Page 1
Copyright 2010 Hayward Industries Inc.
Robotic Cleaner Troubleshooting Guide
Page 2
Table of Contents
TigerShark & TigerShark QC
Important safety instructions Page 1
Service Tools Page 2
Filter Removal/Cleaning and Drain Flaps Pages 4-6
Handle Removal Page 7
Venturi Removal Page 8
Bottom Lid Disassembly Pages 9-10
Side Cover Removal Pages 11-12
Drive Track and Idlers Pages 13-16
Power Cord and Motor Box Pages 17-27
Wheel Tube Brush and Bearings Pages 28-30
Using the Scanner Tool Pages 31-34
Power Supply and Flotation Cord Testing Page 35
Basic Operation Pages 36-37
Troubleshooting Pages 38-43
Page 3
Table of Contents Continued
SharkVAC & E-Vac
Service Tools Page 44
Power Supply Page 45
Filter Removal Pages 46-47
Filter Replacement Page 48
Wheel and Tire Removal Page 49
Side Cover Removal Page 50
Drive Track and Idlers Page 51
Main Drive Pulley Removal Page 52
Wheel Tube Removal Page 53
Wheel Tube Brush Page 54
Power Cord Removal Pages 55-60
Motor Box Removal Pages 61-62
Power Supply and Flotation Cord Testing Page 63
Troubleshooting Pages 64-68
Page 4
Safety
!
Page 1
Page 5
Service Tools
Scanner
Torx DriverTorx Bit Spanner Tool
Torque DriverPin Removal Tool
Page 2
Page 6
Power Supply
On/Off Switch - Lighted
Flotation Power Cord Connector
Page 3
Power Cord
Quick Clean LED
(QC Models Only)
Full Cycle Button
and LED
(QC Models Only)
Page 7
Disassembly – Filter Removal
Remove bottom lid by sliding
LH and RH latch towards center.
Bottom lid removed providing
access to filter cartridge assembly
Page 4
Page 8
Filter cartridge removed
Filter Removal
Page 5
Note the drain flaps, one per side. Not
required to remove for filter cleaning, but
visually inspect when filter is removed.
Page 9
Filter cartridge assembly Filter elements removed
Note: Elements must be installed with support ribs facing outward
Filter Removal
Page 6
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.
Spring cleanup filter
elements. For temporary use
in heavy spring cleaning.
Page 10
Handle removal
1 screw each end
Handle removed
Note: Handle is watertight.
If water is heard sloshing around
in handle it must be replaced.
Handle Removal
Page 7
Page 11
Rotate CCW & lift out Removed, access to impeller
Venturi Removal
Page 8
Page 12
Bottom lid assembly. Pull up
to remove inlet cover.
Inlet cover removed
Bottom Lid Disassembly
Page 9
Page 13
Inlet flaps, check for
free movement.
Inlet flaps removed
for inspection.
Bottom Lid Disassembly
Page 10
Page 14
Bottom view with bottom lid
and filter assembly removed.
Motor assembly Power cordMotor output shaft.
Drive end.
7 screws each end to remove
for side plate removal, drive side.
Power cord end, 7 screws.
Note: Use Torx bit and power driver for removal.
Power cord end
Side Cover Removal
Page 11
Page 15
Screw removal
Side cover removed
Note that ‘drive side’ or motor output
side is side opposite
of where power cord enters unit.
Side Cover Removal
Page 12
Page 16
Drive track removed Track idler pulley (2/side)
Note that flange faces inward.
Drive Track & Idler Pulley Removal
Drive Side
Page 13
Bearings should rotate smoothly
and freely.
Check for missing/broken drive
cogs on inner loop of belt and also
for cracks in belt.
Page 17
Main drive pulley, motor
output side only
Note drive ‘key’ in pulley and
how it mates to the output
shaft drive pin of the motor.
Main Drive Pulley Removal
Page 14
Page 18
Carefully pull wheel tube
away from other side plate.
Roller will slide off track.
Both drive tubes removed.
Wheel Tube Removal
Page 15
Page 19
Screw removal, opposite side cover,
non-drive side.
Side cover removed
Track idler pulleys, (3). Note
this side does not have a keyed drive pulley
at the center pulley since it is opposite the
motor drive end. This pulley is simp ly
an idler pulley similar to the ones to the left
and right.
