Hayward Pool Vac XL™ User manual

Pool Vac Ultra ®
Installation Manual
Plunge into a sparkling clean pool... automatically.™
P/N K498 G

Pool Vac Ultra
INSTALLATION MANUAL
Congratulations on your purchase of the Pool Vac Ultra automatic pool cleaning system from
Hayward. The Pool Vac Ultra is the smart, efficient way to clean your in-ground pool. The Pool Vac
Ultra is powered by your pool's filter system and is designed to work well with most systems.
Therefore the performance of the Pool Vac Ultra in your pool will be relative to that power source.
Because the operation and performance of the Pool Vac Ultra are system reliant, there is a remote
possibility that a “service call” may be necessary to complete the proper installation of your Pool Vac
Ultra. 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 Pool Vac Ultra, including additional hose sections (if
needed) might be applicable to your installation. Consult your Hayward Pool Vac Ultra dealer for price
and availability. or Technical Assistance, call Hayward at 1-800-227-1477 (USA only).
For Your Records
Record the following information for your convenience.
1) Purchase Date ________________________________________________________
2) Serial Number ________________________________________________________
Note
The Pool Vac Ultra 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-installation” condition.

Pool Vac Ultra
OPTIONAL ACCESSORIES
1
The Hayward Skimmer Vac Plate is a great
accessory for achieving a pool cleaning balance that
automatically alternates between skimming the pool’s
surface and vacuuming with each cycle of the filtration
system’s time clock.
Benefits include:
•inger-tip dial control for superior skimmer action and
proper vacuum settings.
•Back-mounted vacuum gauge conveniently located for
simple and accurate vacuum measurements.
•Adjustable standpipe for various skimmer models.
•actory-set pressure relief valve for added safety.
Ruggedly built, the Hayward Leaf
Canister easily connects between
two cleaner hose lengths, trapping
leaves and debris before reaching your
pool’s filter system. Its see-through
design lets you know when to empty.
Benefits include:
•Extra-large basket traps leaves and
debris before they reach the filter
system.
•Superior design ensures that water
will always bypass debris and maintain proper water flow to your pump.
•Easy-open lid provides quick access to the basket.
•Lexan see-through construction lets you see when the basket needs cleaning.

Installation
INSTALLING YOUR POOL VAC ULTRA IS SIMPLE...
2
To prepare your pool for Pool Vac Ultra installation, please follow the easy steps listed below. These instructions
are also shown in the “Pool Vac Ultra Installation Video”. After reading these instructions, the “How To” installation
video 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 Pool Vac Ultra 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 Pool Vac Ultra,
and its performance.
Step 2
Clean or backwash the filter, and clean the hair and lint pot prior to installing the Pool Vac Ultra. ollowing the
installation of Pool Vac Ultra, clean the system at regular intervals according to individual pool conditions.
Step 3
There are nine (9) connector hoses and one (1) leader hose with a hose cuff. The hose cuff has a red sticker
attached to it that reads “REMOVE LABEL A D CO ECT TO CLEA ER”.
Connect the special Pool Vac Ultra 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 section
(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 the
Pool Vac Ultra 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.
Figure 1
TO
POOL VAC ULTRA
ECOND
HO E
ECTION
KIMMER
FIR T
HO E
ECTION
If Optional Leaf Canister is
purchased, install between 1st and
2nd hose sections.

