Hayward AquaVac 500 Troubleshooting Manual
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Hayward AquaVac 500 Troubleshooting Manual

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AquaVac 500 Troubleshooting Guide
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© 2014 Hayward Industries Inc.

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Summary of Contents for Hayward AquaVac 500

  • Page 1 AquaVac 500 Troubleshooting Guide ® © 2014 Hayward Industries Inc.

  • Page 2: Table Of Contents

    Table of Contents Safety Precautions Page Service Tools Page Power Supply Page Motor Unit Page Filter Removal & Replacement Pages Wheel and Tire Removal Page Side Cover Removal Page Drive Track & Pulley Bearing Removal Page Drive Shaft Pulley Removal Page Wheel Tube &...

  • Page 3: Safety Precautions

    Safety • Always place the machine in the water before connecting it to the electrical supply. • Always connect the power supply to an approved GFCI, ground fault circuit interrupter. • Do not handle machine while it is plugged into the electrical supply. •...

  • Page 4: Service Tools

    Service Tools Pin Removal Tool Torque Driver Flat Head & Phillips Head Screwdrivers (not shown) Torx Bit Spanner Tool Torx Driver T10 & T20 T10 & T20 Page 2...

  • Page 5: Power Supply

    Power Supply Control On/Off Power Button Power Indicator Lights Cleaning Cycle Mode Lights Cleaning Schedule Mode Cleaner Cleaner Lights Mode Schedule Button Button Cord Assembly w/Swivel Power Cord (To Cleaner) (To GFCI Outlet) Page 3...

  • Page 6: Motor Unit

    Motor Unit Top view with filter assembly removed. Impeller Motor output shaft. Cord to Power Motor assembly Cover Drive end. Supply Page 4...

  • Page 7: Filter Removal & Replacement

    Filter Removal Step 1: Press Dome Button Step 2: Lift to remove Filter to lift Dome for filter removal. Bucket Housing. Filter Bucket Housing removed Filter Bucket Housing Page 5...
  • Page 8 Filter Removal Step 3: Open filter doors by unsnapping Step 4: Lift filter cartridges out. and lifting up both filter door latches. Spring cleanup filter elements. For temporary use in heavy spring cleaning. Note: Elements can be cleaned by gently spraying with a garden hose.
  • Page 9 Filter Replacement Hold both cartridges toward center. Push down cover and press tab towards fan to lock cartridges in place. Make sure cover snaps in place. Page 7...

  • Page 10: Wheel And Tire Removal

    Wheel and Tire Removal Step 1: Remove snap retainers by Step 2: Remove Side Cover from unsnapping from Side Cover. Cleaner Base. Step 3: Remove wedge Step 4: Remove wheel from wheel bushing and cleaner base. from wheel bushing Page 8...

  • Page 11: Side Cover Removal

    Side Cover Disassembly Step 3: Remove Wheel Step 1: Remove T20 screw Step 2: Remove black cover Shield by unsnapping and Wheel Drive Gear. and idler gear. tabs from Side Cover. With Cover Removed Page 9...

  • Page 12: Drive Track & Pulley Bearing Removal

    Drive Track & Pulley Bearing Removal Drive Side Check for missing/broken drive Pulley Bearings cogs on inner loop of belt and also for cracks in belt. Bearings should rotate smoothly and freely. Note that flange faces inward. Page 10...

  • Page 13: Drive Shaft Pulley Removal

    Drive Shaft Pulley Removal Note drive ‘key’ in pulley and how it mates to the output Drive Shaft Pulley, motor output side only. shaft drive pin of the motor. Remove by pulling away from Cleaner Base. Page 11...

  • Page 14: Wheel Tube & Drive Wheel Removal

    Wheel Tube & Drive Wheel Removal Step 2: Carefully pull Step 3: Remove Roller Step 1: Unscrew T20 screw from wheel tube away from bushing from Roller each side of roller. wheel axles. Wheel Shaft. Step 4: Slide Roller Wheel Shafts away from the Roller Wheels.

  • Page 15: Wheel Tube Brush

    Wheel Tube Brush Removal Replacement Start in the center of the brush and put Brush replacement can be done with the post through the hole in the tab the cleaner assembled or broken with the aid of a pair of needle nose down.

  • Page 16: Power Cord Removal & Installation

    Power Cord Removal Plate removed showing Step 1: Remove Cord Step 2: Remove strain relief strain relief system. Assembly holder from cover plate. Right Side Cover. Threaded plug removed Step 3: Use Spanner Wrench and Torque driver to remove threaded plug. Page 14...
  • Page 17 Power Cord Installation Note: Connector must be installed with tab Note the order of the seals and on connector placed in mating hole of washers. Remember to mate the motor assembly. taper of the seal to the threaded plug. Step 1: After connector is installed, Step 2: Use the Torque driver and apply RTV 162 Sealant to Motor spanner wrench to install the threaded...

  • Page 18: Motor Box Removal

    Motor Box Removal Remove 4 T20 screws securing motor to base. 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.
  • Page 19 Motor Box Removal Rotate motor slightly to remove drive output shaft Output shaft key on motor, mates from side of unit, then lift out motor assembly. with drive gear. Note: The motor assembly is a sealed unit and cannot be serviced, only replaced. It does not Impeller removal contain oil and is water cooled.

  • Page 20: Power Supply And Flotation Cord Testing Pages

    Testing Power Supply Note: Make sure the Power Supply is plugged in and on prior to proceeding. If power LEDs are pulsing, the output voltage is disabled on the power supply. You must press the power button and wait for the power LEDs to light up solid before taking the voltage measurement Step 1: Set the multimeter to measure DC volts.
  • Page 21 Flotation Cord / Motor box Testing If the voltage is more than 0.1VDC, there is likely water in the Cord or Motor Assembly. Continue to Step 3. Step 1: Set the multimeter Step 2: With the floatation cord to measure DC volts. disconnected from the power supply for at least 30 seconds, measure the voltage on the floatation connector pins.

  • Page 22: Troubleshooting

    Troubleshooting 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 • 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.
  • Page 23 Troubleshooting 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. • Check electrical source for proper voltage. •...
  • Page 24 Troubleshooting 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. • Check for belt or roller obstruction •...

  • Page 25: Troubleshooting

    Troubleshooting Debris falls from unit when removed from pool • 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. Page 23...

  • Page 26: Caddy Cart Assembly

    Caddy Cart Assembly Step 2: Insert lower hook using 2 self- Step 1: Remove cleaner, power supply, 2 tapping screws. hooks, 2 wheels and caddy cart kit from caddy cart before installing parts. Upper Hook Power Supply Lower Hook Cleaner 2 wheels Caddy Cart Step 3: Install upper hook using 2 self-...

  • Page 27: Caddy Cart Assembly

    Caddy Cart Assembly Step 6: Turn caddy cart over and support Step 5: Use the second Cap Tool to tap the axle cap at the bottom with the Cap axle cap on the axle top. Tool. Cap Tool Axle cap C ap is attach ed to the axle Cap Tool Step 7: Install remaining axle cap as...

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