Hayward AquaVac 500 User manual

AquaVac 500 Troubleshooting Guide
© 2014 Hayward Industries Inc.

Table of Contents
Safety Precautions Page 1
Power Supply Page 2
Motor Unit Page 3
Filter Removal & Replacement Pages 4-6
Wheel and Tire Removal Page 7
Side Cover Removal Page 8
Drive Track & Pulley Bearing Removal Page 9
Drive Shaft Pulley Removal Page 10
Wheel Tube & Drive Wheel Removal Page 11
Wheel Tube Brush Page 12
Power Cord Removal & Installation Pages 13-14
Motor Box Removal Pages 15-16
Power Supply and Flotation Cord Testing Pages 17-18
Troubleshooting Pages 19-23

Safety
!
Page 1
• 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.
• 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.

Power Supply Control
On/Off Power Button
Cord Assembly w/Swivel
(To Cleaner)
Page 2
Power Cord
(To GFCI Outlet)
Cleaner
Mode
Button
Cleaner
Schedule Button
Power Indicator Lights
Cleaning
Cycle
Mode
Lights
Cleaning
Schedule
Mode
Lights

Motor Unit
Motor output shaft.
Drive end.
Motor assembly
Cord to Power
Supply
Impeller
Cover
Top view with filter assembly removed.
Page 3

Filter Removal
Step 1: Press Dome Button
to lift Dome for filter removal.
Page 4
Filter cartridge removed Filter Bucket Housing
Step 2: Lift to remove Filter
Bucket Housing.

Filter Removal
Page 5
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. Elements
can be cleaned within Filter Housing or after being
removed as shown in Step 4.
Spring cleanup filter
elements.
For temporary use
in heavy spring
cleaning.
Step 3: Open filter doors by unsnapping
and lifting up both filter door latches. Step 4: Lift filter cartridges out.

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 6

Wheel and Tire Removal
Step 1: Remove wheel axle plug from wheel.
Page 7
Step 2: Remove wheel from wheel bushing and cleaner base.
Note: During
re-assembly,
reinstall
wheels to
Side Covers
before
reinstalling
sides to
Cleaner
Base.

Side Cover Removal
Page 8
Step 1: Remove T20 screw
and Wheel Drive Gear.
Step 2: Remove black cover
and idler gear.
Step 3: Remove Wheel
Shield by unsnapping
tabs from Side Cover.
Step 4:
Remove snap
retainers by
unsnapping
tabs from Side
Cover.
With Cover Removed

Pulley Bearings
Note that flange faces inward.
Drive Track & Pulley Bearing Removal
Drive Side
Page 9
Bearings should rotate smoothly
and freely.
Check for missing/broken drive
cogs on inner loop of belt and also
for cracks in belt.

Drive Shaft Pulley, motor output side only.
Remove by pulling away from Cleaner Base.
Note drive ‘key’ in pulley and
how it mates to the output
shaft drive pin of the motor.
Drive Shaft Pulley Removal
Page 10

Step 2: Carefully pull
wheel tube away from
wheel axels.
Wheel Tube & Drive Wheel Removal
Page 11
Step 1: Unscrew T20 screw from
each side of roller.
Step 3: Remove Roller
bushing from Roller
Wheel Shaft.
Step 4: Slide Roller
Wheel Shafts away
from the Roller Wheels.

Wheel Tube Brush
Page 12
Start in the center of the brush and put
the post through the hole in the tab
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.
Brush replacement can be done with
the cleaner assembled or broken
down. Unsnap the tabs that run length
wise of the brush.
Removal Replacement

Step 2: Remove strain relief
cover plate.
Plate removed showing
strain relief system.
Power Cord Removal
Page 13
Step 3: Use Spanner
Wrench and Torque
driver to remove
threaded plug.
Threaded plug removed
Step 1: Remove Cord
Assembly holder from
Right Side Cover.

Note: Connector must be installed with tab
on connector placed in mating hole of
motor assembly.
Note the order of the seals and
washers. Remember to mate the
taper of the seal to the threaded plug.
Step 2: Use the Torque driver and
spanner wrench to install the threaded
plug. Tighten the threaded plug until you
feel the Torque wrench click or slip.
Power Cord Installation
Page 14
Step 1: Before and after inserting
cord, apply RTV 162 Sealant to
Motor connection.

Motor Box Removal
Page 15
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.
Remove 4 T20 screws securing motor to base.

Motor Box Removal
Page 16
Output shaft key on motor, mates
with drive gear.
Impeller removal
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.
Rotate motor slightly to remove drive output shaft
from side of unit, then lift out motor assembly.

Testing Power Supply
Page 17
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.
Step 2: Disconnect floatation
cord from power supply and
check power supply for 30-38
VDC on the holes shown.
If voltage is not correct, verify
proper line voltage from GFCI
outlet. If line voltage is correct,
replace Power Supply.

Flotation Cord / Motor box Testing
Step 1: Set the multimeter
to measure DC volts.
Step 2: With the floatation cord
disconnected from the power supply for
at least 30 seconds, measure the
voltage on the floatation connector pins.
If the voltage is
more than 0.1VDC,
there is likely water
in the Cord or
Motor Assembly.
Continue to Step 3.
Page 18
Step 4: Remove cord from
motor box and check ohm’s
reading between each pin
and the other end of each.
.4 to .8 ohm’s is acceptable.
If resistance is greater,
replace the Cord.
Otherwise, replace the
Motor Assembly.
Step 3: Set the multimeter
to measure continuity.
Note: Pins by the notches on each end
signify same wire.