Maytronics drive motor 5521259-1 disassembly and repair

pictures! Note the disassembled motor: there are shims that sit between planes of the planetary gears (they look like large washers). There is a circlip that holds the output shaft in place on the threaded brass bushing. Note that there is nothing that is preventing the disassembly, other than glue on the plastic nut. The glue failed after just 2-3 minutes with a hairdryer. Note the bearing, 698Z. It is in perfect shape -- the planetary gears take all the load off this bearing. It spins very slowly after the motor speed is reduced. It should not fail unless it is wet.

Now the interesting part: the wear on the outer planetary gears (the second level of gearing that is closest to the output shaft) and the carrier -- look how much slop there is! Note also that the teeth should not be pointed. The teeth in the ring gear are squared off like they should be. In general, I'd say the inner planetary gears are in great shape. The outer gears are reamed out a little (one is huge, compared to the others) and the carrier is completely shot. I'm not even sure how the little pins are still attached. There is almost nothing left of them.

I don't know if it's possible to source these parts from somewhere. I'm 99% sure they were not cast specifically for Maytronics. They reduce the speed of the motor considerably -- I think 1 gear reduces the speed by somewhere around 30%.

BTW, I just reassembled the motor without the shims. It was the only way I could get it to spin freely without binding. I think it creates just enough space for the worn gears to slop around without getting caught. I tried multiple things -- letting the gears float in some motor oil, some wheel bearing grease, some lithium all purpose grease -- none of it helped reduce the binding. On a whim I left out one shim, and then both. My gears are only very lightly lubricated. I can spin the motor in both directions, assembled, with my fingers holding the output shaft now. This should last me a while -- I'm thinking 2-3 days, but hoping for a week or 2!!!
 

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Apparently there is a Canadian company with the motor assembly: Maytronics Pool Cleaner Drive Motor. Site doesn't ship internationally. Not sure this little turd is worth quite that much. Replacing stuff with new parts with retail prices, when the plastics are going to fail from sitting in sun and chlorine, just doesn't make sense. And I think this is why Maytronics doesn't bother to stock or sell replacement motors... It's like my GE front load washer. I COULD buy a new door seal for $220, but the spider for the basket is going to disintegrate from galvanic corrosion sometime in the next 1-2 years, anyway, and they don't sell that part.
 
Wow!! Amazing disassembly work and reverse engineering. You can really see how the gear box for the drive motor can easily get fouled up. Totally agree with your assessment above - make the drive motor last as long as possible and then call it quits. Either suck it up and buy a new robot or move on to a different cleaning method.

I’ll have to go back and try to open my drive motor gear box and see how it compares to yours. I bet I find a similar set of failures.

Great post!! Thanks for the pictures. This information should definitely make it into the TFP Wiki (@ajw22) …

For what it’s worth, I decided to not use robots anymore. Went back to a suction cleaner. The price point on robots is just too rich for my tastes.
 
This information should definitely make it into the TFP Wiki (@ajw22) …

We don't have any Wiki pages on pool cleaners or robot cleaners or Maytronics robots. Basically because I have no experience with them. If someone wants to draft up an article with pictures I am happy to edit it and get it into Wiki format.
 
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Wow!! Amazing disassembly work and reverse engineering. You can really see how the gear box for the drive motor can easily get fouled up. Totally agree with your assessment above - make the drive motor last as long as possible and then call it quits. Either suck it up and buy a new robot or move on to a different cleaning method.

I’ll have to go back and try to open my drive motor gear box and see how it compares to yours. I bet I find a similar set of failures.

Great post!! Thanks for the pictures. This information should definitely make it into the TFP Wiki (@ajw22) …

For what it’s worth, I decided to not use robots anymore. Went back to a suction cleaner. The price point on robots is just too rich for my tastes.
My pool builder installed a pressure port for cleaning - said suction ports are too dangerous. I miss the thwap thwap thwap of my old baracuda from the 1980s :). Surprised to see how expensive pressure-side cleaners are, which is the reason we went with a robot in the first place. For anyone considering a robot, aside from serviceability, I'll note my Dolphin intentionally finds the 2 drains to clean them, but it doesn't have long enough "legs" to actually get off of them. Cleans well if I'm willing to drag it off the drains every 20 minutes. Oh - it also walks its way around my table pedestal and gets caught between it and the bench seat. As soon as my kids are old enough to push the vacuum around with a pole, I'm hoping I can be done with this stuff.
 
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My pool builder installed a pressure port for cleaning - said suction ports are too dangerous. I miss the thwap thwap thwap of my old baracuda from the 1980s :). Surprised to see how expensive pressure-side cleaners are, which is the reason we went with a robot in the first place. For anyone considering a robot, aside from serviceability, I'll note my Dolphin intentionally finds the 2 drains to clean them, but it doesn't have long enough "legs" to actually get off of them. Cleans well if I'm willing to drag it off the drains every 20 minutes. Oh - it also walks its way around my table pedestal and gets caught between it and the bench seat. As soon as my kids are old enough to push the vacuum around with a pole, I'm hoping I can be done with this stuff.
Yeah, VGBA Compliant drain covers ruined all forms of cleaners ability to get around the pool. My pool also has the popped up style main drains. They are terrible for any cleaner. Modern pool builders try to use channel drains (either circular or rectangular) that creates a flat profile with the pool surface so that robots can get over the areas while still maintaining compliance with VGB Act. If I ever built another pool (not likely) I would use channel drains instead.

Great write up again. I’ll see who I can shame and cajole into writing up something for a Wiki article.
 
pictures! Note the disassembled motor: there are shims that sit between planes of the planetary gears (they look like large washers). There is a circlip that holds the output shaft in place on the threaded brass bushing. Note that there is nothing that is preventing the disassembly, other than glue on the plastic nut. The glue failed after just 2-3 minutes with a hairdryer. Note the bearing, 698Z. It is in perfect shape -- the planetary gears take all the load off this bearing. It spins very slowly after the motor speed is reduced. It should not fail unless it is wet.

Now the interesting part: the wear on the outer planetary gears (the second level of gearing that is closest to the output shaft) and the carrier -- look how much slop there is! Note also that the teeth should not be pointed. The teeth in the ring gear are squared off like they should be. In general, I'd say the inner planetary gears are in great shape. The outer gears are reamed out a little (one is huge, compared to the others) and the carrier is completely shot. I'm not even sure how the little pins are still attached. There is almost nothing left of them.

I don't know if it's possible to source these parts from somewhere. I'm 99% sure they were not cast specifically for Maytronics. They reduce the speed of the motor considerably -- I think 1 gear reduces the speed by somewhere around 30%.

BTW, I just reassembled the motor without the shims. It was the only way I could get it to spin freely without binding. I think it creates just enough space for the worn gears to slop around without getting caught. I tried multiple things -- letting the gears float in some motor oil, some wheel bearing grease, some lithium all purpose grease -- none of it helped reduce the binding. On a whim I left out one shim, and then both. My gears are only very lightly lubricated. I can spin the motor in both directions, assembled, with my fingers holding the output shaft now. This should last me a while -- I'm thinking 2-3 days, but hoping for a week or 2!!!
I got 3 cleaning cycles out of the remove-the-shims hack. It was smooth enough to pass the power-on self test cycle and then run for a while, but I think the binding that did eventually ensue was just as bad as before the hack. I can imagine the motor getting really hot in there, so I've pulled it out. I've sent an email to the kibbutz to see if they will share where they get their planetary gear parts with a poor goy like me.
 
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