Polaris 280 Repair Manual

Polaris 280 Workbook

1

2

Welcome to the Polaris 280 Course There are several types of pool cleaners In-Floor- Fittings Mounted in the pool floor that use filtered water to clean the pool. Electric - Cleaners that are plugged into electric with a cable. Suction- Cleaners mounted on the suction side of a pools pump and filter system. Pressure - Cleaners mounted on the return side of a pools pump and filter system and may use a booster pump for extra pressure. The Polaris 280 is a pressure cleaner which requires a booster pump. There are several models of pressure cleaners offered by Zodiac under the Polaris brand. It is easy to identify each model. If you remove the bag and look down the throat of each unit, you will see small jets. The number of jets is the first number in the description of the unit. If the unit requires a booster pump for proper pressure it will have an 8 or 9 as the second number. If a booster pump is not required and the unit operates off the regular pool returns, it will have a 6 as the second number. Example: 280 has two jets and requires a booster pump. To take this course you will need a 280 cleaner as well as a Phillips head and straight edge screw driver. It is recommended that you obtain and read the Polaris 280 Owner’s Manual, TL-200. Our most dependable pool cleaner easily connects to a dedicated pressure line powered by a booster pump and features double jets, and a low-profile, UV-resistant housing

Notes:

3

Features & Benefits • Runs off a separate booster pump (operates independently from the rest of your pool system, always operates at 100% efficiency) • No sweeping or vacuuming by hand • Collects debris in its own bag before it reaches the filter (reduces filter cleaning by up to 80% per year) • Ideal for large debris pools • 31 feet of Hose comes in the box • One Year Standard Warranty, 5 years on the Frame (Excluding wear items such as bags, tires, sweep hose or scrubbers)

Operation and Performance Vacuums, sweeps and scrubs pool floor and walls Automatic in-line back-up valve frees 280 from obstructions and increases its randomness In-Line filter, now standard along with Zipper Filter Bag Works under a pool cover Cleans the pool within 1-1/2 to 3 hours Finished Good Part Number: F5 Zodiac Premium Points: 150

Notes:

4

Notes:

5

Additional Options for the 280 • Black Max 280 • Tank Trax 280 • Tank Trax Conversion Kit • Filter Bags • Tires

280 BlackMax Model BlackMax model is available to complement dark bottom pools

280T Tank Trax Designed for vinyl and other challenging in-ground pools. It easily climbs walls, and maneuvers over stairs or steep breaks.

TankTrax Tire Conversion Kit #C15 Used to convert a 280 to a TankTrax model to solve “hang ups” on challenging pools with steep breaks

6

Filter Bags Filter bags to custom clean in any application from heavy debris (Leaf Bag) to fine debris (disposable filter bags with micro-rating equivalent to cartridge filters), as well as ones for BlackMax models. Standard on Polaris 280 is K13 Zippered All Purpose Filter Bag.

MaxTrax Tires Provides maximum traction without damage to pool finishes. Standard MaxTrax Tire is Part Number: C10 C18 TankTrax Tires C11 BlackMax models

7

Dedicated Booster Pump Line The 180 requires a dedicated pool cleaner line located equidistant from the two furthest points in the pool. ( More technical information on the booster pump is covered in the booster pump course )

Pressure

Pressure

HEATER FILTER

Pressure Suction

PUMP

(vacuum)

Polaris Booster Pump Skimmer Main Drain

Dedicated Cleaner Line

Return Lines

Install the Universal Wall Fitting Installs in minutes on pools with a dedicated cleaner return line and a threaded 1-1/2" female pipe fitting. 1 Turn on the filtration pump and flush out the plumbing line. Turn pump off. 2 Remove the UWF from the Quick Disconnect and screw the UWF with the blue restrictor disk into the return opening. 3 Turn the Quick Disconnect clockwise into the UWF and pull away to secure.

Notes:

8

UWF- Universal Wall Fitting Standard wall fitting ( UWF ) comes with blue restrictor disc installed. If pressure is low, below 28 psi, remove blue. If pressure is over 32 psi, remove blue and install the red.

31 Feet of Hose

Quick Disconnect Fitting with Black pressure release

• • • •

In-line Filter Transparent filter housing Easy access to filter screen Built-in swivel

Notes:

9

Proper Hose Length 31 feet of hose is standard in the box. A one foot section from wall fitting to strainer (C). Two 10 foot feed hose sections after the strainer that are attached by a swivel. The final 10 foot section is the leader hose and has the back-up valve (A) 30 inches from the end of the hose that attaches to the mast of the cleaner (B).

