Hayward Pool Vac Classic User manual

P/N K540AD-Rev E
Owner’s Manual
Hayward Pool Products
620 Division Street Elizabeth, NJ 07207
Phone [phone]
www.hayward-pool.com
Pool Vac XL® Navigator Pro®
Pool Vac Classic

Pool Vac XL
Navigator Pro
Pool Vac
Classic
OWNER’S MANUAL
Congratulations on your purchase of your Hayward automatic suction pool cleaning system
from Hayward. Your Cleaner is the smart, efficient way to clean your in-ground pool.
Hayward Turbine Cleaners are powered by your pool’s filter system and are designed to
work well with most systems. Therefore the performance of the Cleaner in your pool will
be relative to that power source. Because the operation and performance of the Cleaner
are system reliant, there is a remote possibility that a “service call” may be necessary to
complete the proper installation of your Cleaner. Because this is an installation related
call, it will be at the consumer’s expense. Also, one or more of the accessories designed
for the Cleaner, including additional hose sections (if needed), might be applicable to
your installation. Consult your Hayward dealer for the price and availability. For Technical
Assistance, call Hayward at 908-355-7995 (USA only).
Record the following information for your convienience
1) Purchase Date
2) Serial Number
For Your Records
Note
Turbine Suction Cleaner
Hayward Turbine Cleaners should not be used to clean the pool for spring start-up
unless the conditions noted in Step 1 are met. On those occasions, where your pool is
subjected to an abnormal debris load, maintenance steps should be taken to return the
pool to “pre-installations” condition.
LIMITED
WARRANTY LIMITED
WARRANTY

1
Installation
INSTALLING YOUR HAYWARD CLEANER IS SIMPLE...
To prepare your pool for installation, please follow the easy steps listed below. After
reading these instructions, the “How To” installation DVD (included with Pool Vac XL &
Navigator Pro only) will walk you through the installation step-by-step, and it will also give
you some maintenance and trouble-shooting hints. These instructions apply to all Hayward
Turbine Cleaner models.
Step 1
Check the pool and remove any large objects that might interfere with the cleaner’s
operation. Check to see that the water level is at the recommended level. Check the water
chemistry. Make sure that the water is properly balanced and that the pool is free from
algae. Algae can adversely affect the operation of the Cleaner and its performance.
Step 2
Clean or backwash the filter, and clean the hair and lint prior to installing the Cleaner.
Following the installation of your Cleaner, clean the system at regular intervals according to
individual pool conditions.
Step 3
There are connector hoses (9 with PV XL & NAV PRO, 7 with PV Classic) and one leader
hose with a hose cuff are included. The hose cuff has a red sticker attached to it that reads
“REMOVE LABEL AND CONNECT TO CLEANER”.
Connect the exclusive Hayward hose sections together by pushing and twisting the tapered
male connector end of each hose firmly into the open female end of the adjacent hose (see
Figure 1). Depending on the size and shape of your pool, all hose sections might not be
used. However, the leader hose must be used or your Cleaner will not operate properly. It is
not necessary to “Bottom Out” the connections, but they must be tight enough to prevent
any air leaks. Wetting the hose ends will make it easier to connect the hose sections.

2
Step 4
The hose should reach from the skimmer or Hayward Vac Lock® to the furthest point in
the pool, plus two (2) extra hose sections. (The length of each hose section is four feet.)
This extra length is absolutely necessary for proper operation of your Hayward Cleaner. If
the hose is not long enough, it will be necessary to purchase additional hose sections from
your Hayward dealer. The hose length supplied has been determined to be sufficient for
the class and size of pools for which each type of cleaner is sold – 40 feet for PV XL & NAV
Pro, 32 feet for PV Classic. If your hose requirement is more than this, you must obtain
additional hose sections for your cleaner to work properly. After the correct hose length has
been assembled, fill hose completely with water. Insert Flow Gauge into the leader hose,
then attach the C-Clip of the gauge onto the first hose section. Make sure the Flow Gauge
is under water. (see Figure 2)
Step 5
Turn the filter system on and allow it to run long
enough to eliminate any air in the system. Connect the
V093C Skimmer Cone adapter to the tapered male end of
the vacuum hose if you are connecting the hose to your
skimmer. Then, insert the cone into the suction port of
the skimmer (see Figure 3) or, if you are using a
Hayward Vac Lock, insert the hose end directly
into the Vac Lock without using the cone. (Refer
to Important Tips for more specific skimmer
information.)
Installation
INSTALLING YOUR HAYWARD CLEANER IS SIMPLE...

