Polaris Vac-Sweep 380 Handbook

Serial Number

Shown from opposite side.

No. Part# Description Qty.

19-100-1014All Purpose Bag 1 29-100-1152Housing, Turbine Upper 1 39-100-1114Hub Cap 3 49-100-5107E-clip, Stainless Steel 10 59-100-1108Ball Bearing 8 6C-10Tire, White 3 79-100-1008Wheel, Double-side 2 89-100-1017Belt Kit, Small and Large 1

99-100-7011Shield, Bearing 3 10 9-100-1005 Frame, Exchange Only 1 11 9-100-5117 Screw, 8-32 x 3/8" S/S Pan Head 11 12 9-100-1139 Axle Block Assembly 2 13 9-100-1010 Belt Divider, Transfer Pulley 1 14 B-25 Orifice Tip with Orifice Tip Guard 1 15 9-100-1007 Transfer Pulley/Drive Shaft Assembly 1 16 9-100-5115 Screw, 8-32 x 3/4" S/S Pan Head 5 17 9-100-5130 Lock Washer, Axle Block 4 18 9-100-1132 Drive Train Gear Kit w/Turbine Bearing 1 19 9-100-1103 Turbine Wheel with Bearing 1 20 9-100-1116 Wheel, Single-side 1 21 C-131 Thrust Jet Kit 1 22 9-100-7008 Sweep Hose Barb Complete 1 23 B-20 Adjustment Screw, Sweep Hose 1 24 B-15 Sweep Hose Attach Clamp, White 1 25 9-100-9004 Base Weight 1 26 9-100-7170 Hose Clamp for WMS 6 27 9-100-7009 Jet Retainer 2 28 9-100-7010 Water Management System (WMS) 1 29 9-100-1155 Housing, Turbine Lower 1 30 9-100-3105 Sweep Hose Scrubber 1 31 9-100-5132 O-ring, In-head Timer/Feed Pipe Assy 1 32 9-100-7016

Base Assy for In-line Back-up Valve, White

1 33 9-100-1141 Top Cover, Double Wheel Side 1 34 9-100-7003 Feed Pipe/Timer Blank Assembly 1 35 A-20 Float, Head 1 36 9-100-1140 Top Cover, Single Wheel Side 1 37 B-5 Sweep Hose Complete 1 38 B-10 Wear Rings 8 39 9-100-1018 Bag Collar 1

To insure proper operation and long life for the Polaris, be sure to insist on genuine Polaris parts.

380 EXPLODED PARTS DIAGRAM

To insure proper operation and long life for the Polaris, be sure to insist on genuine Polaris parts.

*Not sold separately.

380 HOSE PARTS DIAGRAM

No. Part# Description Qty.

40 9-100-9001 UWF Connector Assembly 1 41 10-108-00 UWF Restrictor Kit 1 42 6-500-00 Universal Wall Fitting (UWF) 1 43 6-504-00 Filter Screen, UWF/QD 1 44 6-505-00 O-ring, UWF/QD 1 45 9-100-9002 Pressure Relief Valve, Black 1 46 D-29 Quick Disconnect, UWF 1 47 D-15 Nut, Feed Hose 10 48 * Adapter Hose, 8-1/2" 1 49 D-20 Swivel, Ball Bearing 3 50 D-10 Float, Feed Hose 9 51 D-45 Feed Hose, White, 10 Foot, Hard 2 52 D-50 Feed Hose, Clear, 10 Foot, Soft 1 53 G-52 Back-up Valve Kit 1 54 G-54 Case Kit for G-52 1 55 G-57 Collar, Back-up Valve 1 56 G-53 Mechanism for G-52 1

Parts Not Shown

G-5 Feed Hose Complete w/UWF,

No Back-up Valve

G-9 Coupling, 1 1/2" NPTF x 3/4" NPTM 9-100-3104 Feed Hose with Floats, White 9-100-3108 Feed Hose with Floats, Clear 9-100-9003 Street Ell

iii

Pool Wall

45 46444341 47 48 47 49

10-foot Clear Hose

Second 10-foot

White Hose

55 56

First 10-foot White Hose

50 51

To The

Polaris

No. Part# Description Qty.

