Nov 24, 2009 I have what I think is the largest collection of Polaris Service Manuals. These are in PDF form. POLARIS MANUALS.
Polaris 360 Workbook
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Welcome to the Polaris 360 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 360 is a pressure cleaner that does NOT require 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: 360 has three jets and does not need a booster pump. A pressure pool cleaner that does not require a booster pump and easily connects to a dedicated pressure line, or pool return. The 360 features three jets. To take this course you will need a 360 cleaner as well as a Phillips head and straight edge screw driver. It is recommended that you obtain and read the Polaris 360 Owner’s Manual.
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Features & Benefits • 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) • Three Vacuum Jets • 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 backup valve frees 360 from obstructions and increases its randomness • Standard with Zipper Filter Bag • Works under a pool cover • Cleans the pool within 1-1/2 to 3 hours Finished Good Part Number: F1 Zodiac Premium Points: 200
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Additional Options for the 360 • BlackMax 360 • Filter Bags • Tires
360 BlackMax Model BlackMax model is available to complement dark bottom pools
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 360 is 9-100-1014 All Purpose Filter Bag.
MaxTrax Tires Provides maximum traction without damage to pool finishes. Standard MaxTrax Tire is Part Number C10 PosiTrax for tile pools is Part Number C13 Black for BlackMax models is Part Number C11
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Installation Dedicated Cleaner Line Pressure
Pressure HEATER FILTER
Pressure Suction
PUMP
(vacuum)
Skimmer
Dedicated Cleaner Line
Main Drain
Return Lines
Installation Preferred Plumbing Configuration
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Installation 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.
Installation 31 Feet of Hose Back Up Valve
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End that attaches to cleaner and has the pressure tester installed. Quick Disconnect Fitting with Float white pressure release
Installation Adjust Feed Hose To Fit Pool Length • Connect hose to the pool wall at the return line. • Turn the pump on as the 360 hose will expand. Taking a measurement with the pump off will leave too much hose. • Extend hose to farthest point of pool. The hose end must be within 6' – longer or shorter – of the farthest point. Hose too long? Separate hose at the wall fitting. Cut the overage from feed hose section. • After adjusting hose, position hose floats as shown
Installation Hose Cutting to Custom Fit to Pool When removing the hose from either the cleaner or a swivel, the hose nuts thread on to the spiral shape of the hose. So follow the thread pattern to loosen and tighten. 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 thread back on the end of the hose. The nut always is put on the swivel or cleaner first and then screwed back on to the hose after it has been pushed on to swivel or cleaner.
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Installation The 360 is packaged with a pressure tester installed on the hose. Simply attach the hose to the pool wall using the quick disconnect fitting. Turn the pump on. Make sure the cleaner has enough pressure to operate . To verify this, place your hand over the white pressure release on the wall fitting. Water must be flowing out from the pressure release.
Every 360 includes a package with two eyeballs and one eyeball fitting. The eyeballs may be used to replace the eyeballs in the existing pool returns to build pressure up to the cleaner. The eyeball return may be used to put in the cleaner line when the cleaner is not in the pool.
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Installation Optional 360 Installation The 360 is able to use the existing pool returns if there is no dedicated cleaner line available.
Return Lines B
A
Equipment Area
Cleaner C D
Eyeball Restrictors
Pool Spa The size of the pump on the existing pool needs to be large enough to provide enough pressure. The other (B, C, D) existing returns may need to be reduced or blocked to provide the operating pressure required by the 360. Pumps vary, but the best rule is to make sure there is at least a 1 HP high head pump on the existing pool.
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360 Aftermarket Kits Because the 360 does not need a booster pump and can be used in regular pool returns, adapters to various return lines are available.
This kit may be used when the existing eyeball fitting has been glued into the wall. You can remove the retainer ring and eyeball but not the threaded fitting to put in the UWF ( Universal Wall Fitting). Because the 360 does not need a booster pump and can be used in regular pool returns, adapters to various return lines are available.
This kit or connector may be used when there is no existing eyeball fitting and the return line is just a 1' opening.
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360 Aftermarket Kits Because the 360 does not need a booster pump and can be used in regular pool returns, adapters to various return lines are available.
This kit may be used when there is no existing eyeball fitting and the return line is just a 1 1/4' opening. Sleeve kit are only the rubber sleeve and must be used with the 1' kit or adaptor.