A-Back Up Valve

C- One Foot Section

B-Cleaner End

The Black Pressure Release on the wall fitting is set to allow any pressure not needed by the cleaner to release out into the pool.

Notes:

10

Adjust Feed Hose To Fit Pool Length • Measure the deepest part of the pool. Cut leader hose, from end that attaches to feed hose, so length is equal to the greatest depth of the pool. • Attach leader hose to feed hose and connect hose to the pool wall at the return line. Extend hose to farthest point of pool. The hose end must be within 6" – longer or shorter – of the farthest point. See dotted circle. • Hose too long? Separate hose at the strainer. Cut the overage from feed hose section. • Hose too short? Buy an additional feed hose section (part #9-100-3104), one swivel (part #D20) and two hose nuts (part #D15). • After adjusting hose, position hose floats as shown.

Hose Cutting When you cut the hose, take care to cut it clean and with a sharp knife. If you do not cut it clean the nut will be hard to push back on the end of the swivel (or cleaner). The nut always is put on the swivel first and then screwed back over the hose after it has been pushed on to swivel (or cleaner).

Notes:

11

Sweep Hose Adjustment The proper operation of the sweep hose is to gently sweep the pool and put debris into suspension where it can be removed by the filter system. A sweep hose with too much pressure will “whip” and wear out quickly as well as spray outside the pool. The standard setting is to screw the sweep hose adjustment screw all the way in and back out 1-1/2 to 2 turns.

Optional Hose Weight For Sweep Hose When a consumer complains that the sweep hose at the proper setting is still spraying their windows, the use of a B2 hose weight may solve the issue. To remove sweep hose, leverage a flathead screwdriver between the jaws of the clamp and gently push apart. Cut 7" off the length and slide on the sweep hose weight.

Notes:

12

Head Float Adjustment Standard position of the Head float should be ½” to 1" from the feed hose mast . Position of the head float is the ballast that allows the front of the cleaner to lift when it encounters the walls of the pool. If the cleaner is doing “wheelies” pull the head float back on the stem. If the cleaner won’t climb walls push the head float in as needed.

Cleaning And Attaching The Bag Remove the bag collar from the feed hose. Twist the bag connector until it disengages with a clicking sound from the feed pipe. Pull off the filter bag, open the closure and dump out the debris. To reinstall align markings on the connector and feed pipe. Click connector into position on pipe and reattach bag collar to hose. •

• Empty the bag when it is half full, especially if the dirt load is sand. • It is easier to empty the bag when it is dry. • Alternate between two bags.

13

Thrust Jet Adjustment The thrust jet powers the direction of the cleaner and gives the Polaris a random pattern. Factory position is straight back, but depending on the pool, other settings may be helpful.

With the Cleaner On… • Check Wheel RPM • 28 – 32 RPM • For an accurate reading, the Cleaner must be held below Water level. • RPM = Revolutions per Minute. Measure of Speed.

Notes:

14

Helpful Installation Options G-12 Over the Deck Kit For Pools Without a dedicated cleaner return G-9 Reducing Bushing For pools with an old Polaris fitting still glued into the wall. ( It was a ¾” thread ) G-35 Pressure Stick Used at the end of the cleaner hose with both the pool pump and booster pump turned on to verify proper operating pressure for the cleaner 10-102-00 Removal Tool Removes UWF (Universal Wall Fitting) and removes pressure release from wall fitting.

Optional Over The Deck Kit G-12 For pools without a dedicated cleaner line

Over The Deck Kit Installation For older pools that do not have a dedicated cleaner return and the installer does not want to lower the water in the pool and drill a return through the pool wall .

G-12 The elbow and valve connects to the booster pump. Connector on valve is a hose bib to connect garden hose. The other end of the garden hose connects to hose bib on the pipe.

15

Special Fittings G-9 can be used for ¾” threaded outlets. Then the UWF (Universal Wall Fitting) can screw in.

With the Cleaner On … Check Supply Pressure • Pressure should be between 28 to 32 PSI • For an accurate reading, you must hold the tip of the Pressure Stick (#G-35) under the Water. • PSI = pounds per square inch. Measure of Pressure.