3
Step 6
Check the water flow reading on the Flow Gauge. (Refer to Step 4, Figure 2). The black disk
should be in the box between the “MIN” and “MAX” markings. If the setting is higher than
required with the black disk outside of the box on the “MAX” side and you have connected
your hose to the skimmer, it will be necessary to reduce the vacuum/water flow by using
a valve or valves in the filter system, or the Hayward V094 Regulator Valve or an optional
Hayward Automatic Skimmer Vacuum Plate designed to adjust vacuum/water flow. To install
the V094 Regulator Valve, turn the filter system off, remove the hose from the V093C
Skimmer Cone, and after closing the Regulator Valve (Rotate the blue collar clockwise until
tight), insert the Valve into the Skimmer Cone, and insert the hose end into the Valve (see
Figure 4).
Turn the filter system on and allow it to run long enough to eliminate any air in the system.
Turn the blue collar counter clockwise until proper reading appears on the gauge. If a
Hayward Skimmer Vacuum Plate is to be used, follow the installation instructions included
with the Skimmer Vacuum Plate.
Installation
INSTALLING YOUR HAYWARD CLEANER IS SIMPLE...

4
Note
The V094 Regulator Valve and the Hayward Skimmer Vacuum Plate can only be used to
LOWER an initial vacuum reading that is TOO HIGH. The Regulator Valve and the Skimmer
Vacuum Plate cannot be used to INCREASE the initial vacuum reading. An initial reading
that is too low to meet the water flow setting necessary to operate the cleaner is indicative
of a system problem, and not a problem with the cleaner.
Contact your Authorized Hayward Dealer for assistance.
If you have connected your hose to the Hayward Vac Lock, it will be necessary to adjust
the vacuum/water flow using the 3-way valve at the filter system. The handle on the valve
should be turned so that the Flow Gauge which is installed in the Cleaner hose reads
properly (refer to Figure 2). After the 3-way valve has been properly adjusted, the 3-way
valve should be marked so that the water flow can be adjusted by referring to the valve
handle mark, rather than reinstalling the Flow Gauge in the hose each time an adjustment
is necessary.
Step 7
Remove the Flow Gauge from the hose and keep it handy. You will want to use the Flow
Gauge to check the Cleaner’s operation from time to time if the Cleaner is connected to
your skimmer. If you are using a Hayward Vac Lock, the Flow Gauge will only be necessary
if you neglect to mark the valve gauge, or if replacement of the valve gauge is necessary.
Step 8
Check the rear flap adjuster dial at the left rear of the Cleaner. It should be set at position
number II which is the middle position (see Figure 5). Submerge the Cleaner into the water
to remove all of the entrapped air. When escaping air bubbles cease, you are ready to
connect the hose.
Connect the hose cuff of the leader hose to the Cleaner and submerge the hose to remove
all air as when vacuuming the pool with a standard hand-vacuum (see Figure 6).
Do not use the return line/inlet water to “sink” the Cleaner hose, as this will force air into
the cleaner head, and possibly cause performance problems.
Installation
INSTALLING YOUR HAYWARD CLEANER IS SIMPLE...

