Polaris ATV Workbook
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Welcome to the Polaris ATV 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 ATV is a suction cleaner.
Suction Cleaner The ATV is a 3-wheel suction cleaner that vacuums both in forward and reverse. It was originally sold as the Polaris 340. It was upgraded and became the Polaris ATV ( All Terrain Vacuum) The 340 can be identified by a dark blue top and solid wheels. The ATV has spoke wheels and a light blue top. Most parts are interchangeable between the two units. The tires are not. To take this course you will need a ATV cleaner as well as a Phillips head and straight edge screw driver. It is recommended that you obtain and read the Polaris ATV Owner’s Manual, TL-300.
Application • For all in-ground pools (gunite, vinyl, tile, or fiberglass). • No booster pump or electrical work required. • Installs
into a dedicated 1-1/2" suction cleaner line or skimmer
Features and Benefits • 1.2" suction opening • 24 GPM required for operation • Auxiliary inlet prevents pump cavitation • Bypass door releases cleaner from hang-ups • Automatic reverse drive backs out of corners • Downforce fan generates 60 GPM circulation and enhances cleaner stability • One Year Standard Warranty, 5 years on the Frame (Excluding wear items such
as bags, tires, sweep hose
or scrubbers) • 42 feet of hose packaged in the box
Operation and Performance ATV is a unique suction cleaner, moving around a pool in special cycle rolling on three wheels. It vacuums in both forward and reverse, as well as opens a bypass door which breaks suction long enough for the cleaner to remove trapped debris and continue on through the cycle. The ATV cycle is as follows: • Forward • Backup • Pivot Right • Forward • Bypass Door Open • Backup • Bypass Door Close • Pivot Left • Total Cycle Time, 4:30 @ 32 RPM
Packaging Finished Good Part Number: F7 Zodiac Premium Points: 200
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Option For Use With ATV Since the year 2000 many pools have been built with raised main drain covers. Some are raised high enough to exceed the clearance built into the cleaner.
UniCover • Fits over most raised anti-vortex drain covers, creating a surface for pool cleaners to travel over without obstruction. Available: • #5820 White • #5825 Grey • #5830 Blue
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Installation There are several options to installing a ATV. It is a suction cleaner and therefore may be installed either through a dedicated suction line attached to the suction side of the pool pump, or installed in a pool skimmer. Because there are many possible ways of installing the ATV the group of fittings, shown below, are packed in a bag with every ATV.
Option #1 Dedicated Suction Line Pressure
Pressure HEATER FILTER
Pressure Suction
PUMP
(vacuum)
Main Drain
Skimmer
Dedicated Suction Line
Return Lines
Installation When installing the hose for the ATV in a dedicated suction line, the hose may fit snug on its own. If not the hose will fall out every time the pump shuts off. In this case use the Universal Adapter (P/N 5-7100) to hold the hose in the wall.
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Installation: Option #2 Skimmer When installing the ATV in a deck skimmer, you may need the Universal Adapter as well if the hose does not fit snug on its own. If there is too much suction you may also need to install the Flow Regulator. This is adjustable to allow water from around the regulator to flow into the hose, so that you may adjust the proper suction to operate the ATV.
Optional Fittings As there are many different styles of pool skimmers in the market. There is also a 45 degree (P/N 5-7250) and 90 degree (P/N 5-7200) elbow in the fitting bag for use to install the hose.
Connecting the Hose 1) Set aside the leader hose and the one standard hose section that have a weight on them. 2) Connect remaining hose sections pushing cuffs securely together until hose reaches from the wall fitting to the farthest edge of the pool. 3) Add the standard hose section with the weight. 4) Now add the leader hose with the weight on it.
Notes:
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Test and Adjust Water Flow Fill the hose with water. Attach the Flow Regulator included in the fitting bag to the end of the leader hose. Hold the flow regulator under water and turn the pool pump on. The target area on the flow regulator represents the correct water flow range.
Proper Flow If there is too little flow: 1) Verify that the pool filter and pump basket are clean. 2) Verify that all suction lines are closed except the one utilized by the flow indicator. 3) Check hose cuffs and connections for leaks that could cause flow loss. 4) For dedicated suction line installations, adjust valve at equipment that controls the dedicated suction line.
