicated suction line. • Keep hands and fingers away from the access cover and any moving part while the cleaner is operating.

  • Page 4: Cleaner Overview

    Cleaner Overview This guide will cover the current Navigator Pro and new Pool Vac XL as well as the previous Navigator and Pool Vac Ultra. Each version has a model designed for Gunite or Vinyl applications. While the colors, shell shapes, names, specific areas of disassembly may be different, the majority of the major components of these cleaners are interchangeable.
  • Page 5 Cleaner Overview Contents of Unitized cleaner box Head Hoses Skimmer cone 9 connector Manual 1 leader Flow Gauge Regulator Page 3...
  • Page 6 Pre-Installation Checklist The majority of issues experienced with the cleaner are due to improper installation or expectations. The following pre-installation checklist will ensure correct performance. • Is the pump size adequate to supply enough suction to operate the cleaner (use the flow gauge)? •...
  • Page 7 Pre-Installation Checklist (Continued) • Remove all large objects from the pool that could interfere with the operation of the cleaner. • Treat and remove algae from the pool water and surfaces. • Check and balance the water chemistry. • Make sure the water level in the pool is correct. •...

  • Page 8: Installation

    Installation Starting with the leader hose, connect the four foot hose sections until they reach eight feet (two hose lengths) past the furthest point Note: Although 10 hoses section are provided, the installation may require more. Connect hoses as shown Leader hose is connected to the Cleaner head...
  • Page 9 Installation Fill the hose with water and eliminate all air that is trapped within the hose. This is done by submerging the entire hose. Connect the flow gauge to the leader hose and clip it to the first hose as shown (fig 1) With the pump off attach hose to the skimmer (fig 2) or “Vac Lock”...
  • Page 10 Installation Turn the pump on and check the flow to the unit by using the flow gauge (submerged). The flow must be between the “min” and “max” (fig 4). Figure 4 Note: A regulator valve (for skimmer) (fig 5) or a valve (dedicated line) (fig 6) may be needed to reduce suction.
  • Page 11 Installation Remove the flow gauge and store for future use. Check the rear flap adjuster at the left rear of the cleaner. It should be set to Position II (fig 7) Check to make sure all returns are pointed down. Returns pointed up can interfere with the hose.
  • Page 12 Operational Tips 1. Disconnect the cleaner from vacuum source during backwashing. 2. Never coil the hose when cleaner is removed from pool. Always store straight. 3. Never leave the leader hose attached to the head when it is out of the pool. 4.
  • Page 13 Major Components Navigator & Ultra (Old Style) Navigator Shell Ultra Shell Cone Gear Upper Middle Body Assy Gear Box Turbine Turbine bearings (2) Lower Middle Body Bumper Lower Body Assy. Page 11...