Drive Track & Idler Pulley Removal
Non-drive Side
Page 16
Page 20
Remove strain relief
cover plate.
Plate removed showing
strain relief system.
Power Cord & Motor Box Removal
Page 17
Page 21
Use spanner wrench and
Torque driver to remove
threaded plug securing
power cord into motor assembly.
CCW removal.
Threaded plug removed
Power Cord & Motor Box Removal
Page 18
Page 22
Gently pull on cord to
disconnect and remove from motor.
Note that plug has taper on bottom side
to mate with rubber seal taper.
Power Cord & Motor Box Removal
Page 19
Note: Any time seal is removed
it is recommended to replace
special rubber seal.
Page 23
Carefully insert pin removal tool
into power cord connector. Push
wires up into connector as far
as possible.
While holding connector firmly, depress
button on pin removal tool to remove
electrical connector pin from housing.
Power Cord & Motor Box Removal
Page 20
Page 24
Power cord electrical pins
removed from connector. Note that white
wire goes on tab side of connector.
Connector, seals and
washers removed.
Power Cord & Motor Box Removal
Page 21
Page 25
Connector must be installed with tab on
connector placed in mating hole of motor
assembly. The white wire must be inserted
on the tab side of the connector.
Note the order of the seals and washers.
Remember to mate the taper of the seal
and threaded plug.
Use the Torque driver and spanner wrench to install
and tighten the threaded plug. Tighten the threaded
plug until you feel the Torque wrench click or slip.
Power Cord & Motor Box Removal
Page 22
Page 26
Gently route power
cord out from unit.
Power cord removed.
Power Cord & Motor Box Removal
Page 23
Page 27
Remove 4 motor assembly
screws 2 from each end.
Location of motor screws when side cover is not
removed. It is possible to remove motor assembly
without removal of side cover. However, the 7 side
cover screws must be loosened on the motor
drive side.
Power Cord & Motor Box Removal
Page 24
Page 28
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,
2 each side and loosen side cover screws before attempting this.
Power Cord & Motor Box Removal
Page 25
Page 29
Rotate motor slightly to remove drive output shaft
from side of unit, then lift out motor assembly.
Power Cord & Motor Box Removal
Page 26
Page 30
Motor assembly removed.
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.
Output shaft key on motor, mates with drive gea r.
Impeller removal
Power Cord & Motor Box Removal
Page 27
Page 31
Remove wheel tube from machine Remove 2 small
phillips screws
securing roller
bearing to tube
Bearing assembly will slip off tube
Wheel Tube Bearings
Page 28
Bearings should rotate smoothly
and freely.
Page 32
Wheel Tube Brush
Brush replacement can be done leaving the machine
assembled or broken down. Unsnap the tabs, these
run length wise of the brush.
Page 29
Page 33
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.
Wheel Tube Brush
Page 30
Foam roller
Page 34
Initializing………….
Please wait
Scanner Setup
Power cord to cleanerScanner male end
Scanner female end
Power switch on
Startup Screen
Using The Scanner Tool
Page 31
Page 35
Motor ON Time
4 Hours
Power ON Time
12 Hours
Total Cycles Run
28 Cycles
Number of hours the unit has spent
in the 4 hour cleaning cycle mode.
The combined total number of hours the
unit has spent with the power switch on.
Includes both hours accumulated in ‘Motor
On Time’ and hours inactive after the cleaning
cycle has been completed.
The total number of times the power switch
was turned on to run the unit. This will not
necessarily represent the complete cleaning
cycles run.
Using The Scanner Tool
Page 32
Page 36
Pump Overcurrent
0 Times
Out of Water
0 Times
The number of times the unit has realized
a low load on the pump motor.
Out of Water Causes
1. Attempting to run the unit out of the water/pool.
2. Air trapped in the filter after placing the unit in the water.
3. Bench testing in manufacture or repair.
4. Machine climbing too high above the waterline.
5. Low voltage at power source.
6. Low voltage from use of an extension cord.
7. Worn or defective pump motor, drawing less than 1
amp at 24 volts.
Number of times the pump motor has realized
an over load condition. Unit will stop after 3-5
seconds in this condition.
Pump Over Current Causes
1. Debris around the pump impeller. Remove impeller and
inspect for hair or grass around pump shaft.
2. Defective pump motor. Motor should turn smoothly by
hand with only a slight resistance from the shaft seals.