If too much flow: 1) For dedicated suction line installations, adjust valve at equipment that controls the dedicated suction line. 2) For skimmer installations, make sure the flow regulator is installed. Turn knob on flow regulator counterclockwise until proper water flow is indicated.
Check for Proper Wheel RPM The proper revolutions per minute (RPM) of the Polaris ATV is 30 to 34. Mark a tire on the outer edge, submerge the ATV and remove air from the hose. Holding the cleaner under the water, turn the pump on and count the wheel revolutions. If the RPM is not with in range check for the proper flow again and make the correct adjustments.
ATV Troubleshooting Verify Wheel Speed • 30 – 34 free 28 – 32 running on floor Verify Hose Length • 2 to 3 sections past the furthest point Verify Placement of the Hose Weights • Up to 6 ft. deep – one weight 4 ft. back • 6 to 8 ft. deep – one 3 ft. & one 6 ft. back • Verify the Cleaner Cycles Properly • Verify that the Propeller is free from debris • Verify that the Vac Inlet is free of debris • Verify that the Swivel moves freely Notes:
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Tune Up Kit 5-9450 ATV Tune-up Kit includes all wear parts but does not include a top or bottom.
Rebuild Kit 5-9420 ATV Rebuild Kit includes all wear parts and includes the top and bottom.
Notes:
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Tear Down: ATV
Notes:
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Remove the ATV Top There are two screws mounted on the top of the ATV. Remove these screws and take the top off.
Remove the Propeller Once the top is off, remove the propeller held on by one screw on the top.
Once the top and propeller have been removed, turn the unit over. There are 5 screws on the bottom. You do not need to remove the 2 in the middle now. But if debris were caught in a unit in the field, these two could be removed to take off the bottom plate to remove the debris.
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Remove the Bottom To remove the bottom, remove the 3 screws and pull the bottom off the unit.
Remove the Belt on the Double Wheel Side Just like a bicycle chain, at the blue reverse drive, pull the belt to the side. Remove the belt
Remove Belt from Single Wheel Side Again, like a bicycle chain, starting at the blue reverse drive, pull the belt to the side and disconnect it.
Notes:
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Remove Drive Module There are three screws that hold the drive module in place. Remove these three screws and pull module out of unit. Please note location of serial number and sticker with instructions on how to replace belt on double wheel side.
Three screws to remove to take module out of unit.
Serial Number Belt Diagram
Remove Reverse Drive Cog The two reverse drives are located on either side of the module. They are held in place by a cog. Which can be removed with the help of a flat edge screw driver. The cog turns but is held in place by the tab on top of the cog. The crew drive will help while you turn to get past the locking device for it on the module. (See next slide)
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Locking tab on the module for the cog.
Direction to turn cog is counterclockwise.
Remove Reverse Drive Mechanism (RDM) Remove the screw that holds the RDM. It will slide off. You only want to have one RDM off at a time. Both of the RDM are mounted to the same shaft. If you remove both at the same time, the shaft will slide out of the unit.
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Timer Cam The timer cam is easier to watch and verify on the left side of the module as it is blue.
The timer cam should complete a full 360 degree and open the bypass door. If the timer cam did not turn, the #5 gear needs to be replaced. If it made the full turn, just the RDBMS need to be replaced.
Remove Front Plate on the Module To access the #5 Gear, remove the three screws that hold the front plate on the module. Remove the front plate.
Notes:
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The #5 Gear is black. It is the most critical gear as well as the one that can be damaged.
You can access the #5 gear without a lot of work. The #1 can be pushed aside as it flexible. Remove the #7. Now the #5 is accessible and can be removed and replaced.
There is no reason to take any more of the module apart. The module is available as a replacement part and if more work is needed than RDM replacement and the #5 Gear, full module replacement is recommended.
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The module also comes as a replacement part in the rebuild kit.
Replace the Front Plate on the Module There are three screws that hold the front plate on the module. Replace the screws and front plate.