Installation
INSTALLING YOUR POOL VAC ULTRA IS SIMPLE...
3
Step 4
The hose should reach from the skimmer or dedicated vacuum line 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 the Pool Vac Ultra. If the hose is not long enough, it will be necessary to purchase
additional hose sections from your Hayward Pool Vac Ultra dealer. The hose length supplied (40 feet) has been
determined to be sufficient for the majority of pools nationally. 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 low Gauge into the leader hose, then attach the C-Clip of the
gauge onto the first hose section. Make sure the low Gauge is under water. (see igure 2)
Figure 2
V574
FLOW GAUGE
FLOW INDICATOR
(DE IRED PO ITION)
FIR T HO E
ECTION
LEADER HO E C-CLIP
POOL DECK/COPING
TO KIMMER
OR VAC-LOCK
POOL VAC ULTRA
HO E
VO93C
CONE
ADAPTER
Figure 3
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 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.)
MIN
MAX

Installation
INSTALLING YOUR POOL VAC ULTRA IS SIMPLE...
4
Step 6
Check the water flow reading on the low Gauge. (Refer to Step 4, igure 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/toward + until closed/tight), insert the Regulator Valve into the
Skimmer Cone, and insert the hose end into the Regulator Valve (see igure 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 the 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.
Figure 4
VO94
REGULATOR
VALVE
VO93C
CONE
ADAPTER
TO MAIN DRAIN
(if applicable)
TO
PUMP

Installation
INSTALLING YOUR POOL VAC ULTRA IS SIMPLE...
5
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 I CREASE
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 Hayward Pool Vac Ultra Dealer for assistance.
If you have connected your hose to a dedicated vacuum line 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 low Gauge
which is installed in the Pool Vac Ultra hose reads properly (refer to igure 2).
Step 7
Remove the low Gauge from the hose and keep it handy. You will want to use the low Gauge to check
the Pool Vac Ultra's operation from time to time.
Step 8
Check the rear flap adjuster dial at the left rear of the Pool Vac Ultra. It should be set at position number II which
is the middle position (see Figure 5). Submerge the Pool Vac Ultra into the water and 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 Pool Vac Ultra 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 Pool Vac Ultra hose, as this will force air into the
cleaner head, and possibly cause performance problems.

Installation
INSTALLING YOUR POOL VAC ULTRA IS SIMPLE...
6
Step 9
Observe the Pool Vac Ultra in operation, and make sure that the return line flow is not affecting the Pool Vac Ultra's
AquaPilot®programmed steering and preventing the Pool Vac Ultra from cleaning the entire pool. If the Pool Vac
Ultra 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 Pool Vac Ultra to move in its programmed cleaning pattern.
Step 10
Observing the Pool Vac Ultra 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 Pool Vac Ultra
seems to get “hung up”, turn the rear flap adjuster to position I (see Figure 5).
Step 11
The Pool Vac Ultra will climb the vertical walls in swimming pools if there is at least a twelve inch (12") radius
where the walls and floor meet. Pool Vac Ultra'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 Pool Vac Ultra does start up
a wall, it will not always go all the way up the wall. If the Pool Vac Ultra does not seem to be “sticking” to the wall,
turn the rear flap adjuster to position III (see Figure 5).
If the Pool Vac Ultra 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 eighty percent (80%) of the dirt in a concrete pool will be on the floor of the pool.
Approximately twenty percent (20%) of the dirt will be on the walls. Your Pool Vac Ultra will spend its
cleaning time accordingly.
Figure 5
Figure 6

7
Pool Vac Ultra
IMPORTANT TIPS
In one piece fiberglass pools there is very little dirt on the walls, but the Pool Vac Ultra will still climb the walls.
Due to the shape (severe angles) of most in-ground vinyl liner pools, the Pool Vac Ultra 's cleaning is mostly
confined to the bottom (both shallow and deep) and the hopper sides. However, normal dirt and debris do not
adhere to these walls.
DO OT 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 Pool Vac Ultra's ability to move properly in your pool. Coiled
hoses are not covered under the Hayward warranty. When removing the Pool Vac Ultra from your
pool, be sure to grasp the cleaner by its handle, not by its hose, otherwise your Pool Vac Ultra might be
damaged should the hose disconnect from the cleaner.
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 Pool Vac
Ultra (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).