Because the 360 does not need a booster pump and can be used in regular pool returns, adapters to various return lines are available.
This kit or connector may be used when there is no existing eyeball fitting and the return line is just a 1 1/2' opening.
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Cleaner Settings and Assembly
Hose Connection
Head Float
Thrust Jet
Sweep Hose
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.
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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.
Removal Tool #10-102-00 Use with pins still existing in the wall fitting ( UWF )
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Removal Tool #10-102-00 Use where pins are missing in the wall fitting (UWF)
Removal Tool #10-102-00 Also removes pressure relief fittings
Head Float Adjustment Standard position of the Head float is pushed all the way in towards the cleaner.
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Cleaning And Attaching The Bag Remove the bag collar from the feed hose. Push the tabs on the bag collar and twist the bag away 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.
Thrust Jet Adjustment The thrust jet powers the direction of the cleaner and gives the Polaris a random pattern. Factory position is 11 o’clock, but depending on the pool, other settings may be helpful.
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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.
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 its side when full of water • Check Wheel Spin - All 3 should spin smoothly. If not the belts and /or drive for the belts are broken or blocked.
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. Filter Is In Quick Disconnect Fitting.
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Verification of Water Flow Diagram
Cleaning The Water Management System If the cleaner has been operated with the filter screen removed, or the hose has been left attached while backwashing a filter. Small debris can travel through the hose and end up in both the vacuum jet or the turbine jet. A paperclip is the tool of choice. Dislodge the debris and with a hose back-flush the system.
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Backups Valve The 9-100-1200 Backups Valve uses water flow to pull a cleaner backwards approximately every 2 ½ minutes.
Reverse Jet
Water Flow
Options for the Backups Valve The 9-100-1210 is a double acting mechanism (guts) for the 9-100-1200 backups valve. Normal 9-100-1200 backs up every 2 ½ to 3 minutes. If you replace the mechanism with a 9-100-1210 is will back up approximately every 1 minute and 30 seconds.
The 9-100-1205 is a booster valve seat for the 9-100-1200 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.
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Aftermarket Kits Tune Up Kit 9-100-9010 Tune-up Kit includes all wear parts but does not include a top or bottom.
Tune Up Kit 9-100-9010 Tune-up Kit includes all wear parts but does not include a top or bottom.
Rebuild Kit 9-100-9060 Rebuild Kit includes all wear parts and includes the top and bottom.
Rebuild Kit 9-100-9060 Rebuild Kit includes all wear parts and includes the top, bottom, complete sweep hose and a bag.
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Tear Down
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Tear Down Remove the bag. Twist the bag connector until it disengages with a clicking sound from the throat.
Tear Down Remove the float. It is not threaded on. Pull straight back to remove.
Tear Down Remove the top. Use a Phillips head screw driver to remove the two screws on the back of the unit.
Once the two screws have been removed and plate pulled back off the unit you can proceed with removing the top.
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With pressure on the tabs holding the top in place, you can pull the top up and off the unit.
If the unit is prior to 2003, there is a screw mounted on the double wheel side of the top. Unscrew it and pry the two sections of the top apart.
Remove the sweep hose. Plastic clamp is split. Separate the split from side to side (straight edge screw driver will help) and the clamp may be removed. Once clamp is off, pull the sweep hose off.
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Remove the sweep hose adjustment screw. A straight edge screw driver will fit the screw or use a pair of pliers. It unscrews counter clockwise.
Remove the three screws from the feed mast and pull it out of the unit.
When you remove or install the feed pipe it is critical to the operation of the unit to note the oring on the bottom of the feed pipe. The o-ring must fit flush in the bottom fitting or the it will leak power away from the operation of the unit.
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Four screws hold the frame in place. Remove the three that are exposed.
To remove the fourth screw under the front axle. Loosen the two screws holding the front axle enough to allow you to move the axle plate back out of the way. Then take out the final frame screw under the plate.
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Remove the frame. It is a tight fit and you must remove the frame by first pulling back toward the hoses and lifting the back of the frame. Lift a very little, push back towards thrust jet. Lift straight up
Grab frame here
Note: There is a disc between the belts on the drive axle. Front belt should always be mounted closest to the frame. To adjust the belts you can loosen the two screws on the front and rear axle. Adjust belt tension and tighten axles back down. You should be able to place your finger on the belt and it will flex less than ¼”.
