Jacuzzi Z Builder Series Mechanics And Repair Download

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The Mechanics and Repair of

Jacuzzi



Whirlpool Bath

Hot Tub Spas

For the Following ELECTRONIC Spas Made 1995-2001

Dealer Premium Model Line

(sold through dealers):

Z Builder Series Line

(sold through big box stores):

(does not include Z101)

Published by Clear Creek Spas



Summary of Contents for Z Builder Series

Page 1: ...Spas For the Following ELECTRONIC Spas Made 1995 2001 Dealer Premium Model Line sold through dealers Z Builder Series Line sold through big box stores does not include Z101 Published by Clear Creek Sp...

Page 2: ...N THE SPA S MAIN POWER OFF UNLESS REQUIRED TO PERFORM A TEST WHEN YOU DO HAVE POWER ON BE CAREFUL AND USE PROPER ELECTRICAL PROTECTION AND PROCEDURES Although this booklet should be able to guide you...

Page 3: ...pter Five Pressure Switch Flow Switch Chapter Six Sensors Chapter Seven Topside Control Chapter Eight Ozonators Chapter Nine Mood Lights Chapter Ten Plumbing Chapter Eleven Spa Jets Chapter Twelve Ste...

Page 4: ...uzzi Whirlpool Bath was also the time the industry was switching to electronic controlled spas Therefore I experienced the changes that have occurred during this time and continue to work in the field...

Page 5: ...ng so made spas available to many who could not afford to buy the dealer line of spas This manual focuses on both the Dealer line of Jacuzzi Whirlpool spas and the Z series SPA SHELL Jacuzzi s spa fin...

Page 6: ...plastic sheet and screwed to the spa frame An attempt to economize cost panels were built of various woods and stained but this has been discontinued Most common now are synthetic plastic panels or s...

Page 7: ...that hold the motor together Then the impellor which attaches to the motor shaft When the impellor rotates its what moves the water Between the impellor and the bracket is the seal The seal is a two p...

Page 8: ...pump The J and K pump are a volume pump at low pressure What this means is that they are designed to move a large volume of water but not at high pressure It s easy to compare the Jacuzzi pump as a wi...

Page 9: ...p cord from the control box Remove pump motor assembly Disassemble Pump wetend A Remove 4 bolts holding the front face of the pump volute to the pump housing B You will see the eye seal on the nose of...

Page 10: ...e red high wire The bottom is the black low wire Extra Help If you strip the bolts that hold the pump face volute to the J light pump housing bracket you can easily buy a long bolt and nut locally and...

Page 11: ...have TWO High Pressure pumps to drive the jets The circulation pump handles the heating and filtering Compare the 2 pump with the 1 Pump If they have an identical face they are both 1JPumps If the 2...

Page 12: ...rab the motor shaft between the pump and motor with a pair of vice grips and hand turn the impellor loose If that doesn t work you will have to use a wrench on the impellor to separate This will likel...

Page 13: ...suggestions found in later Chapters Circulation Pump On early Pinnacle you have either a smaller 110 130vac circulating pump or a larger 220 240vac circulation pump Replacement is easy for both Usual...

Page 14: ...pump motor will come with a cord It easy to splice the wires together On the larger circ pump you will remove the cord connection from the back of the motor and install into the new...

Page 15: ...better design it s a personal preference The two basic flow methods start the same way the water is pulled from the lower part of the spa called suction fittings and one or two assemblies with filter...

Page 16: ...inserted into the heater assembly On the Pinnnacle Model the heater used is a similar model to the first production model but longer On the Z112 models they used a short horizontal heater on the top o...

Page 17: ...ust be used Save the nuts because you normally must reuse them Disconnect heater assembly from plumbing ID the heater strap holding the heater in place Reach around to the back of the strap where the...

Page 18: ...an comfortably reach down and loosen the 2 other bolts holding the heater in place Remove bolts or loosen to end Now the only thing holding the assembly in place are the OH sensor and the two wires co...

Page 19: ...s on the upper strap holding the heater assembly I usually only loosen the lower 2 bolts to the end of their thread This will allow you to remove the heater assembly Reverse to install Tighten nuts sc...