Using The Scanner Tool
Page 33
Page 37
Water Detected
0 Times
Drive Overcurrent
0 Times
Drive Over Current Causes
1. Unit caught under a ladder
2. Debris caught in traction drive
belt and or pulleys under side cover.
3. Riding or standing on unit during operation.
4. Defective wheel tube bearings or side cover idler bearings
5. Defective drive motor.
Number of times the water has
contacted the sensor inside the
motor box. Continuous
contact will stop operation of the
unit. Severe water damage will
cause a ‘Communication Failure’
when hooked to the scanner.
Using The Scanner Tool
Page 34
Number of times the drive motor has re alized
an over load condition. Unit will stop after 3-5
seconds in this condition.
Page 38
Communication
Failure
Check Power and
Connections
Communication Failure Causes
1. Damaged power supply, check for 21-25 volts DC
2. Water inside power connection to motor box, check
seal at motor box and for breaks in flotation hose
3. Damaged flotation cord, check for ohms reading of .4 to .8 ohms
Circuit failure between power supply and
and the PCB (printed circuit board)
in the motor assembly box.
DC voltage test on power
supply
21 to 25 volts dc is acceptable.
The power
supply is not repairable and
must be replaced
if defective.
Insert voltage probes in pin terminal 1 and 2 and
turn on power supply to test.
Flotation cord test. Remove cord from
motor box and check ohm’s reading
between each pin and wire end. .4 to
.8 ohm’s is acceptable.
Testing Power Supply & Flotation Cord
Page 35
Page 39
• Machine will sequence between pump and drive motor for up to 1 minute.
• During this time the microprocessor is sampling motors for proper electrical load.
¾Startup
Troubleshooting
• At about 2 minutes the machine will begin mapping the immediate section of the pool.
• Wall climbing will be every other floor pass and the time on the wall climb will
be random.
• The pattern is not permanently imbedded and will be reconfigured with each
use of the cleaner.
¾Mapping Sequence
¾Wall Climbing
• Once in the cleaning cycle the machine will typically perform a wall climb every
other floor pass and vary the amount of time on the wall.
• At random the machine will perform a free fall from the wall to aid in random
navigation.
• The startup of each 4 hour cycle may require up to 30 minutes as the machine
measures the pool configuration before climbing the walls completely to the water line.
Page 36
Page 40
¾In Process Mapping
• As the unit encounters large changes in pool configuration it will revert to the
mapping process for a few passes to adjust itself to the change in shape.
• Mapping will take several passes and is undetectable from normal operation.
¾Navigation
• The unit navigates itself primarily by running in a diagonal direction at the water line.
• This is the key to complete pool coverage.
¾Shutdown
• The machine will shut down after 4 hours for the standard TigerShark.
• TigerShark QC will shutdown after 90 minutes if the Quick Clean LED is
illuminated, or after 4 hours if “Full Cycle” is selected.
Page 37
Troubleshooting
• 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 41
¾Will not climb walls
• Pool condition is unacceptable for cleaner use. Sweep walls, vacuum pool, balance
chemicals and algaecide to an acceptable swimming condition. Resume use of
TigerShark for pool maintenance as often as required.
• Increase frequency of TigerShark filter cleaning, especially during the initial use.
Filter may have to be cleaned 30 minutes to 3 hours in the first few cycles until the
pool is in an acceptable condition.
• Algae on pool walls. Brush walls and chemically treat for algae. Increase frequency
of TigerShark use and filter maintenance.
• D.E. or sand filter leak. The primary pool filter may leak diatomaceous earth or fine
sand that can overload the filter. Service and inspect the pool filter system, vacuum
the pool and resume use of the TigerShark for pool maintenance.
Filter Too Dirty to Allow Proper Machine Performance
Filter Too Dirty to Allow Proper Machine Performance
Page 38
Troubleshooting
Page 42
¾Will not climb walls
Pool design or configuration
Pool design or configuration
• Broken impeller. Inspect and replace it if required. Inspect for tears that may allow
objects to pass through and entangle or damage the impeller.
• Defective pump motor can be identified by a slow or non-rotating impeller. Replace
the motor box assembly.
Machine problem
Machine problem
Page 39
Troubleshooting
• The pool bottom corner design may be too sharp. Some pool designs feature a
sharp, 90 degree bottom corner. A guideline for the best machine performance is a
corner radius similar in contour to a basketball. In a clean
pool the machine symptom
will be movement to the wall with repeated bumping and infrequent climbing, The
PVC rollers can be replaced with foam rollers only if a dirty pool condition is
ruled out.