  • Page 14: Navigator Components

    Major Components Navigator ( New Style) Navigator Shell Cone Gear assembly Upper Middle Body Assy. Medium Turbine Assy. Turbine &Turbine Bearings (2) Large White Floats Rear Screen (Middle Posts) Gear Box (2) Small blue Floats (Rear posts) Lower Middle Body Page 12...
  • Page 15 Major Components Pool Vac XL( New Style) Pool Vac XL Shell assembly Cone Gear Upper Middle Body Assy. Medium Turbine Assy. Turbine &Turbine Bearings (2) Large White Floats Rear Screen (Middle Posts) Gear Box (2) Small blue Floats (Rear posts) Lower Middle Body Page 13...
  • Page 16 Major Components All Cleaners (lower body) A Frame Bearings (4) A-Frame (2) Screw and lock washer Keeper Saddle Rear Flap Assembly Pod Plug (2) Right Pod Assy. Lower Body Pod Bearing Left Pod Assy. Front Flap Assembly Shoes (4) Wings (2) Access Plate Page 14...
  • Page 17 Lower Body Disassembly 1. Remove the access cover screw (captured) and cover (fig 9 & 10). Figure 9 Figure 10 2. Remove the four lower body screws to remove the lower body (Fig 11 & 12) Figure 11 Figure 12 Page 15...
  • Page 18 Wing Removal & Replacement Using a screwdriver, remove the plugs from the pods on both sides (fig 13). Remove the wings by bending the wings up toward the side of the cleaner and lift them off the pod’s hooks (fig 14). Figure 13 Figure 14 Page 16...
  • Page 19 Wing Removal & Replacement Replace the wings if necessary (see wear marker in fig 15), making sure that you match the “L” (left) and “R” (right) of the wings to the correct pods (fig 16 & 17) Figure 16 Figure 17 Figure 15 Replace the pod plugs and tap them into place using the screwdriver’s handle.
  • Page 20 Pod Removal & Replacement Remove the plug on each pod covering the pod screw (fig 18). Unscrew and remove the pod screws and washers (fig 19). Gently pry the pod off from the lower body of the cleaner (fig 20). Figure 18 Figure 19 Figure 20...
  • Page 21 Pod Removal & Replacement Inspect pods and A-Frames for wear caused by loose connection between the two parts. Both parts should move together as shown (fig 21). Note: If either the pods or the A-frames are worn, replace both for proper operation.
  • Page 22 A Frame Removal & Replacement Remove the pod and A-frame bushings from the lower body on both sides (fig 27). Remove the screw and saddle assembly holding the A-Frames in place from the inside of the lower body (fig 28). Tighten Securely when replacing. Pull the A-Frame arms in towards each other from inside the lower body to remove (fig 29) Note: If either the pods or the A-Frames are worn, replace both for proper operation.
  • Page 23 Shoe Removal & Replacement Note the wear line (highlighted) on the side of the shoe. Replace shoes if worn beyond this mark (Fig 24). Insert a flat head screwdriver between the pod foot and the shoe. Using a lifting motion, remove the shoe from the foot (Fig 25) When installing the new shoe, make sure all water and debris are removed from the surface and hole.
  • Page 24 Flap Removal & Replacement Prior to removal, note the position of flap springs for correct replacement. Rear flap (fig 30) Front flap (fig 31). Figure 31 Figure 30 Remove the front and rear flaps from the lower body by inserting a small flathead screwdriver between the flap and body near the flaps pivot point (fig 32 &...
  • Page 25 Flap Removal & Replacement The flaps are marked “FRONT” and “REAR” (fig 34 & 35). When replacing make sure they are installed in the correct location Figure 34 Figure 35 Page 23...
  • Page 26 Middle Body Disassembly STYLE Remove the four screws attaching the bumper to the lower middle body and remove the bumper (fig 36 & 37) Remove the two remaining screws holding the lower middle body to the upper middle body (fig 38) Figure 36 Figure 37 Figure 38...
  • Page 27 Middle Body Disassembly STYLE Remove the six screws holding the lower middle body to the upper middle body (fig 39) STYLE Turn the cleaner upright and remove the upper middle body from the lower middle body (fig 40). Figure 39 Figure 40 Page 25...

  • Page 28: Gear Box Removal & Disassembly

    Gear Box Removal & Disassembly Pull up on the gearbox to remove from the lower middle body (fig 41 ) Pull up to remove the red disc and white ring on the gearbox (fig 42) Remove the top access plate to inspect the internal gears for damage or debris (fig 43) Note: When removing the gears, lay them out in order for correct replacement (fig 44) Figure 41...
  • Page 29 Turbine Assembly Removal & Replacement 1. Remove the turbine and bearings by pulling up the center of the turbine (fig 45) Note: Cleaner shown (fig 45) has four floats. Floats 2 & 4 are blue and small, while floats 1 & 3 are large and white.
  • Page 30 Turbine Assembly Removal & Replacement The turbine end and lower middle body are marked to ensure correct turbine placement (fig 49 & 51) . When replacing, make sure the bearing’s outside race locks into position in the lower middle body. (fig 50 & 51) Figure 49 Figure 50 Figure 51...
  • Page 31 Medium Turbine Assembly Remove the two screws holding the cover over the medium turbine assembly (fig 53). Remove cover and ensure the turbine is clean and free spinning (fig 54) . Figure 54 Figure 53 Page 29...
  • Page 32 Upper Gear Assembly Access Style Remove the four screws holding the upper middle body to the shell. Note the length of the screws (fig 55 ) Turn the cleaner upright and carefully remove the shell from the upper middle body (fig 56) Figure 55 Figure 56 Page 30...
  • Page 33 Upper Gear Assembly Access Style Navigator Pro Using a flat blade screwdriver carefully lift up on the top shell at the provided cutouts (fig 57 & 58) Remove the four screws holding the shell to the body (fig 59 ). Lift...
  • Page 34 Upper Gear Assembly Access Style Pool Vac XL Using a flat blade screwdriver carefully lift up on the top shell and remove as indicated (fig 61). Remove the four screws holding the Handle/frame to the body. Note the screw size for reassembly (fig 62). Figure 61 Figure 62 Page 32...
  • Page 35 Upper Gear Assembly Access Style Pool Vac XL. (continued) Remove the Handle frame from the lower frame assembly (fig 63) Remove the lower frame assembly (fig 64) Figure 63 Figure 64 Page 33...
  • Page 36 Upper Gear Assembly Both the clear cone gear and the black intermediate gear can be removed by lifting up (fig 65 & 66). Remove the spindle gear screw to remove spindle gear, spindle bushing and medium turbine drive gear (fig 67). Note: When replacing any parts in this section always install a medium turbine kit rather than individual parts.