Page 20: ...when loosing tightening so you don t bend the heater posts Remove old heater Reverse above to install new heater On Vertical Heater For spas with a vertical heater on the left side of the control box...

Page 21: ...opside motors and heaters Some will notify you when its time to replace the filter They are design both to make operation of the spa easier keep the water cleaner and filter the water on a regular bas...

Page 22: ...hours These cycles usually default when you first power up the spa Then it filters 2 hours at that point and 12 hours later On some models you can set a jumper on the board to increase the cycle 5 hou...

Page 23: ...control box They are helpful but it s better to replace the board systematically F106 7 and F108 9 These boards are fairly easy to replace if you are careful First turn off main power at the main brea...

Page 24: ...main power b Remove control box cover c Unbolt the 2 bolts holding the copper straps to the board Save for reuse d Unplug phone type cord from board e Label incoming power line to which terminal they...

Page 25: ...oosen the screws that hold the incoming cord The hardest thing about the replacing the board is its in a small space It has 1 2 screws holding the board to the box and 2 nylon posts Remove the screw s...

Page 26: ...g the bottom of the seating area and applying air into those nozzles Electronic spas have an automatic blowout at least a couple of times a day The spa will turn on several times a day and run for a c...

Page 27: ...ter element If sufficient pressure closes the microswitch the board turns the heater on Otherwise it does not Due to the low pressure of Jacuzzi pumps 2 speed pumps should use a 1lb pressure switch 2...

Page 28: ...way I remove the board except for the wires connected directly to the board I swing the board out and to the left and protect the board Now any water that comes out of the pressure switch hole will no...

Page 29: ...acuzzi s spas use pressure switches It wasn t until about 2000 did Jacuzzi introduce the flow switch on it s electronic spas specifically late editions of the Pinnacle the Triton and some Quantum Plus...

Page 30: ...t is how is determines spa temp Some spas have their temperature sensor inserted into the actual spa Others in a housing inserted into the spa Jacuzzi s most common design is the sensor inserts into t...

Page 31: ...ew sensor fast enough to minimize water The Over Heat sensor clips on the heater Again simply pull out Connection to the board The most common connection of the sensors to the board is a joint plug wh...

Page 32: ...models it s a step process each time you press on the switch the board responds going to the next step On other models its simply an on off response Example Press the air blower button on the topside...

Page 33: ...spas require a hot wired method your spa s control system should have a socket designed for an ozonator to plug in Once the ozonator is plugged in depending on the configuration of the spa the board...

Page 34: ...of colors through red blue and green bulbs Some systems allow you to chose the color some follow a certain rotation and others allow you to start and stop at certain colors Many system that came with...

Page 35: ...is care First you need clean both inside and outside of couplings and pipes that will come into contact Then prime Primer cleaner remove dirt and soften the plastic Again do both side of the pipe whe...

Page 36: ...he older have the AMH jet with is a medium size jet with directional nozzle but you can adjust the flow This jet is commonly used in the footwell area Because you can t adjust the flow the water from...

Page 37: ...o DC and lowers the voltage to 12 volts Jacuzzi used major brand car radios to add music and outdoor speakers Some stereos pick up noise when on AM but not FM I have found the common problem is the st...

Page 38: ...er all possibilities Just make it a routine to turn off main power when doing any service There are only a handful of times you might have to do tests that require power to be on Special care must be...

Page 39: ...TROUBLESHOOTING SECTIONS I Trips GFCI or GFI II Doesn t Heat III Motor hums IV Pump Leaks V Diagnosing by CLICKS VI Error Codes on the Topside...

Page 40: ...top and below to loosen and remove the nut Do so You will then have a totally disconnected heater from the loop Turn ON power If the spa comes on and operates fine without tripping the gfci as it did...

Page 41: ...er 110 130vac or 220 260vac depending on your spa and incoming power service To check remove the metal cover on the control box Turn on spa and let the motor come on and the heat light to come on soli...

Page 42: ...end to fail one of two ways They no longer pass current through the element and therefore no longer heat The most common cause of this failure is water quality Over time water quality can cause the el...

Page 43: ...balanced and not using too much or too little chemicals...