99-100-7011Shield, Bearing 3 10 9-100-1005 Frame, Exchange Only 1 11 9-100-5117 Screw, 8-32 x 3/8" S/S Pan Head 11 12 9-100-1139 Axle Block Assembly 2 13 9-100-1010 Belt Divider, Transfer Pulley 1 14 9-100-3135 Collar, Bag Tie 1 15 9-100-1007 Transfer Pulley/Drive Shaft Assembly 1 16 9-100-5115 Screw, 8-32 x 3/4" S/S Pan Head 5 17 9-100-5130 Lock Washer, Axle Block 4 18 9-100-1132 Drive Train Gear Kit w/Turbine Bearing 1 19 9-100-1103 Turbine Wheel with Bearing 1 20 9-100-1116 Wheel, Single-side 1 21 C-131 Thrust Jet Kit 1 22 9-100-7008 Sweep Hose Barb Complete 1 23 B-20 Adjustment Screw, Sweep Hose 1 24 B-15 Sweep Hose Attach Clamp 1 25 9-100-3005 Base Weight 1 26 9-100-7170 Hose Clamp for WMS 6 27 9-100-7009 Jet Retainer 2 28 9-100-7014 Water Management System (WMS) 1 29 9-100-1155 Housing, Turbine Lower 1 30 9-100-3105 Sweep Hose Scrubber 1 31 9-100-5132 O-ring, In-head Timer/Feed Pipe Assy 1 32 9-100-7016

Base Assy for In-line Back-up Valve, White

1 33 9-100-1141 Top Cover, Double Wheel Side 1 34 9-100-1002 Feed Pipe/Timer Blank Assembly 1 35 A-20 Float, Head 1 36 9-100-1140 Top Cover, Single Wheel Side 1 37 9-100-1011 Sweep Hose Complete 1 38 B-10 Wear Rings 7

To insure proper operation and long life for the Polaris, be sure to insist on genuine Polaris parts.

360 EXPLODED PARTS DIAGRAM

Serial Number

Shown from opposite side.

To insure proper operation and long life for the Polaris, be sure to insist on genuine Polaris parts.

*Not sold separately.

360 HOSE PARTS DIAGRAM

No. Part# Description Qty.

39 9-100-3008 UWF Connector Assembly 1 40 6-500-00 Universal Wall Fitting, UWF 1 41 6-504-00 Filter Screen, UWF/QD 1 42 6-505-00 O-ring, UWF/QD 1 43 9-100-3009 Pressure Relief Valve, White 1 44 9-100-3006 Quick Disconnect, UWF 1 45 9-100-3109 Hose Nut 12 46 9-100-3102 Feed Hose, 6 Foot 4 47 9-100-3002 Swivel, Hose 4 48 9-100-1206 Float, Feed Hose 3 49 9-100-1200 In-line Back-up Valve 1 50 9-100-1202 Case Kit, In-line Back-up Valve 1 51 G-57 Collar, Back-up Valve 1 52 9-100-1204 Mechanism, In-line Back-up Valve 1 53 9-100-3103 Feed Hose, 1 Foot 1 54 * Pressure Tester 1

Parts Not Shown

9-100-3100 Feed Hose Complete w/UWF,

No Back-up Valve

9-100-9003 Street Ell

vii

REPLACEMENT PARTS TO STOCK

All parts are interchangeable between the 380 and 360 except where noted.

Name Part # Polaris 380/360 Tune-up Kit 9-100-9010 Polaris 380 Rebuild Kit 9-100-9030

Polaris 360 Rebuild Kit 9-100-9060

380 In-line Back-up Valve Conversion Kit 9-100-9040

360 In-line Back-up Valve Conversion Kit

9-100-3200 360 Pressure Gauge Kit 9-100-6400 360 In-line Back-up Valve Case Kit 9-100-1202