• Clean
vinyl or tile pool surface is too slick. Replace the PVC rollers with foam rollers
only if a dirty pool condition is ruled out.
Page 43
Page 40
¾Will not climb walls
Confusion on normal operation
Confusion on normal operation
¾Climbs Too High, Falls off Wall at Waterline, Blows Air
Bubbles Through the Exit Venturi
• Above average traction in a clean pool. Install the Restrictor Plate Kit RCX11206 in
the venturi.
• Inspect bottom lid filter plate gasket and replace if torn or missing.
• Set handle position at an angle, machine should never operate with the handle in the
center or straight position.
• Check water chemical balance.
Troubleshooting
• The startup of each 4 hour cycle may require up to 30 minutes as the machine
measures the pool configuration before climbing the walls completely to the water
line.
• During the 4 hour cycle the machine will randomly re-measure the pool configuration
or release itself from the wall. The machine will not climb the walls during this 15-30
minute cycle.
Page 44
¾Runs only a few seconds or minutes
• Alternate handle position with each use.
• Be sure machine is not getting caught on obstructions in the pool such as raised
drains, in floor cleaning heads, toys, etc.
¾Cord twisting
Troubleshooting
Page 41
• 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.
• If using an extension cord, test for proper voltage. An extension cord is not
recommended.
• Check for missing or broken impeller blades.
• Check for pump impeller obstruction.
• Check pump impeller for hard rotation and pump motor binding.
Page 45
¾No movement but impeller turns
• Check with the scanner for communication failure, see scanner section to diagnose.
• Check for impeller obstruction.
• Check for broken blades.
• Check electrical source for proper voltage range of 115-125v, including extension
cord if used.
¾No movement and no pump discharge
• 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. The Scanner will display a Drive Over Current signal if the machine has
been caught on an obstruction.
• Check for belt or roller obstruction
• Check for broken impeller
• Check for missing roller tube bearing screws, 2 per side.
Troubleshooting
Page 42
Page 46
¾Debris falls from unit when removed from pool
Troubleshooting
Page 43
• 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. Avoid dropping or
throwing machine into the pool.
Page 47
Service Tools
Torx Drivers
T-10 & T-25
(not supplied)
Torx Bit
T-20
(not supplied)
Spanner Tool
Torque Driver
Pin Removal
Tool
Power Driver (not supplied)
Page 44
Belt Installation Tool
Page 48
Power Supply
On/Off Switch - Lighted
Flotation Power Cord Connector
Page 45
Power Cord
Installation
and Care
Instructions
Page 49
Filter Removal
Press Dome Button
to lift Dome for filter removal.
Page 46
Filter cartridge removed Filter Bucket Housing
Lift to remove Filter Bucket
Housing
Page 50
Filter Removal
Page 47
Note: Elements can be cleaned by gently spraying
with a garden hose. Be careful not to use high
pres
sure or this may damage the element.
Spring cleanup filter
elements. For temporary use
in heavy spring cleaning.
Open filter doors by pushing the tabs
toward the outside and then pulling up.
Lift filter cartridges out.
Page 51
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 48
Page 52
Wheel and Tire Removal
Remove wheel cap to access screw
holding wheel on axel.
Unscrew T25 screw
Remove wheel from axel. Notice how wheel and axel mate.
Page 49
Page 53
Top view with bottom lid
and filter assembly removed.
Motor assemblyPower cord Motor output shaft.
Drive end.
4 T20 screws each side to remove
for side plate removal.
Side Cover Removal
Page 50
Impeller
Drive side view with cover removed.
Page 54
Track idler pulleys
Note that flange faces inward.
Drive Track & Idler Pulley Removal
Drive Side
Page 51
Bearings should rotate smoothly
and freely.
Check for missing/broken drive
cogs on inner loop of belt and also
for cracks in belt.
Page 55
Main drive pulley, motor
output side only
Note drive ‘key’ in pulley and
how it mates to the output
shaft drive pin of the motor.
Main Drive Pulley Removal
Page 52
Page 56
Carefully pull wheel tube away from
wheel axels.
Wheel Tube Removal
Page 53
Unscrew T20 screws from each side of roller.