Page 44: ...he possibilities most techs will opt to replace the motor rather than having it rebuilt A major reason is economics both for the tech and the homeowner If the customer pays the cost of removing rebuil...

Page 45: ...gether If you have leak from there make sure the bolts or screws that hold the halves together are tight or not stripped The s of the pump must be tight together Rarely but possible are the o ring sea...

Page 46: ...see the temperature and overheat sensor are within tolerance and close to identical It also checks the pressure switch to confirm it s open If everything is fine CLICK 2 The 1 pump comes on If the spa...

Page 47: ...failure is one of the sensors See the ERROR codes section But let me mention the failures that can occur here in case the ERROR doesn t display either in Digital readout or on some ECHO spas the heate...

Page 48: ...vac check for that On 2 pump 220vac systems the 1 and 2 pump are labeled On most spas you can just ID the 2 slots the pump wires use for the white and black lines and check the voltage for 220 260vac...

Page 49: ...n t work What the board will do is catch your short When the water reaches temp and turns the 1 pump off it immediately looks at the switch to make sure it s now open your wire has made it constantly...

Page 50: ...ignal This rarely happens but when it does you have to replace the board The CLICKS are not over After the pump and heater come on and don t touch any topside control you will hear another CLICK That...

Page 51: ...he pressure switch you can try turning the wheel one full turn clockwise Otherwise replace the pressure switch Flashing FLO or FL with temperature and possibly COOL or FC This means the board has turn...

Page 52: ...pa is in Economy Mode Unit will go up to 20 degrees below the temperature set It is NOT a more economical setting It is usually set when you are on vacation and will not be using the spa STAN Standard...

Page 53: ...the PC board or Not enough water is moving over the element which is a flow problem many times due to dirty filters or Failed sensor Flashing More On then Off Meaning PC Board sees a sensor failure I...

Page 54: ...c Models AERO PLUS and SELECT ALEXA and DELFINO CIRRUS LEXUS PLUS LC and SELECT LASER PLUS and SELECT PALIO PINNACLE QUANTUM PLUS SANTINA SOLARIS TIRAGE TRITON Z 100 Z 110 Z 112 Z 120 Z 130 Z 135 Z 14...

Page 55: ...elect Accessory Air Blower on Earlier Production None on Select Series Heater 5 5kw Pump Wetend Only CC 2jp Motor Only 2500 204 or CC C180 HD Pump Motor Complete 2500 255 or CC F570HD Heater 2600 050...

Page 56: ...Water Weight 1965 lbs Voltage 110vac Pumps ONE 2hp Pump Accessory None Heater 1 5kw Part Part Pump Wetend Only CC 2jp Motor Only 2500 204 or CC C180 HD Pump Motor Complete 2500 255 or CC F570HD Heater...

Page 57: ...1hp Pumps Accessory Air Blower Heater 5 5kw Some Models 3hp 2 Pump On those it uses a CC 3jp wetend 2500 203 motor or 2500 251 pump motor complete Part Part Pump Wetend Only CC 1jp Motor Only 2500 200...

Page 58: ...ight 771 lbs Voltage 220vac Pumps Two Pump motor either 2 X 1hp OR 1 1hp and 1 3hp Accessory Air Blower Optional Heater 5 5kw Lexus Continues next page Part Part Pump Wetend Only CC 1jp Motor Only 250...

Page 59: ...or 2500 251 pump motor complete Part Part Pump Wetend Only CC 1jp Motor Only 2500 200 Pump Motor Complete 2500 250 Heater 2600 050 Board 2600 016 Topside 2500 151 Part Part Pump Wetend Only CC 1jp Mot...

Page 60: ...ght 409 lbs Water Weight 2558 lbs Voltage 115vac Pumps One 2hp 2 Speed Pump Heater 1 5 11kw Part Part Pump Wetend Only CC 2jp Motor Only 2500 204 or CC C180 HD Pump Motor Complete 2500 255 or CC F570H...

Page 61: ...lation Pump 2 High Pressure Single Speed Pumps Accessory Air Blower Optional AM FM Radio Heater 5 5kw Low Flow Part Part Circ Pump If Small Pump 110v Tiny Might If Large Pump 2500 259 High Volume 1 Sp...