5
Step 9
Observe your Cleaner in operation, and make sure that the return line flow is not affecting
the Cleaner’s programmed steering and preventing the Cleaner from covering the entire
pool. If the cleaner hose is being pushed across the surface of the pool, it will be necessary
to redirect the return line water flow downward. This is to allow the Cleaner to move its
programmed cleaning pattern.
Step 10
Observing the Cleaner in operation, it should move about the pool without spending an
excessive amount of time against the steps or other obstructions (vertical walls, ladders,
etc.) If the Cleaner seems to get “hung up,” turn the rear flap adjuster to position I (see
Figure 5).
Step 11
Your Cleaner will climb the vertical walls in concrete and fiberglass swimming pools if there
is at least a seven inch (7") radius where the walls and floor meet. The Cleaner’s wall
climbing is governed by the programmed steering and therefore it will not climb the wall
each time it comes in contact with a wall. When the Cleaner does start up a wall, it will not
always go all the way up the wall. If the Cleaner does not seem to be “sticking” to the wall,
turn the rear flap adjuster to position III (see Figure 5). If the Cleaner climbs to the water’s
surface and sucks air, turn the rear flap adjuster to Position I (see Figure 5). If the cleaner
continues to climb too high, reduce the water flow until proper operation is achieved.
Approximately ninety percent (90%) of the dirt in a concrete pool will be on the floor of
the pool. Approximately ten percent (10%) of the dirt will be on the walls. Your Cleaner will
spend its cleaning time accordingly.
Installation
INSTALLING YOUR HAYWARD CLEANER IS SIMPLE...

6
Pool Vac XL/Navigator Pro
In one piece fiberglass pools there is very little dirt on the walls, but your Cleaner will still
climb the walls. Due to the shape (severe angles) of most in-ground vinyl liner pools, your
Cleaner’s cleaning is confined to the bottom (both shallow and deep) and the hopper sides.
Hayward Turbine Cleaners do not climb the vertical walls of in-ground or on-ground vinyl
liner pools. However, normal dirt and debris do not adhere to these walls.
1. Skimmers come in many configurations and cannot all be described here. Three basic
types are discussed however.
Some skimmers have two (2) holes in the bottom. There might be a valve, float or cover
over the holes. Remove everything in the skimmer, exposing the holes. The rear hole is
usually the suction port. In some cases it will be necessary to use the V094 Regulator Valve
to control water flow through the Cleaner (see Figure 4).
Some skimmers have only one hole in the bottom. This suction port is usually controlled by a
valve at the filter system and most likely will not need a V094 Regulator Valve (see Figure 3).
DO NOT COIL HOSE
When storing your cleaner the hose sections must be stored straight, not coiled. A coiled
hose will create a memory in the hose that will impede the Cleaner’s ability to move
properly in your pool. Coiled hoses are not covered under the Hayward warranty. When
removing the Cleaner from your pool, be sure to grasp the cleaner by its handle, not by its
hose, otherwise the Cleaner might be damaged should the hose disconnect from the cleaner.
IMPORTANT TIPS
Turbine Suction Cleaners

7
Some skimmers have a vari-flow or diverter valve in the bottom of the skimmer. This valve
can be turned to regulate skimming and main drain suction. Turn the valve to full skim
and then adjust the Flow Gauge by turning the valve toward main drain suction. Usually
this valve is the same size as the Cleaner’s hose end, and it will therefore be necessary
to purchase a V098 Hose Adapter (see Figure 7). After the proper gauge reading has been
established, the diverter valve will have to be locked in the place with a wedge of some
kind so that it won’t change position with operation of the Cleaner.
2. Periodically check the water flow/vacuum to be sure that your Cleaner is operating as
efficiently as possible. Remember, too much vacuum is just as bad as too little.
3. Periodically check to make sure that the Cleaner hose is securely attached to its suction
source (i.e. Skimmer, Skimmer Vac Plate Vac Lock, etc.)
4. Disconnect the Cleaner hose from the skimmer/regulator valve, or, if using a “dedicated
line”, turn cleaner valve off prior to “backwashing”, so as not to restrict water flow.
5. Never coil the Cleaner hose. Coiled hose is not covered under the warranty.
6. When the Cleaner is out of the pool, always disconnect the leader hose from the
Cleaner’s head.
7. Always carry your Cleaner by the molded-in handle. Do not carry it by the hose.
8. When swimming in the pool, remove your Cleaner from the water.
9. If you are going to super chlorinate, shock, or add gas chlorine to your pool, make sure
the cleaner and its hose are removed prior to doing so.
IMPORTANT TIPS
Turbine Suction Cleaners
CLEANER