Rear Tube
Front Tube
Page 57
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.
Wheel Tube Brush
Page 54
Brush replacement can be done
leaving the machine assembled or
broken down. Unsnap the tabs that run
length wise of the brush.
Removal Replacement
Page 58
Remove strain relief cover plate. Plate removed showing strain relief system.
Power Cord Removal
Page 55
Use spanner wrench and Torque
driver to remove threaded plug.
Threaded plug removed
Page 59
Gently pull on cord to
disconnect and remove from motor.
Note that plug has taper on bottom side
to mate with rubber seal taper.
Power Cord Removal
Page 56
Note: Any time seal is removed
it is recommended to replace
special rubber seal.
Page 60
Push wires up into connector as far
as possible. Carefully insert pin removal tool
into power cord connector.
While holding connector firmly, depress
button on pin removal tool to remove
electrical connector pin from housing.
Power Cord Removal
Page 57
Page 61
Power cord electrical pins
removed from connector. Note that white
wire goes on tab side of connector.
Connector, seals and washers removed.
Power Cord Removal
Page 58
Page 62
Connector must be installed with tab on
connector placed in mating hole of motor
assembly. The white wire must be
inserted on the tab side of the connector.
Note the order of the seals and
washers. Remember to mate the
taper of the seal and threaded plug.
Use the Torque driver and spanner wrench to install
and tighten the threaded plug. Tighten the threaded
plug until you feel the Torque wrench click or slip.
Power Cord Removal
Page 59
Page 63
Gently route power
cord out from unit.
Power cord removed.
Power Cord Removal
Page 60
Page 64
Motor Box Removal
Page 61
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.
Page 65
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.
Motor Box Removal
Page 62
Rotate motor slightly to remove drive output shaft
from side of unit, then lift out motor assembly.
Page 66
Communication Failure Causes
1. Damaged power supply, check for 21-25 volts DC
2. Water inside power connection to motor box,
check seal at motor box and for breaks in
flotation hose
3. Damaged flotation cord, check for ohms reading
of .4 to .8 ohms
DC voltage test on power supply
21 to 25 volts dc is acceptable. The power
supply is not repairable and must be replaced
if defective.
Insert voltage probes in pin terminal 1 and 2 and
turn on power supply to test.
Flotation cord test. Remove cord from
motor box and check ohm’s reading
between each pin and wire end. .4 to
.8 ohm’s is acceptable.
Testing Power Supply & Flotation Cord
Page 63
Page 67
• Machine will sequence between pump and drive motor for up to 1 minute.
• During this time the microprocessor is sampling motors for proper electrical load.
¾Startup
Troubleshooting
• At about 2 minutes the machine will begin mapping the immediate section of the pool.
¾Mapping Sequence
• The pattern is not permanently imbedded and will be reconfigured with each
use of the cleaner.
Page 64
¾In Process Mapping
• As the unit encounters large changes in pool configuration it will revert to the
mapping process for a few passes to adjust itself to the change in shape.
• Mapping will take several passes and is undetectable from normal operation.
Page 68
¾Navigation
• The unit navigates itself primarily by running in a diagonal direction at the water line.
• This is the key to complete pool coverage.
¾Shutdown
• The machine will shut down after 2 hours.
• 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 65
Troubleshooting
¾Cleaner flips upside down and continues to run
• The machine should correct itself and flip upright.
• Check for water in handle. Replace if necessary.
• Replace motor.
Page 69
¾Runs only a few seconds or minutes
• Be sure machine is not getting caught on obstructions in the pool such as raised
drains, in floor cleaning heads, toys, etc.
¾Cord twisting
Troubleshooting
Page 66
• 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.
• If using an extension cord, test for proper voltage. An extension cord is not
recommended.
• Check for missing or broken impeller blades.
• Check for pump impeller obstruction.
• Check pump impeller for hard rotation and pump motor binding.
Page 70
¾No movement but impeller turns
• Check for impeller obstruction.
• Check for broken blades.
• Check electrical source for proper voltage range of 115-125v, including extension
cord if used.
¾No movement and no pump discharge
Troubleshooting
Page 67
• 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
• Check for broken impeller
• Check for missing roller tube bearing screws, 2 per side.
Page 71
¾Debris falls from unit when removed from pool
Troubleshooting
Page 68
• 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. Avoid dropping or
throwing machine into the pool.
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