Replace the RDM ( Reverse Drive Mechanism)
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Replace the Cog The cog now turns clockwise going on making sure that the tab on the top of the cog goes past the locking tab on the module. This will prevent the cog from moving in operation and hold the RDM in place.
Replace Drive Module Place the module back in the frame. Replace the three screws that hold it in place.
Replace the belt on the double wheel side. The diagram for the belt is on the bottom of the module. It is easiest to place the belt in the correct position on all pulleys except the back wheel first. Then press over the pulley on the back wheel.
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Adjust Belt Tension Double Wheel Side There is a black axle block at each wheel. Each has two screws. To adjust the belt tension loosen the screws. With a flat head screw driver behind the axle, pick up the tension.
Axle Block Screws
Tighten the two screws down. You should be able to press down on the belt with your finger and have ½” play.
Replace the Belt on the Single Wheel Side Place the belt on the blue reverse drive first, leaving the belt off the wheel pulley. Then move it on to the wheel pulley.
Adjust Belt Tension on Single Wheel Side There are two screws on the black axle block. Loosen the crews. With a flat edge screw driver behind the axle block pick up the belt tension by moving the block forward. Tighten down the axle screws. This belt should be tight with little or no play.
Notes:
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Axle Block Screws
Replace the Bottom To replace the bottom, there are 3 screws.
Replace the Propeller There is one screw on the top of the propeller that crews into the shaft.
Replace the ATV Top There are two screws mounted on the top of the ATV.
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Replace Tires To replace tires, just pull off the wheel.
To remove wheels. Remove the hub cap. Each hub cap has an open spot on them that a flat head screw driver will fit. Then pop them off. When putting hub caps back on make sure they snap into place.
Once the hub cap is off, a wheel may be removed. Wheels are held on to the axle with e-clips. A flat head screw driver will pry the e-clip off the axle. There is a groove on the axle for the e-clip. When replacing e-clips take care to get them fully into position and pressed all the way into the groove
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Serial Number Serial Number is located on the bottom of the module and under the handle on the top.
The serial number is a bar code. It indicates the product. The date the product was built. The number of that product built that day.
Product
Date Built
Number Built that Day
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Troubleshooting Cleaner is slow or sluggish, running with less power than normal.
Check for proper wheel RPM
Clean the filter pump and pump basket.
Cleaner is not moving.
Inspect propeller for debris or damage.
Check for broken bearings or belts.
Cleaner only turns in one direction or is running in circles
Check for proper wheel RPM
Make sure that the swivel turns freely.
Inspect propeller for debris or damage.
Remove bottom plate and verify that the intake area is free of debris.
Check for worn tires.
Verify that cleaner is cycling properly. Check power module parts. Check for broken bearings or belts.
Verify that cleaner is cycling properly. Check power module parts.
Proper Flow If there is too little flow: 1) Verify that the pool filter and pump basket are clean. 2) Verify that all suction lines are closed except the one utilized by the flow indicator. 3) Check hose cuffs and connections for leaks that could cause flow loss. 4) For dedicated suction line installations, adjust valve at equipment that controls the dedicated suction line.
If too much flow: 1) For dedicated suction line installations, adjust valve at equipment that controls the dedicated suction line. 2) For skimmer installations, make sure the flow regulator is installed. Turn knob on flow regulator counterclockwise until proper water flow is indicated.
Check for Proper Wheel RPM The proper revolutions per minute (RPM) of the Polaris ATV is 30 to 34. Mark a tire on the outer edge, submerge the ATV and remove air from the hose. Holding the cleaner under the water, turn the pump on and count the wheel revolutions. If the RPM is not with in range check for the proper flow again and make the correct adjustments.
ATV Troubleshooting Verify Wheel Speed • 30 – 34 free 28 – 32 running on floor Verify Hose Length • 2-3 sections past the furthest point Verify Placement of the Hose Weights • Up to 6 ft. deep – one weight 4 ft. back • 6 to 8 ft. deep – one 3 ft. & one 6 ft. back • Verify the Cleaner Cycles Properly • Verify that the Propeller is free from debris • Verify that the Vac Inlet is free of debris • Verify that the Swivel moves freely
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