8
1. Check the condition of the “shoes, wings and flaps” periodically. The shoes and wings
have wear indicators on their sides and should be checked occasionally to determine
if they need replacing. The shoe wear indicator is a line on the side of the shoe that
appears as a difference in texture. When this texture difference is no longer visible at the
bottom of the shoe when viewed from either side, the shoes must be changed (see
Figure 8). Also on the side, the wing wear indicator is a horizontal line which has three
(3) vertical lines above it. When you can no longer see the horizontal line, the wings
must be changed (see Figure 9). The Hayward Tune-Up Kit is available from your dealer.
Shoes, wings and flaps may also be purchased separately.
2. SHOE REPLACEMENT:
a) Turn unit upside down.
b) Insert screwdriver between foot and shoe on one of the pads (see Figure 8).
c) Using a lifting motion, remove the shoe from the foot.
d) Dip a new shoe in water and attach the shoe to the foot, making sure to put the small
post into the small hole and the large post into the large hole. These posts and holes
are different sizes to prevent the shoes from being improperly installed.
e) Repeat Steps b,c, and d for each shoe.
.250
WORN SHOE
WEAR MARK
GOOD SHOE
MAINTENANCE TIPS
Turbine Suction Cleaner
.250
WORN SHOE
WEAR MARK
GOOD SHOE

9
3. WING REPLACEMENT:
a) Using a screwdriver, remove the plugs from both pods (see Figure 9).
b) Remove the old wings by bending the wings up toward the sides of the cleaner, and
lift them off their hooks (see Figure 10). If any of the wing hooks are broken, take the
Cleaner to your dealer for pod replacement as the unit will not function properly if the
wings are not properly attached.
c) Replace the wings, making sure that you match the “L” (Left) and “R” (Right) of the pods.
d) Replace the pod plugs and tap them into place with the screwdriver handle.
MAINTENANCE TIPS
Turbine Suction Cleaner

10
4. FLAP REPLACEMENT:
a) Remove the front and rear flaps from your Cleaner by inserting a small screwdriver
between the flap and the lower body near the pivot point of the flaps (see Figure 11).
b) You will notice that your replacement flaps look similar but are marked “Front” and
“Rear” on the flap. Because the springs in the flaps are different, it is absolutely
necessary to install the proper flap in the front and rear of the unit. Failure to do
so will result in unsatisfactory performance of your Cleaner. When installing the front
flap, be sure that the extended leg of the spring is inserted into the notch on the
front of the lower body (see Figure 12). Push the flap in place. You will actually feel
and hear a snap when the flap is in place. Fold the flap in towards the bottom of the
Cleaner. You will feel some resistance at this point (that is normal). As the flap snaps
into its normal position, you will feel the spring action and notice that the front flap is
now in its normal operating position.
When installing the rear flap, the extended leg of the spring must fit against one of the flat
surfaces of the cam (see Figure 12).
MAINTENANCE TIPS
Turbine Suction Cleaner