Page 62: ...ccessory Air Blower Heater 5 5kw Low Flow Part Part Pump Wetend Only CC 1jp and CC 3jp Motor Only 2500 200 and 2500 203 Pump Motor Complete 2500 250 and 2500 251 Small Circulation Pump if your spa has...

Page 63: ...562 lbs Water Weight 4771 lbs Voltage 230vac Pumps Two Single Speed 1hp some models replaced one 1hp with a 3hp pump Heater 5 5kw Part Part Pump Wetend Only CC 1jp Motor Only 2500 200 Pump Motor Comp...

Page 64: ...78x72x32 Capacity 249 g Water Weight 4281 lbs Voltage 230vac Pumps 2 x 1hp Heater 5 5kw Part Part Pump Wetend Only CC 1jp Motor Only 2500 200 Pump Motor Complete 2500 250 Heater 2600 050 Board 2600 01...

Page 65: ...p and 1 3hp Pumps or 1 Circulation and 2 High Pressure Pumps Accessory Air Blower Heater 5 5kw Part Part Pump Wetend Only CC 1jp and CC 3jp Motor Only 2500 200 and 2500 203 Pump Motor Complete 2500 25...

Page 66: ...bs Voltage 230vac Pumps 1 Circulation Pump 2 Single Speed Pumps Accessory Air Blower Optional AM FM Radio Heater 5 5kw Part Part Circulation Pump 6500 035 Pump Motor Complete 6500 763 Heater 6500 301...

Page 67: ...s Water Weight 2365 lbs Voltage 110 220vac Pumps One 2 Speed 110v Pump Accessory None Heater 1 5 5 5kw Part Part Pump Wetend Only CC 2jp Motor Only 2500 204 or CC C180 HD Pump Motor Complete 2500 255...

Page 68: ...Heater 1 5 5 5kw Pump Wetend Only CC 2jp Pump Wetend Only CC 2jp Motor Only 2500 204 or CC C180 HD Motor Only 2500 204 or CC C180 HD Pump Motor Complete 2500 255 or CC F570HD Pump Motor Complete 2500...

Page 69: ...s Water Weight 3129 lbs Voltage 110 220 vac Pumps One 110vac 2hp Pump Accessory None Heater 1 5 5 5kw Part Part Pump Wetend Only CC 2jp Motor Only 2500 204 or CC C180 HD Pump Motor Complete 2500 255 o...

Page 70: ...Weight 430 lbs Water Weight 3641 lbs Voltage 110 220vac Pumps One 110vac 2hp Pump Accessory None Part Part Pump Wetend Only CC 2jp Motor Only 2500 204 or CC C180 HD Pump Motor Complete 2500 255 or CC...

Page 71: ...apacity 325 g Empty Weight 587 lbs Voltage 230vac Pumps TWO 1hp Pumps Accessory None Heater 5 5kw Part Part Pump Wetend Only CC 1p Motor Only 2500 200 Pump Motor Complete 2500 250 Heater 2600 050 Boar...

Page 72: ...Pump Heater 1 5 5 5kw Part Part Pump Wetend Only CC 2jp Motor Only 2500 204 or CC C180 HD Pump Motor Complete 2500 255 or CC F570HD Heater 2600 050 Board 2600 015 Topside 2500 152 Pump Wetend Only CC...

Page 73: ...Voltage 220vac Pumps Two 1hp Pumps Heater 5 5kw Part Part Pump Wetend Only CC 1p Motor Only 2500 200 Pump Motor Complete 2500 250 Heater 2600 050 Board 2600 601 Topside 2500 152 Pump Wetend Only CC 1p...

Page 74: ...lbs Voltage 230vac Pumps Two 1hp Pumps Heater 5 5kw Pump Wetend Only CC 1p Motor Only 2500 200 Pump Motor Complete 2500 250 Heater 2600 050 Board 2600 601 Topside 2500 152 Pump Wetend Only CC 1p Motor...

Page 75: ...ght 619 lbs Water Weight 3878 lbs Voltage 220vac Pumps Two 1hp and 3hp Accessory None Heater 5 5kw Pump Wetend Only CC 1h CC 3hp Motor Only 2500 200 or 2500 203 Pump Motor Complete 2500 250 or 2500 25...

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