*All Purpose Bag 9-100-1014 *Wheel, Single-side 9-100-1116 *Wheel, Double-side 9-100-1008 *Transfer Pulley/Drive Shaft Assembly 9-100-1007 *Axle Block Assembly 9-100-1139 *Drive Train Gear Kit w/Turbine Bearing 9-100-1132 *Belt Kit, Small and Large 9-100-1017 *Sweep Hose Scrubber 9-100-3105 *Tire, White C-10 *E-clip, Stainless Steel 9-100-5107 *O-ring, In-head Timer/Feed Pipe Assy. 9-100-5132 *Hub Cap 9-100-1114 *Ball Bearing 9-100-1108 *Hose Clamp for WMS 9-100-7170 *Housing, Turbine Upper 9-100-1152 *Shield, Bearing 9-100-7011 **380 Back-up Valve Kit G-52 **380 Base Weight 9-100-9004 **Jet Retainer 9-100-7009 **Sweep Hose Attach Clamp, White B-15 **Feed Pipe/Timer Blank Assembly 9-100-7003 **380 Sweep Hose Complete B-5 **Adjustment Screw, Sweep Hose B-20 **Thrust Jet Kit C-131 **Top Cover, Single Wheel Side 9-100-1140 **Top Cover, Double Wheel Side 9-100-1141 **Housing, Turbine Lower 9-100-1155 **Sweep Hose Barb Complete 9-100-7008 **380 Water Management System 9-100-7010

Pool Wall

40 41

To The Polaris

Diagrams

380 Exploded Parts Diagram..................................i

380 Hose Parts Diagram........................................ii

360 Exploded Parts Diagram................................iv

360 Hose Parts Diagram.......................................vi

Replacement Parts to Stock.....................................vii

I. Introduction ................................................................2

Serviceman’s Tools ...............................................2

II. Installation Basics

380 Installation Basics...........................................3

360 Installation Basics...........................................6

III. Head Adjustments and Functions............................10

IV. Troubleshooting Over the Phone.............................11

V. Troubleshooting On the Bench ................................14

VI. Troubleshooting Procedures Poolside

380 Poolside Procedures ....................................17

360 Poolside Procedures ....................................18

VII. Problem/Solution Troubleshooting ........................20

VIII. How to Check and Service ......................................25

A. Pressure ..........................................................25

B. Wheel RPM .....................................................26

C. Water Flow Diagram .......................................28

D. Jets..................................................................29

E. Drive Jet ..........................................................29

F. In-line Back-up Valves ....................................32

G. In-head Back-up Timer ...................................31

H. Converting an In-head Timer to an

In-line Back-up Valve ......................................32

I. Drive Train.......................................................33

J. Hose Length....................................................34

IX. Part Removal and Replacement..............................35

A. Single-side Wheel ...........................................35

B. Drive Train Removal & Replacement .............35

C. Double-side Wheels........................................36

D. Drive Belts.......................................................37

E. Water Management System ...........................38

F. Frame Exchange.............................................38

G. Transfer Pulley/Drive Shaft Assembly............39

H. Gear Kit ...........................................................40

X. Polaris Booster Pump ..............................................41

A. Exploded Parts Diagram .................................41

B. Installation Basics ...........................................42

C. Problem/Solution Troubleshooting .................43

D. Seal Replacement...........................................45

XI. Index ........................................................................47

viii

**Base Assembly, White 9-100-7016 **Float, Head A-20 UWF Restrictor Kit 10-108-00 Float, Feed Hose D-10 Wear Rings B-10 Universal Wall Fitting 6-500-00 Mender Nut, Feed Hose D-15 Swivel, Ball Bearing D-20 Filter Screen, UWF/QD 6-504-00 Quick Disconnect, UWF D-29 Pressure Relief Valve, Black 9-100-9002 Pressure Relief Valve, Red D-28 Screw (Axle Blocks, Tops) 9-100-5115 Screw 9-100-5117 In-head Timer Assembly 9-100-7006 Pump Seal P-55 Impeller P-15 Pump Motor P-61

360 Base Weight 9-100-3005 360 UWF Eyeball Fitting 6-511-00 360 Feed Hose Complete, w/UWF,

No Back-up Valve 9-100-3100 360 Feed Hose, 1 Foot 9-100-3103 360 Mechanism, In-line Back-up Valve 9-100-1204 360 Base Weight 9-100-3005 360 Collar, Bag Tie 9-100-3135 360 Water Management System 9-100-7014 360 Feed Pipe/Timer Blank Assembly 9-100-1002 *360 Sweep Hose Complete 9-100-1011 360 UWF Connecter Assembly 9-100-3008 360 Pressure Relief Valve, White 9-100-3009 360 Quick Disconnect, UWF 9-100-3006 360 Hose Nut 9-100-3109 360 Hose Feed, 6 Foot 9-100-3102 360 Hose Swivel 9-100-3112 360 Float, Feed Hose 9-100-1206 360 In-line Back-up Valve 9-100-1200