11
5. POOL VAC XL SKIRT/MID SECTION REPLACEMENT:
Replacement of the Pool Vac XL Skirt/Mid Section is not recommended as DIY repair.
There is strong possibility that the replacement could cause propulsion system issues. It is
strongly suggested that you bring your Pool Vac XL to a HAYWARD dealer for replacement.
Tools required — #2 Phillips screwdriver
1/8” flat screwdriver
Preliminary steps — Turn off pool pump
Remove Pool Vac XL from pool
Disconnect suction hose from cleaner
Change out steps —
1. Insert the 1/8” flat screwdriver into each slot in the
handle and pry each cover snap off the
handle.
2. Using the phillips screwdriver, remove and retain the
four screws holding the Handle onto the Middle Body.
3. Lift the Handle off the Middle Body.
4. Lift the old Skirt/Middle Body assembly off the
Main Drive Assembly
5. Set the new Skirt/Middle Body assembly onto the
Main Drive Assy.
6. Replace the Handle.
7. Reattach the Handle by screwing in the four
screws previously removed.
8. Engage the Top Cover rear hooks under the top
rear retainers in the Middle Body. Rotate the Top
Cover down in front. Insure the snaps are aligned
inside the front of the Handle and push the Top
Cover down until it snaps into the Handle.
MAINTENANCE TIPS
Pool Vac XL
12
3
4
1
1
1
2
3
D
C
B
A
A
B
C
D
1
2
3
4
5
6
7
8
8
7
6
5
4
3
2
1

12
5. Navigator Pro Skirt/Mid Section Replacement:
Replacement of the Navigator Pro Skirt/Mid Section is not recommended as DIY repair. There
is strong possibility that the replacement could cause propulsion system issues. It is strongly
suggested that you bring your Navigator Pro to a HAYWARD dealer for replacement.
Tools required — #2 Phillips screwdriver
1/8” flat screwdriver
Preliminary steps — Turn off pool pump
Remove Navigator Pro from pool
Disconnect suction hose from cleaner
Change out steps —
1. Insert the 1/8” flat screwdriver into each slot in the
Middle Body and pry each Handle snap off the
Middle Body.
2. Using the phillips screwdriver, remove and retain the four
screws holding the Middle Body onto the Main Drive
Assembly.
3. Lift the old Skirt/Middle Body assembly off the Main
Drive Assembly.
4. Set the new Skirt/Middle Body assembly onto the
Main Drive Assy.
5. Reattach the Skirt/Middle Body assembly by
screwing in the four screws previously removed.
6. Engage the Handle rear hooks under the top rear
retainers in the Middle Body. Rotate the Handle
down in front. Insure the snaps and the side tabs
are aligned to the Middle Body slots and push the
Handle down until it snaps into the Middle Body.
MAINTENANCE TIPS
Navigator Pro
12
3
4
1
1
1
2
3
D
C
B
A
A
B
C
D
1
2
3
4
5
6
7
8
8
7
6
5
4
3
2
1

13
“EASY OPENING BOTTOM”
Removal Instructions
6. “EASY OPENING BOTTOM”
The purpose of the “EASY OPENING BOTTOM” is to allow quick access to the turbine/
vacuum chamber for easy cleaning and maintenance.
Should the Cleaner stop moving or become sluggish due to debris trapped in the throat
or inside the unit, the turbine/vacuum chamber is accessible following the instructions on
pages 13 & 14 of this manual.
1. Turn off pump.
2. Remove Cleaner from pool.
3. Disconnect Cleaner from leader hose.
4. Turn Cleaner upside down.
5. Locate and loosen the captive screw behind the throat in the center of the bottom
(see Figures 14 and 15).
12
3
4
1
1
1
2
3
D
C
B
A
A
B
C
D
1
2
3
4
5
6
7
8
8
7
6
5
4
3
2
1

14
6. Lift “Easy Opening Bottom” (see Figures 14 & 15).
7. Clean turbine/vacuum chamber (see Figure 16).
8. Check turbine for free movement.
9. Reinstall “Easy Opening Bottom” by lining up the cover screen with the two slots shown
in Figures 14 and 15. Then slide the cover in place and tighten the captive screw.
10. Reinstall your Cleaner in the pool per installation instructions.
“EASY OPENING BOTTOM”
Removal Instructions