8
Pool Vac Ultra
IMPORTANT TIPS
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 low Gauge
vacuum
gauge by turning the valve toward main drain suction. Usually this valve is the same size as the Pool
Vac Ultra 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 place with
a wedge of some kind so that it won't change position with operation of the Pool Vac Ultra.
2. Periodically check the water flow/vacuum to be sure that the Pool Vac Ultra 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 Pool Vac Ultra hose is securely attached to its suction source (i.e.
Skimmer, Skimmer Vac Plate, Vac Lock, etc.)
4. Disconnect the Pool Vac Ultra 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 Pool Vac Ultra hose. Coiled hose is not covered under the warranty.
6. When the Pool Vac Ultra is out of the pool, always disconnect the leader hose from the Navigator head.
7. Always carry Pool Vac Ultra by the molded-in handle. Do not carry it by the hose.
8. When swimming in the pool, remove Pool Vac Ultra 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.
Figure 7
NAVIGATOR
HO E
VO98 OPTIONAL
HO E ADAPTER
TO MAIN DRAIN
TO PUMP
KIMMER
DIVERTER
VALVE

Pool Vac Ultra
MAINTENANCE TIPS
1. CHECK THE CO DITIO 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 Pool Vac Ultra Tune-Up Kit is available from your dealer. Shoes, wings and flaps may
also be purchased separately.
2. SHOE REPLACEME T:
a) Turn unit upside down.
b) Insert screwdriver between foot and shoe on one of the pods (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.
Figure 8 GOOD HOE
WEAR MARK
WORN HOE
9

10
Pool Vac Ultra
MAINTENANCE TIPS
3. WI G REPLACEME T
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 Pool Vac Ultra 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
Figure 9
POD PLUG
WEAR MARK
Figure 10

Pool Vac Ultra
MAINTENANCE TIPS
4. FLAP REPLACEME T:
a) Remove the front and rear flaps from your Pool Vac Ultra by inserting a small screwdriver between
the flap and the lower body near the pivot point of the flaps (see igure 11).
b) You will notice that your replacement flaps look similar but are marked “ ront” 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. ailure to do so will result in unsatisfactory performance of the Pool Vac
Ultra. When installing the front flap, be sure that the extended leg of the spring is inserted into the notch an
the front of the lower body (see igure 12). Push the flap in place. You will actually feel and hear a snap
when the flap is in place. old the flap in towards the bottom of the Pool Vac Ultra. 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).
Figure 11
Figure 12
FRONT REAR
CAM
BOTTOM OF CLEA ER
BOTTOM OF CLEA ER
11

12
Pool Vac Ultra
MAINTENANCE TIPS
5. POOL VAC ULTRA BUMPER REPLACEME T:
Replacement of the Pool Vac Ultra Bumper is not recommended as a “Do It Yourself” repair, because there is a
slight possibility that the replacement might cause a problem in the propulsion system. We strongly suggest that
you consult your Hayward Pool Vac Ultra dealer for this repair.
A #2 Phillips screwdriver is necessary for this repair.
a) Turn off pump.
b) Remove Pool Vac Ultra from pool.
c) Disconnect Pool Vac Ultra from leader hose.
d) Turn Pool Vac Ultra upside down, and place it in a position that is steady/firm.
e) Locate and loosen the captive screw behind the throat in the center of the bottom
(see Figures 13, 14 & 15).
Figure 13
BUMPER
CAPTIVE CREW
LOWER BODY
A EMBLY
FRONT
FLAP

Pool Vac Ultra
MAINTENANCE TIPS
f) Lift “Easy Opening Bottom” (see igures 14 & 15).
g) Remove four (4) “A” screws (see igure 13).
h) Lift the Lower Body Assembly off the Pool Vac Ultra (see igure 13).
i) Remove four (4) “B” screws (see igure 13).
j) Remove bumper carefully, making sure that other cleaner parts are not moved or disturbed.
k) Remove two (2) “C” screws (see igure 13).
l) Replace bumper, again making sure that other cleaner parts are not moved or disturbed.
m)Reinstall screws and parts, following steps in reverse - k, i, h, g, f, e, d, c.
n) Reinstall Pool Vac Ultra in pool per installation instructions and/or installation video.
Figure 14 - Pool Vac Ultra Concrete
CAPTIVE CREW
CAPTIVE CREW
Figure 15 - Pool Vac Ultra Vinyl
BOTTOM OF CLEA ER
BOTTOM OF CLEA ER
13