*Included in Polaris 380/360 Tune-up Kit and 380 Rebuild Kit **Included in Polaris 380 Rebuild Kit

I. INTRODUCTION

This handbook is designed as a quick reference guide for the service professional to aid in identifying and correcting problems with a Polaris VacSweep® 380 or a Polaris Vac-Sweep® 360 automatic pool cleaner. Information

exclusive to the 360 is shown in blue text. As you use this handbook, please

refer to the exploded parts diagrams and the hose parts diagrams at the beginning of this book to identify part location and part numbers. If you still have questions after using this handbook, please call our Customer Service Department at 1-800-VAC-SWEEP (822-7933), Monday through Friday, 7:30am-5:00pm, Pacific Standard Time or fax us at 1-800-479-TECH (8324).

Serviceman’s Tools

Phillips-head Screwdriver Needle-nose Pliers Flat-blade Screwdriver 0-60 psi Pressure Gauge Knife or Scissors Slip Joint Pliers Tape Measure 1/2” and 9/16” Wrench Magic Marker 1/8” Hex Wrench Tube of Silicone Sealant Paper Clip

0-30 psi Gauge

Special Polaris Tools

Name Part # 380 Pressure Tester G-35 380 Wet Function Bench Test G-110 UWF Removal Tool, Plastic 10-102-00 UWF Removal Tool, Stainless Steel 10-104-00

360 Pressure Stick 9-100-6000 360 Wet Bench 9-100-6005

II. INSTALLATION BASICS

380 INSTALLATION BASICS Connection Points

1. Dedicated cleaner line: 1-1/2 inches female threaded wall fitting in the midpoint of the long wall, approximately 6 inches below the water surface.

2. Over deck: Over-the-deck Kit (part #G-12) for pools without a dedicated cleaner line.

Booster Pump

The booster pump should be installed downstream from the filter and heater, but upstream from any air inducing equipment, solar systems and/or chlorinator. Never run the booster pump without the pool filtration pump running. (Refer to page 41 for booster pump installation basics.)

Hose Cutting

1. Straighten the feed hose by soaking it in hot water or laying it flat in the sun.

2. Measure and mark the deepest part of the pool (usually the main drain) with a telepole. If

the pool depth is 10 feet or more, do not cut the clear hose and skip to step 4.

Floats Are Evenly Distributed

(1-1/2 to 3 Feet Apart)

Universal Wall Fitting

Properly Sized Feed Hose

2-3 Feet Apart

White Hoses Are Cut to Equal Lengths

Clear Hose is Equal to Greatest Depth of Pool

Entire Feed Hose Reaches Within 6" of Farthest Point of Pool

Telepole

Mark Water Level

Greatest Depth of Pool

10. On the clear hose, make sure one float is against the back-up valve on the side opposite the cleaner and another float is within 2-3 feet. On the white hoses, space the floats no less than 1-1/2 feet and no more than 3 feet apart, so that the white hoses do not sag. It may be necessary to remove floats to maintain proper spacing.

11. After the cleaner has been connected, it is important to check the wheel RPM:

• Mark the single-side wheel.

• Turn on the filtration and

booster pumps, and allow the back-up valve to complete a back-up cycle.

• Hold the cleaner completely

under the water and count the wheel revolutions for one minute.

• RPM range needs to be 28-32. (If it is not, refer to page 25.)

3. Lay the telepole next to the clear hose. If the clear hose is longer than the mark on the telepole, cut the excess from the end attached to the white hose. Do not cut off the float. Reattach the clear hose to the white hose. It is easier to reinstall the swivels when the hose and swivels are wet.

4. Screw the universal wall fitting into the dedicated return line. Attach the Quick Disconnect at the end of the white hose to the Universal Wall Fitting.

5. Extend the hose to the farthest point of the pool. (The Polaris will not usually climb onto the top step, so do not count it in your measurement.) If the hose is within 6 inches of the farthest point of the pool, go to step 10 on the next page. If the hose is more than 6 inches short, add a 10-foot section of White Feed Hose with Floats (part #9-100-

3104), two Mender Nuts (part #D-15), and one Swivel (part #D-20). Do not add more than one 10-foot hose section.

