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Repair instructions for - TOP1
Table of Contents
I. Tools needed for repair Page 3
II. Dismantling the Dolphin Page 4
III. Testing and replacing main components Page 11
– Analyze power supply Page 11
– Analyze cable Page 12
– Repair/replace cable Page 14
– Replace motor unit Page 21
IV. Replacing brushes Page 22
V. Replacing filter bags Page 25
2
*NOTE: Some images may differ slightly in shape, color, etc.
I. Tools needed for repair
• Dolphin tester
• Dolphin key
• Screwdriver or screw gun
• Needle nose pliers
• Wire cutters
• Wire strippers
•Cable crimper
•1.5 x 50mm hex screwdriver
Please note: when repairing any Dolphin cleaner,
only hand-tighten screws. Do not over tighten! For
automatic screw guns use low torque setting only.
3
II. Dismantling the Dolphin
Remove screws
attaching handle to
body.
Remove handle. Use
gentle pressure from a
screwdriver to help pry
it away from the body
if necessary.
4
II. Dismantling the Dolphin
Flip the unit over and
remove the bottom
plate.
5
Remove the two
screws attaching the
plastic screen to the
body.
II. Dismantling the Dolphin
Remove the plastic
screen.
6
Use the silver key to
remove cable from
motor unit.
II. Dismantling the Dolphin
Unplug cable by gently
pulling upward.
7
Remove the 12 screws
(6 per side) that hold
the side panels to the
chassis.
II. Dismantling the Dolphin
Location of screws.
6 per side.
8
Remove the side
panels.
II. Dismantling the Dolphin
Note that the cable
passes through the
panel on one side of
the unit.
9
The brushes and tracks
are now free to be
removed.
II. Dismantling the Dolphin
Note: the center guide
wheel contains a
removable slot for the
drive shaft. This must
be removed to replace
the motor.
10
Also, it’s easiest to
wind the tracks around
the center guide wheel
first and then attach to
unit.
III. Testing the Dolphin
Step 1. Analyze power supply
Insert round end of
Dolphin tester into
power supply where
cable connects. Plug in
power supply and push
power button.
If you get a green light,
power supply is good!
If there is no light, the
power supply should
be replaced.
11
III. Testing the Dolphin
Step 2. Analyze cable
Plug cable into
triangular end of
Dolphin tester.
Plug other end of cable
into power supply and
turn the power supply
on.
12
III. Testing the Dolphin
Step 2. Analyze cable
A green light indicates
the cable is good. If
you do not get a green
light, and you are sure
all connections are
secure, replace cable.
13
III. Testing the Dolphin
Step 3. Repairing/replacing cable
Cut off the triangle end
and pull the cable out
through the side plate.
14
Strip off the outer
cable casing to expose
the internal wires.
III. Testing the Dolphin
Step 3. Repairing/replacing cable
Strip each wire approx.
¼ inch. Note that some
cables may have three
wires: white, black and
red.
15
Using wire cutters,
separate the metal
elements, trimming
away any excess.
III. Testing the Dolphin
Step 3. Repairing/replacing cable
Crimp one element
onto the end of each
wire. This can be done
with pliers if necessary.
16
Insert the cable
through the pieces of
the cable kit in the
order shown.
III. Testing the Dolphin
Step 3. Repairing/replacing cable
Push the wires into the
triangle end as
pictured. The white
wire will always be to
the right of the
channel in the
connector, the black
wire to the left, and
the red wire (if
present) in the back.
To replace Amphenol
plug, first cut off
molded end.
17
present) in the back.
III. Testing the Dolphin
Step 3. Repairing/replacing cable
Insert the cable
through the pieces of
the cable kit in the
order shown.
18
Strip each wire approx.
¼ inch. Note that some
cables may have three
wires: white, black and
red.
III. Testing the Dolphin
Step 2. Analyze cable
Using the 1.5 x 55mm
hex screwdriver, loosen
the necessary
terminals.
• AC = white 1, black 2
• DC = white 2, black 3
• Red = ground
19
Insert the wires into
their appropriate
terminals and tighten.
III. Testing the Dolphin
Step 3. Repairing/replacing cable
Re-assemble the
Amphenol plug first by
screwing “C” into the
end, then screwing “A”
into “C” with “B”
inside.
20
Note: screwing “A”
into “C” first will twist
the cable inside the
connector and may
damage the wires!
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