  • Page 37: Hang Test

    Troubleshooting/Hang Test Step A Before getting started with troubleshooting, understanding how the Hang Test is performed will help in diagnosing a problem. Before using the test or performing any other test, attach the flow gauge and make sure the suction setting is correct, See page 8 .
  • Page 38 Troubleshooting/Hang Test Does the cleaner rotate in both directions with a Step B stop in-between in a 5 minute time period If the cleaner turns in one If the cleaner does not turn at direction only go to page 26. all go to page 26 or 34 or check the rear screen for debris.
  • Page 39 Troubleshooting/Hang Test Doing this test pool side is invaluable. For the retail or service dealers retail location this test can be accomplished using air. Procuring at least a 3hp Shop-Vac along with a cleaner leader hose gets you most of the way towards building your own in-house cleaner tester.

  • Page 40: Troubleshooting

    Troubleshooting Cleaner does not move Verify the suction setting is correct (page 8). If the suction is Step A correct go to Step B. After confirming proper suction, place the cleaner on Step B the pool floor. If the cleaner does not move, check the shoes for wear and the pool surface for algae (treat and remove) or remove the access cover and check for debris in the turbine area.

  • Page 41: Cleaner Turns In One Direction

    Troubleshooting Cleaner turns in one direction Perform Hang Test on page 35 & 36. If Cleaner turns in both Step A directions correctly go to Step B If the cleaner while on the bottom of the pool goes in circles in Step B only one direction, or turns heavily in only one direction, there is excessive play or wear between the A-frame and turbine, A-frame...
  • Page 42 Troubleshooting Cleaner goes too slow or fast Verify the suction setting is correct (page 8). If the suction is Step A correct go to Step B. Check and replace any worn shoes, wings or flaps. If the Step B problem is not solved go to step C Note wear indicators on these parts See page 21 See pages 16 &...
  • Page 43 Troubleshooting Cleaner goes too slow or fast Check and make sure pods are tightly connected to A-frames. Step C If connection becomes loose shortly after tightening replace both A-frames and pods. If problem persists go to Step D See pages 18, 19 or 20 Check turbine for wear or correct Step D placement.

  • Page 44: Cleaner Is Floating Or Lifting

    Troubleshooting Cleaner is floating or lifting, Hose is twisting or curling Note: Since the cleaner is heavier than water, the only way it can float is from an external source. This is usually caused by air trapped in the cleaner or on the hose. Ensure all air is removed from the cleaner and hoses.
  • Page 45 Troubleshooting Cleaner Gets Stuck In Corners or on Steps Verify the suction setting is correct (page 8). A cleaner running Step A too slow or too fast may not turn off a step or corner. If the suction is correct go to Step B. Check return fittings direction.
  • Page 46 Troubleshooting Cleaner Gets Stuck In Corners or on Steps Check and replace any worn shoes, wings or flaps. Step D See page 21 See pages 16 & 17 See pages 22 & 23 Adjust rear flap Step E adjuster to #1 Page 44...
  • Page 47 Troubleshooting Cleaner Does Not Climb Walls Verify the suction setting is correct (page 8). If the suction is Step A correct go to Step B. Check and replace any worn shoes, wings or flaps. Step B See pages 16 & 17 See page 21 See pages 22 &...
  • Page 48 Troubleshooting Cleaner Does Not Climb Walls Step B Adjust rear flap adjuster to #3 Vinyl liners: The ability for a cleaner to climb a wall may be hindered by hoppers or walls that have smaller than a 7” radius Make sure the cleaner is a vinyl unit and has cork shoes Concrete: Cleaners will not climb walls with a radius smaller...

  • Page 49: Hose Collapsing

    Troubleshooting Hose Collapsing If using the cleaner with a skimmer, make sure the angle Step A where the hose attaches to the skimmer is not too sharp. The suction may be too great. Reduce the suction by using the Step B regulator valve.

This manual is also suitable for:

Pool vac ultraNavigatorPool vac xl™

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