Separation Disc
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Remove the belts from the wheels on the double wheel side of the frame. Just like a bicycle chain. Lift the belt off to one side and spin the wheel.
Remove the wheels. A flat head screw driver will in a small opening in each hub cap to pop them off.
Remove the wheels. There is an e-clip mounted on the end of each shaft. A flat head screw driver will help pop them out.
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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.
There are two bearings in each of the wheels on the double wheel side of the cleaner.
There are no bearings in the wheel on the single wheel side of the cleaner. Note that this wheel is different than the wheels on the double wheel side of the cleaner. Tires remain the same.
With the wheels off you can see that the axle blocks could be removed and replaced. You are down to the frame with the drive gear assembly and axles left in it.
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Note the spacers on each axle. They are hard to see when you first pull off the wheels because they will be tight up against the frame.
Remove the turbine cover
Review this diagram of the drive assembly.
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In order to remove the drive axle, there is an e-clip to remove on the axle just inside the white plastic up against the turbine wheel. Remove the e-clip and pull axle out from the turbine pulley.
Turbine Pulley Do not remove the eclip on the pulley.
Pull out the transfer pulley drive shaft
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You can remove the turbine wheel and drive gear. Please note that there is a bearing in the turbine wheel. It is embedded in the wheel and the only way to replace the turbine wheel bearing is to replace the entire turbine wheel. Turbine Wheel
Turbine Wheel Bearing
Turbine Pulley/ Drive Shaft
To put the turbine pulley/drive shaft back in, remove the bearing on the single wheel side of the frame. Replace the turbine wheel and drive gear. Push the drive side ¾ of the way through the unit so that it is just sticking out of the bearing holder.
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Drive Gear
Put the e-clip back on the drive shaft
This is why it is important to leave the bearing out to this point. You need to mount the e-clip before it is back in position, behind the frame. Now replace bearing. Remember, solid blue side out
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Lift shaft up and push all the way in so eclip is now behind frame
Replace the turbine cover
Remove the weight.
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Replace the wheels and belts. Don’t forget the spacers.
Front wheel belt first.
Frame with wheels should be all reassembled. Let’s take a look at the bottom.
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The water management system starts at the bottom of the feed pipe. It supplies water to the turbine to make the wheels turn, a hose to the thrust jet, and a hose to the sweep hose. To Turbine
To Thrust Jet
To Sweep Hose
The water management system also supplies two fittings on either side of the throat. These are held in place by two clips. They are covered by silicone when they leave the factory. This is to prevent dirt and sand from getting into the unit on initial start up. You can remove the silicone and clamps to replace the entire water management system.
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You could remove and/or replace the water management system by cleaning out the silicone. With pliers pull the clamps out on either side of the throat. .
Water Management Replacement.
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The most common mistake when rebuilding a unit is to leave the lower turbine cover out. Please replace it in the bottom now.
Replace the weight.
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Replace the frame. It is a tight fit and you must replace the frame by holding the back of the frame. Getting the front of the frame in place first. Then push back of frame down as close to the back of the unit as possible. Grab frame here
Pull the front wheel forward to the proper tension for the belt. Tighten down the axle screws.
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Four screws hold the frame in place. Remove the three that are exposed.
Replace the three screws from the feed mast and pull it out of the unit. Making sure the o-ring at the base of the feed pipe is flush and clean. .
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Replace the top.
Replacing float. Head float gets pushed all the way forward to the cleaner.
Make sure the thrust jet is set at 11 o’clock.
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Replace the sweep hose and sweep hose adjustment screw. Screw the adjustment screw in until it bottoms out, then back it out 1 ½ to 2 turns. This will allow the sweep hose to sweep and not whip.
Serial Number Serial Number is located on the frame and on the back of the unit.
Serial Number It is a bar code label. The product identifier.
This is the date the unit was built.
This is the number of the unit that was built on that date. 42
Troubleshooting 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 its side when full of water • Check Wheel Spin - All 3 should spin smoothly. If not the belts and /or drive for the belts are broken or blocked.
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.
