Polaris 340 & ATV Power Module Training and Troubleshooting Guide

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1 Polaris 340 & ATV Power Module Training and Troubleshooting Guide Summary: This guide is intended as a training tool for the mechanical evaluation and troubleshooting of a 340 or ATV power module only. It does not contain any information pertaining to cleaner in-pool performance or setup.

2 Evaluation: Step 1 Step 1: Remove the Engagement Cogs (qty. 2) and Reverse Drive Mechanisms (qty. 2) from the power module assembly by unsnapping the cogs and removing the screws on the end of the drive shaft. Set aside the mechanisms and replace the two screws onto the ends of the drive shaft to ensure that it does not slide into the module. Reverse Drive Mechanism Replace Screws Onto End of Shaft Rotate Engagement Cog to Release from Snap and Remove. Engagement Cog

3 Evaluation: Step 2 Step 2: With a MANUAL Phillips head screwdriver placed on the right hand drive shaft screw, begin to spin in a clockwise direction. This will allow you to advance the module through each phase of its cycle. Rotate Shaft in Clockwise Direction from Right Hand Side of Module to Advance Cycle

4 Evaluation: Step 3 Step 3: While spinning the drive shaft, verify that the module spins smoothly and that there are no binding points. If any binding occurs, check for debris wound up around the turbine. If this is clean then the problem is likely due to a bad internal bearing. Replace the module. Check For Debris Wound Around Turbine While Rotating Shaft, Ensure No Binding Occurs

5 Evaluation: Step 4 Step 4: While continuing to spin the drive shaft, verify that the propeller shaft is also spinning in a counter-clockwise direction. With a finger, place a small amount of tension on the propeller shaft while spinning to ensure gears are fully engaging. If the propeller shaft does not spin, there is a failure of the propeller miter gears. Replace the power module assembly. Prop Shaft Should Spin Counter Clockwise Place Light Tension on Prop Shaft with Finger to Ensure Gears Fully Engaged Rotate Shaft in Clockwise Direction

6 Evaluation: Step 5 Step 5: While continuing to spin the drive shaft, verify that the blue and white timer cams are spinning. Note that these will spin at a much slower rate than the drive shaft. Observe for s for verification. If the timer cams do not spin there is a failure in one of the drive train gears, likely gear #5 (the worm gear). Go to step 5b on the next page. If they do spin, skip to Step 6. White Timer Cam Should be Rotating Counter- Clockwise While Shaft is Turned Blue Timer Cam Should be Rotating Clockwise

7 Evaluation: Step 5b (Worm Gear Replacement) 1.) Loosen and remove screws (3) securing transmission housing cover. 2.) Remove bearing support and gear #7 to access gear #5 (worm gear). 3.) Spin gear #5 counterclockwise and pull off. Ensure all pieces of gear are dislodged and removed by rotating the timer cross shaft. 4.) To install new gear push in and rotate clockwise to engage. New gear will be black in color in Fall, ) Reinstall #7 gear, bearing support, and transmission cover. *Note - If at any point all the gears should fall out, reinstall by placing gears in order 1-7 with the numbers facing out. Rotate timer cross shaft to dislodge broken remnant Remove bearing support and #7 gear Rotate counterclockwise and pull to remove broken gear

8 Evaluation: Step 6 Step 6: While continuing to spin the drive shaft, verify that when the blue and white timer cams are oriented horizontally, that at the same time the left and right actuators have fully extended. If the actuators do not extend than there is a failure on the timer cam. Replace the power module. White Cam Horizontal Blue Cam Horizontal Actuator Extended out of Module Housing Actuator Extended out of Module Housing

9 Evaluation: Step 7 Step 7: While continuing to spin the drive shaft, after verifying that that timer cams are turning, verify that they make contact with and open the bypass door. If this does not occur, replace the bypass door or power module assembly as required. Verify that cams open and close bypass door

10 Evaluation: Step 8 Step 8: If you have performed evaluation steps 1 7 without finding any problems, then the gear train inside the power module is performing as expected and there is no need for a full power module replacement. The Reverse Drive Mechanisms should now be inspected for replacement. Cycle the module until the white timer cam is pointing straight down and then reassemble the reverse drive mechanisms and engagement cogs. With timer cam cycled to down position, reassemble the reverse drive mechanisms and engagement cogs

11 Step 8: Reverse Drive Mechanism Evaluation Step 8: With the Reverse Drive Mechanisms now assembled, again, with a screwdriver placed on the right side of the main drive shaft, spin in a clockwise direction. As you spin through the cycle you should see the mechanisms engage, spin in reverse, disengage, and return to forward motion. If this sequence does not happen, replace both mechanisms. (*- Note that tension may need to be applied to the blue pulley to allow mechanism to fully engage in reverse) With cam in horizontal position, white portion of reverse drive mechanism should extend out and pulley should reverse direction Pulley spins counter clockwise Rotate Shaft Clockwise

12 Part Name Quick Reference No. Description Reverse Drive Mechanism Engagement Cog Reverse Drive Actuator Timer Cam Bypass Door Main Drive Shaft Propeller Shaft

13 The Full Cycle of a Power Module The various forward and reverse phases of the cleaner can be identified by keying on the location of the timer cam on the power module. The following pictures follow the white timer cam through the course of a full module cycle: Cleaner in forward motion 2. Cleaner in reverse motion 3. Cleaner makes right hand pivot 4. Cleaner in forward motion 5. Bypass door opens 6. Cleaner in reverse motion (bypass door closes) 7. Cleaner makes left hand pivot 8. Cleaner returns to forward motion

14 Quick Reference Sheet 340/ATV Module Troubleshooting 8 Steps to module troubleshooting: 1. Remove the Reverse Drive Mechanisms and Engagement Cogs from the Power Module asy. Replace screws onto end of shaft. 2. Place Phillips head screwdriver on right side of drive shaft and spin clockwise. While spinning, check the following: 3. Check for any binding of the module. 4. Verify that the propeller shaft is spinning. 5. Verify that the blue and white timer cams are rotating (replace #5 gear if needed). 6. Verify that the left and right actuators are functioning. 7. Verify that the bypass door opens 8. Verify proper operation of the reverse drive mechanisms

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