Pressure Stick # G-35

Notes:

16

Removal Tool #10-102-00 Also removes pressure relief fittings

Removal Tool #10-102-00 Use with pins still existing in the wall fitting ( UWF )

Removal Tool #10-102-00 Use where pins are missing in the wall fitting (UWF)

17

Quick Troubleshooting • Check if In-Line Strainer is Clean - This will not allow enough pressure for unit to work properly • Check if Bag is Full - Unit will run on its side if bag is too heavy • Check Head Float - Should be full of air not water. The cleaner will also be on it’s side when full of water • Check Wheel Spin- All 3 should spin smoothly. If not bearings and gears could be blocked or worn. • Check Water Flow - Wet Function Bench Test (G-110). Allows you to plug in at a sink or at a hose bib and verify that all jets are clear and working properly

Cleaning the Filter Always disconnect the Polaris before cleaning or backwashing the pool filter, and let the filtration system run for at least five minutes before reconnecting the cleaner. To clean the filter screen, pull it out of the wall fitting assembly, rinse it and press it firmly back into place. Current Filter In-Line Hose

Wet Function Bench Tester G-110 is available so that a cleaner can be hooked to a sink faucet or a hose bib to test water flow through the unit and if the jets are all clear, allowing for proper flow.

Notes:

18

Old Filter In Quick Disconnect Fitting

Verification of Water Flow Diagram

Back-Up Valve The G-52 Backup Valve is mounted on the hose near the cleaner. Using a paddlewheel and gear system , it pulls the cleaner backwards Using water flow every 2 ½ minutes.

Notes:

19

Backup Valve The backup valve mechanism may be changed.

Backup Valve The paddle wheel and gear system in the mechanism changes water flow from the cleaner to the open port to pull the cleaner away from any obstructions.

Options for the Backup Valve The G-56 is a booster valve seat for the G52 and that will increase the flow from the back up valve when it is in reverse mode. This will pull the cleaner farther back than the normal backup valve. The G-65 is a double acting mechanism (guts) for the G-52 backup valve. Normal G52 backs up every 2 ½ min. If you replace the mechanism with a G-65 is will back up approximately every 1 min and 45 sec.

20

Tune Up Kit A-49 Tune-up Kit includes all wear parts but does not include a top or bottom.

Tune Up Kit A-49 Tune-up Kit includes all wear parts and internal drive but does not include a top or bottom.

Rebuild Kit A48 Rebuild Kit includes all wear parts and includes the top and bottom.

21

Polaris 280 Tear Down

Notes:

22

Polaris 180 Tear Down Remove the bag. Twist the bag connector until it disengages with a clicking sound from the throat.

Remove the float. It is not threaded on. Pull straight back to remove.

Remove the sweep hose. Plastic clamp is split. Separate the split from side to side and the clamp may be removed. Once clamp is off, pull the sweep hose off.

23

Remove the sweep hose adjustment screw. A typical flat head screw driver will fit the screw or use a pair of pliers. It unscrews counter clockwise.

Remove the top. A Phillips head screw driver fits the screw mounted in the hole directly in front of the throat.

Notes:

24

Remove the wheels. A flat head screw driver will remove the plastic screws in each wheel.

Remove wheel bearings. There are two in each wheel. A flat head screw driver placed between the two bearing will help pop them out.

25

Please note the look of the wheel bearings. One side has a solid blue face, while the other side exposes the ball bearings. When installing these bearings always make sure the blue face is out so that the balls are not exposed.

Remove the bottom. There are two screws holding the bottom on and require a Phillips head screw driver.

Notes:

26

Please note that the two front axles have sand-silt guards on them. The rear wheel does have not a sand-silt guard as there is no gear action on that wheel. It is driven by the idler wheel.

Remove the turbine shaft cover plate. It is held on by two Phillips head screws.

Remove the three screws holding down the turbine cover.

27

The small opening could become blocked with debris and stop the wheels from turning. A simple paper clip can be used to remove debris.

Remove the wheel axles.

The wheel axles are held on by two Phillips head bolts. There are star washers and a plate to protect the axle.

Notes:

28

Remove the axle assembly. There are two sealed bearings on each end of the axle.

Remove the 4 Phillip head screws.

The blue bearings have a flat side with printing on it and always needs to be installed pointing out.

Bearing with rounded side always pointing in.

29

The turbine shaft is protected by a plastic straw covering. This is critical to hold the turbine in position and protect the shaft.

Remove the water management system. It is held on by two Phillips head screws.

The water management system is critical to the operation of the unit. Debris may get caught in the two jets or thrust jet. O-ring seal is important to flow as well.

Notes:

30

Replace the Water Management System (WMS) taking care to clean oring and make sure it is secure.

Replace the two screws.

Replace Drive Axle Remember: Flat side of the bearings with the print face out. Round part of bearing fits down into frame. Replace the axle assembly. There are two sealed bearings on each end of the axle. Replace the 4 Phillip head screws.

31

Replace all the wheel axles. There are 6 screws. Will cover adjustments later. When installing axles, they all point forwards. That is the actual axle sticks out on one end of the block. The axle side of the block is always forward towards front of unit.

Replace the turbine cover with elbow. Replace the three screws.