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
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Polaris 360 - 3/11 46
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Welcome to the Polaris 360 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 360 is a pressure cleaner that does NOT require 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: 360 has three jets and does not need a booster pump. A pressure pool cleaner that does not require a booster pump and easily connects to a dedicated pressure line, or pool return. The 360 features three jets. To take this course you will need a 360 cleaner as well as a Phillips head and straight edge screw driver. It is recommended that you obtain and read the Polaris 360 Owner’s Manual.
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Features & Benefits • 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) • Three Vacuum Jets • 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 backup valve frees 360 from obstructions and increases its randomness • Standard with Zipper Filter Bag • Works under a pool cover • Cleans the pool within 1-1/2 to 3 hours Finished Good Part Number: F1 Zodiac Premium Points: 200
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Additional Options for the 360 • BlackMax 360 • Filter Bags • Tires
360 BlackMax Model BlackMax model is available to complement dark bottom pools
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 360 is 9-100-1014 All Purpose Filter Bag.
MaxTrax Tires Provides maximum traction without damage to pool finishes. Standard MaxTrax Tire is Part Number C10 PosiTrax for tile pools is Part Number C13 Black for BlackMax models is Part Number C11
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Installation Dedicated Cleaner Line Pressure
Pressure HEATER FILTER
Pressure Suction
PUMP
(vacuum)
Skimmer
Dedicated Cleaner Line
Main Drain
Return Lines
Installation Preferred Plumbing Configuration
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Installation 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.
Installation 31 Feet of Hose Back Up Valve
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End that attaches to cleaner and has the pressure tester installed. Quick Disconnect Fitting with Float white pressure release
Installation Adjust Feed Hose To Fit Pool Length • Connect hose to the pool wall at the return line. • Turn the pump on as the 360 hose will expand. Taking a measurement with the pump off will leave too much hose. • Extend hose to farthest point of pool. The hose end must be within 6' – longer or shorter – of the farthest point. Hose too long? Separate hose at the wall fitting. Cut the overage from feed hose section. • After adjusting hose, position hose floats as shown
Installation Hose Cutting to Custom Fit to Pool When removing the hose from either the cleaner or a swivel, the hose nuts thread on to the spiral shape of the hose. So follow the thread pattern to loosen and tighten. 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 thread back on the end of the hose. The nut always is put on the swivel or cleaner first and then screwed back on to the hose after it has been pushed on to swivel or cleaner.
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Installation The 360 is packaged with a pressure tester installed on the hose. Simply attach the hose to the pool wall using the quick disconnect fitting. Turn the pump on. Make sure the cleaner has enough pressure to operate . To verify this, place your hand over the white pressure release on the wall fitting. Water must be flowing out from the pressure release.
Every 360 includes a package with two eyeballs and one eyeball fitting. The eyeballs may be used to replace the eyeballs in the existing pool returns to build pressure up to the cleaner. The eyeball return may be used to put in the cleaner line when the cleaner is not in the pool.
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Installation Optional 360 Installation The 360 is able to use the existing pool returns if there is no dedicated cleaner line available.
Return Lines B
A
Equipment Area
Cleaner C D
Eyeball Restrictors
Pool Spa The size of the pump on the existing pool needs to be large enough to provide enough pressure. The other (B, C, D) existing returns may need to be reduced or blocked to provide the operating pressure required by the 360. Pumps vary, but the best rule is to make sure there is at least a 1 HP high head pump on the existing pool.
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360 Aftermarket Kits Because the 360 does not need a booster pump and can be used in regular pool returns, adapters to various return lines are available.
This kit may be used when the existing eyeball fitting has been glued into the wall. You can remove the retainer ring and eyeball but not the threaded fitting to put in the UWF ( Universal Wall Fitting). Because the 360 does not need a booster pump and can be used in regular pool returns, adapters to various return lines are available.
This kit or connector may be used when there is no existing eyeball fitting and the return line is just a 1' opening.
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360 Aftermarket Kits Because the 360 does not need a booster pump and can be used in regular pool returns, adapters to various return lines are available.
This kit may be used when there is no existing eyeball fitting and the return line is just a 1 1/4' opening. Sleeve kit are only the rubber sleeve and must be used with the 1' kit or adaptor.
Because the 360 does not need a booster pump and can be used in regular pool returns, adapters to various return lines are available.