15
Problem: Slow/no forward movement
Problem: Cleaner fails to climb vertical walls gunite/concrete pool
CAUSES SOLUTIONS
Lack of/improper water flow through cleaner Check water flow with Flow Gauge and
adjust as per Step 6.
Blockage of the Cleaner throat Clear blockage
Worn shoes Replace shoes
Worn wings Replace wings
Improper cleaner model for application Call 908-355-7995 (U.S.A. only)
CAUSES SOLUTIONS
Improper shoes for application Call 908-355-7995 (U.S.A. only)
Lack of/improper water flow through cleaner Check water flow with Flow Gauge and
adjust as per Step 6.
Blockage of the Cleaner throat Clear blockage
Worn shoes Replace shoes
Worn wings Replace wings
Hose too short Install additional hose sections per
installation instructions.
Improper tension on rear flap Turn rear flap adjuster to |||
TROUBLESHOOTING GUIDE
Turbine Suction Cleaner

16
CAUSES
Cleaner head is HEAVIER than WATER, and
should not “float”
The cleaner head is actually being pulled or
lifted off the bottom of the pool by the
cleaner hose, or return line flow – either
at the surface or at the bottom of the pool –
or both
Problem: Cleaner climbs to water surface and sucks air.
Problem: Cleaner head “floats”
CAUSES SOLUTIONS
Too much/improper water flow through cleaner Check water flow with Flow Gauge and
adjust per instructions in Step 6
Improper tension on rear flap Turn rear flap adjuster to position 1
If still climbing too much, reduce water flow
until proper operation is achieved
Steering failure 1) Check and clean rear screen
2) Check to see that cone gear is free and
rotates smoothly in both directions
3) Check medium turbine and spindle gear
assemblies for malfunction
SOLUTIONS
Remove all air from cleaner head
Stop all air from entering the pool through
the return lines
If cleaner head and hose are covered with
fine bubbles, give the hose a good tug. This
will release the air bubbles and allow the
cleaner head to settle to the bottom of the
pool until the hose is covered with bubbles
again
Readjust return outlets to prevent water flow
interfering with cleaner head and/or hose
TROUBLESHOOTING GUIDE
Turbine Suction Cleaner

17
Problem: Cleaner sticks at steps, corners, etc.
CAUSES SOLUTIONS
Improper water flow Check water flow with Flow Gauge and
adjust as per Step 6.
Worn shoes Replace shoes
Worn wings Replace wings
Hose too short Install additional hose per installation
instructions.
Steering failure 1) Check and clean rear screen
2) Check to see that cone gear is free and
rotates smoothly in both directions
3) Check steering program and troubleshoot
- then:
a) clean, repair or replace gearbox
b) check pod/A-frame connection and
REPLACE IF NECESSARY. DO NOT
ATTEMPT TO RETIGHTEN LOOSE
PODS.
c) check medium turbine and spindle
gear assemblies
TROUBLESHOOTING GUIDE
Turbine Suction Cleaner

18
To better serve you, please have the following information available if you call Hayward’s
Technical Service Department at 908-355-7995 (U.S.A. only):
1) The Purchase Date of your Hayward Turbine Suction Cleaner.
2) The Serial Number of your Hayward Turbine Suction Cleaner.
3) The number of the Hose Sections used.
4) A current water flow indicator setting (refer to Step 6, Figure 2).
A) Pool plaster is affected by age, water, chemistry, etc.
B) Pool plaster can deteriorate over a period of time.
C) The integrity of “good” pool plaster is such that a pool vacuum cleaner - automatic or
manual cannot remove that plaster.
D) The integrity of “good” pool plaster is such that the plaster will cause wear on the
Cleaner - not vice versa.
E) Vinyl is affected by age, sunlight and water chemistry.
F) Vinyl can become brittle and weak.
G) Vinyl can also be affected by the installation and the pool’s surroundings.
H) When installing your Cleaner, you must assume all responsibility for the
condition of the pool and the pool’s surroundings.
DISCLAIMER
Turbine Suction Cleaner