How To Use the Inside of a Hayward Navigator Suction Cleaner

This guide will tell you about the Navigator to check mechanisms that typically go wrong. Is your Hayward Floor Vacuum (or Ultra Vacuum) not performing like it used to? Is it spinning in circles or getting stuck in corners instead of going around the pool? There are an assortment of gears and moving parts inside the Navigator that need to be checked and replaced now and then. Sometime, it’s just debris interfering with the movement of the gears. 

1. Tools you will need. 1) Phillips screwdriver - small and medium. 2) A work area where you can spread out. TIP: It is very important that you are careful when taking this apart. If you lay all the pieces out in a row as you remove them, it will be easier to put back together. 3) Five small Tupperware or paper bowls to put parts and small pieces in. Label them #1 – #5 with a magic marker. If Tupperware, use masking tape for a label. 4) Patience!

2. Here is a parts list for the inside of a Hayward Navigator Cleaner. 

3. Turn the Navigator upside down and remove the plug in the center. The screw will not come out all the way but you should be able to lift it out. Now remove the other four screws. You will have to hold the flaps back to access these screws. Put the screws and plug into the #1 container.

4. Pull the two sections apart. Once apart, they will look like this; the Middle Body on the left; and the Lower Body on the right.

5. Turn the bottom of the Lower Body over and inspect the bearings of the rubber wheels. If they are worn, remove the wheel subassembly and get a new one. Replacement Part # XXXX A Frame Kit. Set this Lower Body aside as we will not be working on it further.

6. Returning to the Middle Body, remove the four screws on the bumper and put them in container #2. Lift off the bumper.

7. We will now divide the Middle Body into its two sections: the Lower Middle Body and the Upper Middle Body. Remove the two screws as shown on the picture and put them in the same container. They are smaller than the others, so remember that when putting it back together. Gently lift the Lower Middle Body away from the assembly and turn it over. The names seem off, but remember that the Navigator is on its back. If the Navigator was placed right side up, this Lower Middle Body would be on the bottom.

8. When you turn the Lower Middle Body over it might look like this. Sometimes the little red 3/4 circle show here (the Spinner) and the black Turbine fall off their mountings and end up in the other section. Remember this when you are putting the two sections back together. Carefully lift out the red Spinner and the white washer that's behind it and put them in container #3.

9. Inspect the Rear Screen on the Lower Middle Body. Again this may have stayed with the Upper Middle Body. Brush the screen with a brush to remove any debris. If the screen is damaged, replace it. Replacement Part # 3259-0040, Screen.

10. Lift out the black Turbine and inspect the wheels and bearings. These are the most common things to wear out. Replacement Part # 3259-0006, Main Turbine Bearings. Put the Turbine and Bearings in container #3. NOTE: The ends of the Turbine and the Middle Body Assembly have L & R letters for left and right. When you put it back together, it is important that they go back together like this.

11. Lift the Gear Box Assembly out of the Lower Middle Body. You don’t need to open it as it consists of layers of gears.

12. Blow into the little square hole on the angled end. The gears should make a high spinning sound. If not, or it sounds off, carefully remove the top and see if there is any debris inside of it. If you do open this, be careful that the gears don’t spill out. (I once found a small copper wire in one)

13. Move to the Upper Middle Body. Remove the two screws on the Medium Turbine Case and put them in container #4. Remove the case. Open the case and inspect the gear on the Aqua green Medium Turbine. Replace if worn. Replacement Part #3259-0008, Medium Turbine. Put case and Turbine in container #4.

14. Remove the four screws on the Upper Middle Body and put them in container #5. The gear circled is the Medium Turbine Drive Gear that it is connected to the shaft of the Spindle Gear. This gear is discussed in steps 16 and 17 below.

15. Turn the Upper Middle Body over and let the Cone Gear assembly drop onto your hand (The Cone Gear may fall out separately). If the Cone Gear dropped out with the rest of the assembly, it will look like this.

16. After you lift the Cone Gear off, the assembly will look like this. The most common pieces to wear out are the Intermediate Gear, the Spindle Gear, and the Medium Turbine Drive Gear that is connected to other end of the shaft for the Spindle Gear. After checking the Intermediate Gear for wear, pull it out and set in container #5. Replacement Part # 3259-V301, Intermediate Gear.

17. Wiggle Spindle Gear a little. Is it firmly in place or does it feel sloppy? If the later of the two, it needs to be replaced. You can replace it by removing the screw on top. Replacement Part # 3259-V303, Spindle Gear. Check the Medium Turbine Drive Gear that is on the other end. Replacement Part # 3266-0010, Medium Turbine Drive Gear. The Cone Gear usually doesn’t wear out but check it anyway. Replacement Part # 3259-V070.

18. That’s it! If you experienced any of the problems mentioned in the guide, research the parts and prices at Navigator Part List. Remember, if you have to replace several parts, it may be less expensive to replace the whole Navigator.

19. To reassemble the Navigator, start by reassembling The Cone Gear assembly to look like this. Make sure all the gears line up.

20. Put the top back on, and gently turn the assembly over. Using the four screws from container #5, reconnect the top to the Cone assembly. From the top turn the cone assembly tube to make sure all the gears are meshed and turning. You should see the white gear on the other side of the Cone Gear assembly rotate.

21. Put the Medium Turbine and Medium Turbine Case back together and screw in place using screws from container #4. Be sure the teeth on the Medium Turbine match up with the white gear. This completes the reassembly of the Upper Middle Body.

22. Moving to the Lower Middle Body, put the Gear Box Assembly in place. The little tab will be facing out towards the back of the assembly.

23. From container #3 put the white washer on the small square of the Gear Box and the red spinner on top of that (it doesn’t matter which way it faces). Put the Turbine Bearings back onto the black Turbine. The bearings have a little slot in them so they can only go on one way. Then put the Turbine back into its slot in the Lower Middle Body Remember that there are LEFT and RIGHT markings on the Turbine and Body Frame.

24. Put the Middle Body back together by placing the Upper Middle Body on top of the Lower Middle Body. This can get a little tricky because the Rear Screen slips into little grooves. Carefully turn the combined Middle Body over and secure it using the two smaller screws from container #2. DO NOT put the last four screws in yet. It will mess things up.

25. Put the Bumper on top of the Middle Body using the remaining four screws from container #2.

26. Put the Lower Body back on taking care that the black wheels fit snuggly on the outside of the turbines. DO NOT FORCE. It should just drop in but you may have to wiggle it a bit.

27. Use the screws from container #1 and put it all back together.

28. Now, with the top of the cone gear protruding from the top of the vacuum, pull up on it and turn it. You should hear a nice slow spinning sound coming from the Navigator. If you hear any kind of crunchy sounds or the mechanism doesn’t sound right, then you did something wrong and will have to take it apart (that’s how I leaned!). However, before doing so, put it in your pool and see how it works.

29. TIP: Under one of the back pods you will see a turquoise screw marked I, II, and III. By adjusting this you create more service tension on the flaps. A "II" setting is the normal operation level for the cleaner. A "I" setting slows the Navigator/Pool Vac Ultra down if it's climbing the walls or sticking in corners; A "III" setting speeds the Navigator/Pool Vac Ultra up if it can't climb the slopes.

If you have any other questions about pool and spa products please do let us know - we are here to help!

Leave a comment