This kit or connector may be used when there is no existing eyeball fitting and the return line is just a 1 1/2' opening.
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Cleaner Settings and Assembly
Hose Connection
Head Float
Thrust Jet
Sweep Hose
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.
Notes:
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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.
Removal Tool #10-102-00 Use with pins still existing in the wall fitting ( UWF )
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Removal Tool #10-102-00 Use where pins are missing in the wall fitting (UWF)
Removal Tool #10-102-00 Also removes pressure relief fittings
Head Float Adjustment Standard position of the Head float is pushed all the way in towards the cleaner.
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Cleaning And Attaching The Bag Remove the bag collar from the feed hose. Push the tabs on the bag collar and twist the bag away 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.
Thrust Jet Adjustment The thrust jet powers the direction of the cleaner and gives the Polaris a random pattern. Factory position is 11 o’clock, but depending on the pool, other settings may be helpful.
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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.
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 its side when full of water • Check Wheel Spin - All 3 should spin smoothly. If not the belts and /or drive for the belts are broken or blocked.
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. Filter Is In Quick Disconnect Fitting.
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Verification of Water Flow Diagram
Cleaning The Water Management System If the cleaner has been operated with the filter screen removed, or the hose has been left attached while backwashing a filter. Small debris can travel through the hose and end up in both the vacuum jet or the turbine jet. A paperclip is the tool of choice. Dislodge the debris and with a hose back-flush the system.
Notes:
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Backups Valve The 9-100-1200 Backups Valve uses water flow to pull a cleaner backwards approximately every 2 ½ minutes.
Reverse Jet
Water Flow
Options for the Backups Valve The 9-100-1210 is a double acting mechanism (guts) for the 9-100-1200 backups valve. Normal 9-100-1200 backs up every 2 ½ to 3 minutes. If you replace the mechanism with a 9-100-1210 is will back up approximately every 1 minute and 30 seconds.
The 9-100-1205 is a booster valve seat for the 9-100-1200 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.
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Aftermarket Kits Tune Up Kit 9-100-9010 Tune-up Kit includes all wear parts but does not include a top or bottom.
Tune Up Kit 9-100-9010 Tune-up Kit includes all wear parts but does not include a top or bottom.
Rebuild Kit 9-100-9060 Rebuild Kit includes all wear parts and includes the top and bottom.
Rebuild Kit 9-100-9060 Rebuild Kit includes all wear parts and includes the top, bottom, complete sweep hose and a bag.
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Tear Down
Notes:
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Tear Down Remove the bag. Twist the bag connector until it disengages with a clicking sound from the throat.
Tear Down Remove the float. It is not threaded on. Pull straight back to remove.
Tear Down Remove the top. Use a Phillips head screw driver to remove the two screws on the back of the unit.
Once the two screws have been removed and plate pulled back off the unit you can proceed with removing the top.
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With pressure on the tabs holding the top in place, you can pull the top up and off the unit.
If the unit is prior to 2003, there is a screw mounted on the double wheel side of the top. Unscrew it and pry the two sections of the top apart.
Remove the sweep hose. Plastic clamp is split. Separate the split from side to side (straight edge screw driver will help) and the clamp may be removed. Once clamp is off, pull the sweep hose off.
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Remove the sweep hose adjustment screw. A straight edge screw driver will fit the screw or use a pair of pliers. It unscrews counter clockwise.
Remove the three screws from the feed mast and pull it out of the unit.
When you remove or install the feed pipe it is critical to the operation of the unit to note the oring on the bottom of the feed pipe. The o-ring must fit flush in the bottom fitting or the it will leak power away from the operation of the unit.
25
Four screws hold the frame in place. Remove the three that are exposed.
To remove the fourth screw under the front axle. Loosen the two screws holding the front axle enough to allow you to move the axle plate back out of the way. Then take out the final frame screw under the plate.
Notes:
26
Remove the frame. It is a tight fit and you must remove the frame by first pulling back toward the hoses and lifting the back of the frame. Lift a very little, push back towards thrust jet. Lift straight up
Grab frame here
Note: There is a disc between the belts on the drive axle. Front belt should always be mounted closest to the frame. To adjust the belts you can loosen the two screws on the front and rear axle. Adjust belt tension and tighten axles back down. You should be able to place your finger on the belt and it will flex less than ¼”.