6. Measure the amount of hose that extends past the farthest point of the pool. This is the overage measurement. Do not cut the hose yet.

7. Lay the hose on the deck. Go to the swivel between the 10-foot white hoses. Slide the floats away from the swivel and remove the swivel.

8. Cut an equal amount of the overage measurement from each 10-foot white hose.

9. Reinstall the swivel with the flow arrows on the swivel pointing toward the

Polaris. (Refer to the “Proper Mender Nut Placement” diagram above.)

Cut Clear Hose Equal to Greatest Depth of Pool

Water Level Mark

Telepole

SwivelWhite Hoses

Remove Excess Hose From This End

Feed Hose

Mender Nut

Swivel

Water Flow To Polaris

Proper Mender Nut Placement

Overage

Measurement

Universal Wall Fitting

Farthest Point from Universal Wall Fitting

Overage Measurement

Remove

Here

White Hoses are

Cut to Equal Lengths

Floats

Swivel

Floats

Remove

Here

Floats Are Evenly Distributed

(1-1/2 to 3 Feet Apart)

Universal Wall Fitting

Properly Sized Feed Hose

2-3 Feet Apart

White Hoses Are Cut to Equal Lengths

Clear Hose is Equal to Greatest Depth of Pool

Entire Feed Hose Reaches Within 6" of Farthest Point of Pool

Feed hose is cut correctly if:

A. Clear hose is equal to greatest depth of pool. B. Hard white hoses are equal in length. C. Entire feed hose reaches within 6” of farthest point of pool. D. Floats on white hoses are spaced evenly, between 1-1/2 to 3 feet apart.

Cutting the Feed Hose

1. With the pool pump on, hold the pressure tester underwater. Pull the

hose to the farthest point of the pool. (The Polaris will not usually climb onto the top step, so do not count it in the measurement.) If the hose just reaches the farthest point of the pool, go to “Hooking Up the Polaris.”

2. If the hose is short of the farthest point, add an additional 6 Foot Hose (part #9-100-3102), one Swivel (part #9-100-3002), and two Hose Nuts (part #9-100-3109). Do not add more than one 6 foot hose.

3. If the hose extends past the farthest point of the pool, mark the excess

hose. Turn off the pump and measure the marked amount.

4. Go to the first section of hose

from the pool wall and disconnect the hose at the swivel. Cut off the measured amount of excess hose. Reconnect the hose to the swivel.

5. Double check the hose length

by repeating Step 1.

Hooking Up the Polaris

1. Remove the pressure tester

from the hose by unscrewing the hose nut. See the “Hose Nut Removal” diagram above.

2. Remove the hose nut from the

pressure tester and push it onto the feed pipe. Connect the hose to the feed pipe with the hose nut. If the end of the hose

360 INSTALLATION BASICS

Pool Connections

1. The Polaris 360 comes equipped to connect to a 1-1/2 inch female pipe fitting on a dedicated cleaner line. An adjustable valve and pressure gauge should be installed to allow you to adjust the water flow to the Polaris.

2. If the pool does not have a dedicated cleaner line, you may be able to connect the Polaris 360 by using a special adapter kit. All of the kits connect to plastic pipe only.

3. If a spa is connected to the pool filtration equipment, you may also need to obtain some expansion regulators in addition to one of the standard kits available. Contact our Technical Support Department at 1-800-VACSWEEP to determine what parts are necessary.

Installing the Universal Wall Fitting

1. Turn on the filtration pump and flush out the plumbing line. Then turn pump off.

2. Remove the Universal Wall Fitting (part #6-500-00) from the Quick Disconnect (part #9-100-3006).

3. Screw the Universal Wall Fitting into the return line by hand. Turn the Quick Disconnect clockwise into the Universal Wall Fitting and pull away to secure. Turn the Quick Disconnect by hand to tighten the Universal Wall fitting; do not over tighten. Once the Universal Wall Fitting is secure, the Quick Disconnect can be removed without removing the Universal Wall Fitting.

Pressure Testing Instructions

1. Before installing the Polaris 360, make sure the pool filter is clean.

2. Connect the Quick Disconnect to the Universal Wall Fitting.

3. While someone holds the free end of the hose in the pool, turn on the pool pump. Hold the free end of the hose underwater and cover the large hole at the end of the pressure tester. Reach down and feel around the Quick Disconnect to see if the Pressure Relief Valve (part #9-100-3009) is releasing water. If it is, continue with “Cutting the Feed Hose.” If it isn’t, the filtration pump may not have sufficient water pressure to operate the Polaris.