Notes:

32

Replace the Bottom There are two screws that hold the bottom on and require a Phillips head screw driver.

Replace the turbine shaft cover plate. It is held on by two Phillips head screws.

Put the Bearings Back in the Wheels

Remember: There are two bearings in each wheel. Exposed balls point in. Flat blue face pointed out

Pointed Out

Notes:

33

Replace Wheels The most important stage will be the match between the metal axle and the teeth of the plastic wheel.

Wheel Adjustment Procedure Single Wheel Side: • Loosen but do not remove the two screws holding the axle block in place. • Use a flat-blade screwdriver to lever the axle until the wheel and the drive shaft are firmly engaged. • Slide the axle block back until the drive shaft engages about 3/4 of the wheel gear teeth depth and tighten the axle block screws. A properly adjusted wheel will spin without skipping over the teeth, but will not bind up.

34

Wheel Adjustment Procedure Front Double Wheel Side: • Loosen but do not remove the two screws holding the axle block in place. • Use a flat-blade screwdriver to lever the axle until the wheel and the drive shaft are firmly engaged. • Slide the axle block back until the drive shaft engages about 3/4 of the wheel gear teeth depth and tighten the axle block screws. A properly adjusted wheel will spin without skipping over the teeth, but will not bind up.

The idler wheel takes power from the front wheel to turn the rear wheel.

35

Rear wheel should be moved forward to engage the idler wheel. The idler wheel must flex on spring. This allows debris such as twigs to not block the two wheels.

Spin the front wheel. All wheels should spin freely. If they stop as soon as you let go of the front wheel, they are too tight. If they wobble or skip, they are too loose. If they are too tight or too loose, readjust the axles.

Notes:

36

Replace the top. A Phillips head screw driver fits the screw mounted in the hole directly in front of the throat.

Replace the sweep hose adjustment screw Screw it in until it bottoms out. Back it out 1 ½ to 2 turns. This will allow the sweep hose to sweep and not whip.

Notes:

37

Replace the sweep hose. Then replace the plastic clamp.

Replacing float. Two fingers works well as a guide. ½ “ to 1 “ back from the mast on a 280.

Notes:

38

Serial Number Serial Number is located on the frame on the back of the unit.

Serial Number It is a bar code label.

Product Identifier

This is the date the unit was produced. This is the number of the unit that was built on that date.

Notes:

39

Quick Troubleshooting • Check if In-Line Strainer is Clean - This will not allow enough pressure for unit to work properly • Check if Bag is Full - Unit will run on its side if bag is too heavy • Check Head Float - Should be full of air not water. The cleaner will also be on it’s side when full of water • Check Wheel Spin- All 3 should spin smoothly. If not bearings and gears could be blocked or worn. • Check Water Flow - Wet Function Bench Test (G-110). Allows you to plug in at a sink or at a hose bib and verify that all jets are clear and working properly

Troubleshooting Back-up Valve is always on or won’t engage.

Check wheel RPM and pressure to verify proper flow.

Check Back-up valve for debris or damage.

Cleaner is not moving.

Check wheel RPM and pressure to verify proper flow.

Verify WMS hose is attached and clamp is secure.

Cleaner only turns in one direction or is running in circles

Check the filter bag. If full, empty it or replace if needed.

Cleaner stays in one end of the pool, does not clean entire pool.

Verify that feed hose is within 6” longer or shorter of the farthest point of the pool.

Cleaner is slow or sluggish, running with less power than normal.

Verify thrust jet is in the correct position. (180, 280, 480 = straight back), (360, 380 = 11 o’clock) (3900 = 7 o’clock)

Sweep hose sprays water out of the pool.

Notes:

40

Check WMS for obstructions.

Verify thrust jet is in the correct position. (180, 280, 480 = straight back), (360, 380 = 11 o’clock) (3900 = 7 o’clock) Verify thrust jet is in the correct position. (180, 280, 480 = straight back), (360, 380 = 11 o’clock) (3900 = 7 o’clock)

Verify thrust jet is in the correct position. (180, 280, 480 = straight back), (360, 380 = 11 o’clock) (3900 = 7 o’clock)

Check hoses, connections, and swivels for leaks.

Replace the sweep hose scrubber if it worn or missing.

With cleaner on, verify that vacuum jets have clear unobstructed flow.

Verify that all of the wheels are moving together. Check for broken belts.

With cleaner on, verify that vacuum jets have clear unobstructed flow.

Verify the back-up valve is cycling.

Check for proper flow by confirming proper PSI and than Proper RPM’s.

Check bearings are clear of debris and replace if worn.

Add a sweep hose weight, part #B2

41

Polaris 280 - 3/11 42