Removal Instructions
14
“EASY OPENING BOTTOM”
6. “EASY OPE I G 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 Pool Vac Ultra 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 12 and 13 of this manual.
1. Turn off pump.
2. Remove Pool Vac Ultra from pool.
3. Disconnect Pool Vac Ultra from leader hose.
4. Turn Pool Vac Ultra upside down.
5. Locate and loosen the captive screw behind the throat in the center of the bottom (see Figures 14 and 15).
6. Lift “Easy Opening Bottom” (see Figures 14 and 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 igures 14
and 15. Then slide the cover in place and tighten the captive screw.
10. Reinstall Pool Vac Ultra in pool per installation instructions and/or installation video.
Figure 16
TURBI E/VACUUM CHAMBER

Pool Vac Ultra
TROUBLESHOOTING GUIDE
CAUSES SOLUTIONS
Lack of/improper water flow through cleaner Check water flow with low Gauge and adjust as
per Step 6, igure 2.
Partial blockage of Pool Vac Ultra throat Clear blockage
Worn shoes Replace shoes
Worn wings Replace wings
Improper cleaner model for application Call 1-800-227-1477 (U.S.A. only)
Problem: Slow/no forward movement
CAUSES SOLUTIONS
Improper shoes for application Call 1-800-227-1477 (U.S.A. only)
Lack of/improper water flow through cleaner Check water flow with low Gauge and adjust as
per Step 6, igure 2.
Partial blockage of Pool Vac Ultra 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 III
Problem: Cleaner fails to climb vertical walls gunite/concrete pool
15

16
Pool Vac Ultra
TROUBLESHOOTING GUIDE
CAUSES SOLUTIONS
Too much/improper water flow through cleaner Check water flow with low Gauge and adjust per
instructions in Step 6.
Improper tension on rear flap Turn rear flap adjuster to I
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
Problem: Cleaner climbs to water surface and sucks air
CAUSES SOLUTIONS
Head buoyancy Refer to this manual to ensure enough hose
lengths are installed
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
The cleaner head is actually being pulled or lifted Readjust return lines to prevent water flow from
off the bottom of the pool by the cleaner hose, interfering with cleaner head and/or hose
of return line flow - either at the surface or at the
bottom of the pool - or both
Problem: Cleaner head “floats”

Pool Vac Ultra
TROUBLESHOOTING GUIDE
CAUSES SOLUTIONS
Improper water flow Check water flow with low Gauge and adjust as
per Step 6, igure 2.
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 I NECESSARY. DO NOT ATTEMPT TO RETIGHTEN LOOSE PODS.
c) check medium turbine and spindle gear
assemblies
Problem: Cleaner sticks at steps, corners, etc.
17

18
Pool Vac Ultra
DISCLAIMER
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 Pool Vac Ultra - not vice
versa.
E) Vinyl is affected by age, sunlight and water chemistry.
) Vinyl can become brittle and weak.
G) Vinyl can also be affected by the installation and the pool's surroundings.
H) When installing the Pool Vac Ultra, you must assume all responsibility for the condition of the pool and the
pool's surroundings.
To better serve you, please have the following information available if you call Hayward's
Technical Service Department at 1-800-227-1477 (U.S.A. only):
1) The Purchase Date of your Pool Vac Ultra.
2) The Serial Number of your Pool Vac Ultra.
3) The number of Hose Sections used.
4) A current water flow indicator setting (refer to Step 6 , igure 2).