Separation Disc
Notes:
27
Remove the belts from the wheels on the double wheel side of the frame. Just like a bicycle chain. Lift the belt off to one side and spin the wheel.
Remove the wheels. A flat head screw driver will in a small opening in each hub cap to pop them off.
Remove the wheels. There is an e-clip mounted on the end of each shaft. A flat head screw driver will help pop them out.
Notes:
28
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.
There are two bearings in each of the wheels on the double wheel side of the cleaner.
There are no bearings in the wheel on the single wheel side of the cleaner. Note that this wheel is different than the wheels on the double wheel side of the cleaner. Tires remain the same.
With the wheels off you can see that the axle blocks could be removed and replaced. You are down to the frame with the drive gear assembly and axles left in it.
29
Note the spacers on each axle. They are hard to see when you first pull off the wheels because they will be tight up against the frame.
Remove the turbine cover
Review this diagram of the drive assembly.
30
In order to remove the drive axle, there is an e-clip to remove on the axle just inside the white plastic up against the turbine wheel. Remove the e-clip and pull axle out from the turbine pulley.
Turbine Pulley Do not remove the eclip on the pulley.
Pull out the transfer pulley drive shaft
Notes:
31
You can remove the turbine wheel and drive gear. Please note that there is a bearing in the turbine wheel. It is embedded in the wheel and the only way to replace the turbine wheel bearing is to replace the entire turbine wheel. Turbine Wheel
Turbine Wheel Bearing
Turbine Pulley/ Drive Shaft
To put the turbine pulley/drive shaft back in, remove the bearing on the single wheel side of the frame. Replace the turbine wheel and drive gear. Push the drive side ¾ of the way through the unit so that it is just sticking out of the bearing holder.
Notes:
32
Drive Gear
Put the e-clip back on the drive shaft
This is why it is important to leave the bearing out to this point. You need to mount the e-clip before it is back in position, behind the frame. Now replace bearing. Remember, solid blue side out
Notes:
33
Lift shaft up and push all the way in so eclip is now behind frame
Replace the turbine cover
Remove the weight.
34
Replace the wheels and belts. Don’t forget the spacers.
Front wheel belt first.
Frame with wheels should be all reassembled. Let’s take a look at the bottom.
Notes:
35
The water management system starts at the bottom of the feed pipe. It supplies water to the turbine to make the wheels turn, a hose to the thrust jet, and a hose to the sweep hose. To Turbine
To Thrust Jet
To Sweep Hose
The water management system also supplies two fittings on either side of the throat. These are held in place by two clips. They are covered by silicone when they leave the factory. This is to prevent dirt and sand from getting into the unit on initial start up. You can remove the silicone and clamps to replace the entire water management system.
Notes:
36
You could remove and/or replace the water management system by cleaning out the silicone. With pliers pull the clamps out on either side of the throat. .
Water Management Replacement.
37
The most common mistake when rebuilding a unit is to leave the lower turbine cover out. Please replace it in the bottom now.
Replace the weight.
Notes:
38
Replace the frame. It is a tight fit and you must replace the frame by holding the back of the frame. Getting the front of the frame in place first. Then push back of frame down as close to the back of the unit as possible. Grab frame here
Pull the front wheel forward to the proper tension for the belt. Tighten down the axle screws.
Notes:
39
Four screws hold the frame in place. Remove the three that are exposed.
Replace the three screws from the feed mast and pull it out of the unit. Making sure the o-ring at the base of the feed pipe is flush and clean. .
40
Replace the top.
Replacing float. Head float gets pushed all the way forward to the cleaner.
Make sure the thrust jet is set at 11 o’clock.
41
Replace the sweep hose and sweep hose adjustment screw. Screw the adjustment screw in until it bottoms out, then back it out 1 ½ to 2 turns. This will allow the sweep hose to sweep and not whip.
Serial Number Serial Number is located on the frame and on the back of the unit.
Serial Number It is a bar code label. The product identifier.
This is the date the unit was built.
This is the number of the unit that was built on that date. 42
Troubleshooting 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 its side when full of water • Check Wheel Spin - All 3 should spin smoothly. If not the belts and /or drive for the belts are broken or blocked.
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.
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
Notes:
43
44
45
Polaris 360 - 3/11 46
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
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
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