Dedicated Line Installations: Increase flow to dedicated line until Pressure Relief Valve releases water.

Feed Hose Hose Nut Swivel

Flow Arrow

To the Polaris

O-ring

Hose Nut Removal

1. Unscrew hose nut (reversed threads).

2. Pull hose off swivel.

Feed Hose

Head Float

Feed Pipe

Thrust

Jet

Sweep Hose

Sweep Hose Adjustment Screw

Hose Nut

Assembling the Polaris

Universal Wall Fitting

Entire Feed Hose Reaches Within 6" of Farthest Point of Pool*

Cut excess hose from first section of hose

Float

Measure with pool pump on and pressure tester underwater

Pressure Tester

Properly Sized Feed Hose

To avoid damaging the Polaris, hold it by the blue top, suspended on its side just below the water level. Hold it away from the pool wall with the single-wheel side up. Hold the sweep hose to

avoid getting wet.

Count the revolutions of the marked wheel for exactly one minute, beginning after it has completed a back-up cycle. This gives the wheel Revolutions Per Minute (RPM).

For proper operation, the Polaris should operate between 28 and 32 RPM. If it has less than 28 RPM, follow the instructions below.

1. Clean the Filter Screen (part #6-504-00). A dirty filter screen will restrict the water flow to the Polaris.

2. Clean the pool skimmer, filter, and pump basket.

3. Check the hoses, connections, and swivels for leaks that could cause loss of water pressure.

4. If an adjustable valve has been installed, adjust the valve to increase water to the Polaris.

5. You may need to install Adjustable Eyeball Fittings (part #10-104-00) in some returns.

If you have more than 32 RPM, unscrew the Pressure Relief Valve (part #9-100-3009) until the proper RPM is reached. If an adjustable valve has been installed, adjust the valve to reduce the amount of water going into the Polaris.

that connects to the Polaris has a curve to it, align it with the curve in the feed pipe.

3. Loop the velcro strip through the eye on the bag tie collar. Bag tie should be attached below the first swivel.

4. Gently place the Polaris into the pool. Turn on the pool filtration pump.

5. Verify that the wheel RPM is between 28 and 32. Refer to “Fine Tuning the Polaris, Checking Wheel RPM” below.

Checking Operation

Approximately every 3-1/2 minutes the Polaris 360 will go into back-up mode. At this time the back-up valve will pull the Polaris away from potential obstacles. The sweep hose operates in a gentle sweeping motion to prevent debris from becoming trapped in hard-to-reach corners of the pool. If the Polaris does not travel into all areas of the pool, turn off the pool filtration pump and make the necessary adjustments below.

Fine Tuning the Polaris

• Thrust Jet Adjustment

The thrust jet adjusts the direction of the Polaris. Its standard position is eleven o’clock. See the “Assembling the Polaris” diagram shown on page 7for the location of the thrust jet.

•Sweep Hose Adjustment

The sweep hose should operate in a gentle sweeping motion. To decrease the motion of the sweep hose, turn the sweep hose adjustment screw clockwise. Make sure the Sweep Hose Scrubber (part #9-100-3105) is not blocking the water flowing out the end of the sweep hose. See the “Assembling the Polaris” diagram on page 7.

• Checking the Wheel RPM

To determine whether the Polaris is receiving proper water pressure, turn off and carefully remove the Polaris from the pool. Mark the outer edge of the tire on the single-wheel side of the Polaris. Place the Polaris back into the pool and turn on the filtration pump.

Bag Tie Collar

Prong

Square Hole

Single-wheel Side

Blue Top

Sweep Hose

+ 19 hidden pages

Polaris Vac-Sweep 380 Handbook

380 EXPLODED PARTS DIAGRAM

380 HOSE PARTS DIAGRAM

360 EXPLODED PARTS DIAGRAM

360 HOSE PARTS DIAGRAM

REPLACEMENT PARTS TO STOCK

TABLE OF CONTENTS

I. INTRODUCTION

Serviceman’s Tools

II. INSTALLATION BASICS

380 INSTALLATION BASICS Connection Points

360 INSTALLATION BASICS