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Pro-Team Upright Vacuum Service Manual Download Page 22

Wire Harness

21 

www.pro-team.com      866.888.2168

WIRE HARNESS REPLACEMENT 

(CONTINUED FROM PAGE 20)

Remove wire ties. Remove the circuit breaker and 
power nozzle lockout switch. Do not remove power 
nozzle motor.
*ProCare models do not have a power nozzle 
lockout switch.

23.

Disconnect all wire connections.

22.

To replace lower wire harness remove (8)
baseplate screws and turn vacuum back over to 
remove base cover.

21.

Attach bag housing. Insert (4) bag housing screws. 
Upper wire harness replacement now complete.

20.

(Continued on page 22)

Summary of Contents for Upright Vacuum

Page 1: ...Upright Service Manual ...

Page 2: ...27 Hose Sleeve Replacement 28 Pivot Bearing Replacement Wheel Replacement 29 Detent Spring Replacement 30 HOSE AND POWER CORD Index 31 HANDLE Index 32 Assembly 33 35 Handle New Power Cord Strain Relief Replacement 36 37 Handle and Power Cord Installation 38 Impact Bumper Installation 39 FINAL VACUUM Assembly 40 TROUBLESHOOTING Clearing Hose and Wand Obstructions 41 42 www pro team com 866 888 2168...

Page 3: ...e Plate Phillips Screws Bag Cover Latch Spring Bag Cover Latch Plate Bag Housing Cover Bag Cover Release Latch Release Button Springs BASE HEPA MODEL Bag Cover Release Latch Release Button Springs Bag Housing Cover Bag Cover Latch Spring Bag Cover Latch Plate Crossover Duct Inlet Seal Duct Crossover Bag Cover Lower Crossover Duct Bag Cover Nozzle Plate Seal Bag Cover Nozzle Plate Bag Cover Gasket ...

Page 4: ...as 4 Phillips screws 2 Using a flathead screwdriver pry upward on bag cover latch spring to release 4 Insert flathead screwdriver beneath bag cover latch plate to release Make sure rounded points clear holes in bag cover 5 Using thumb to hold in place insert flat head screwdriver into bag cover near top to release bag cover release latch 6 Lift transition duct duct crossover from bag cover nozzle ...

Page 5: ... Housing Completed Bag Housing Bag Housing Seal Gasket Filter Lock Out Cover Switch Phillips Screw Filter Lock Out Switch Bag Housing Assembly with Riveted Hinge and Bag Cover Nozzle Plate Handle Nut Plate Rivet for Bag Housing Assembly ...

Page 6: ...itch cover and filter lockout switch To remove the switch cover insert a flathead screwdriver under switch lever and gently pry upward 3 Remove crimps by pressing locking tab on locked connector 4 Remove cover screw 2 To Reassemble Repeat steps in reverse Remove 4 screws located near bottom of bag housing 2 front 2 back Remove bag housing 5 ...

Page 7: ... bag housing Remove filter bag 1 Remove switch cover and filter lockout switch To remove the switch cover insert a flathead screwdriver under switch lever and gently pry upward 3 Remove crimps by pressing locking tab on locked connectors Reverse steps to reassemble 4 Remove cover screw 2 ...

Page 8: ...ease cuff and re glued into the bag cover If this collar test fails Proceed to Step 2 1 Clean the quick release cuff and bag cover with rubbing alcohol to ensure a secure grip Apply a continuous bead of adhesive around the entire perimeter of the detached collar Care should be taken to avoid drips and runs 2 Quickly insert collar into bag cover evenly pressing firmly for 20 seconds to ensure an ad...

Page 9: ...www pro team com 866 888 2168 8 QUICK RELEASE CLIP REPLACEMENT Aligh tabs Push ends together 1 Snap into place 2 Bag Housing ...

Page 10: ...n f Fasten switch cover with screw g If replacing the bag housing seal do not let the seal cover the lockout switch cover opening NOTE Make sure the handle nut plate is in place before you replace the bag housing gasket seal Switch Cover Phillips Screw Bag Housing Gasket Seal Filter Lock Out Switch Cover Filter Lock Out Switch a Bag Housing Assembly Left Right Wand Guide or both Duct Assembly APPL...

Page 11: ...Lockout Switch Upper Motor Mount Lower Motor Mount Motor Includes Wires Left Panel Motor Housing Sound Foam Front Panel Motor Housing Sound Foam Rear Panel Motor Housing Sound Foam Rear Wheel Pivot Bearing E Power Nozzle Switch Harness A Main Power Supply Harness 105754 Wire Harness Kit Includes A D C Bag Full Indicator Sensor B Jumper Harness BASE MODEL APPLIES TO XP MODELS ONLY Completed Motor H...

Page 12: ...Open bag housing cover Remove Intercept Micro Filter 1 Remove switch cover and filter lockout switch To remove the switch cover insert a flathead screw driver under switch lever and gently pry upward 3 Remove switch cover screw 2 Remove crimps by pressing locking tab on connector 4 Motor Housing ...

Page 13: ... 13 Remove the bag full indicator tube tube not pictured from the bulkhead and lift off the bulkhead 6 Remove 4 bag housing screws and bag housing 5 Remove upper motor mount Lift motor from housing 7 Disconnect motor crimps from motor and from lower air duct Remove motor 8 Motor Housing ...

Page 14: ...n page 14 Turn vacuum over and remove 8 screws 11 Housing should look like this after the foam and air duct are removed 10 Remove 2 lower air duct screws from inside motor housing then remove the foam that covers wire harness 9 Slide duct flex hose from powerhead 12 Motor Housing ...

Page 15: ...SSEMBLY CONTINUED FROM PAGE 13 To Reassemble Repeat steps in reverse Remove 2 wheel clamp screws on left and right wheels 13 Remove wheels and pivot bearings Pull wire harness through body housing 14 Remove exhaust filter 15 Motor Housing ...

Page 16: ...snap lock latches and pry open wand guides using your two fingers 1 Switch Installation Seat switch into the left wand guide Snap lock latches together all the way up both sides of the wand guides 2 Unsnap latches closest to fingers first Left Wand Guide Lock Latches Right Wand Guide Guide Latch Switch Latch Hole Note Use care in prying open latches with screwdriver so as not to break tabs Motor H...

Page 17: ...andle and power cord Open bag housing cover Remove Intercept Micro Filter 1 Remove switch cover and filter lockout switch To remove the switch cover insert a flathead screwdriver under switch lever and gently pry upward 3 Remove switch cover screw 2 Remove crimps by pressing locking tab on connector 4 ...

Page 18: ...NTINUED FROM PAGE 16 Continued on page 18 Remove the bag full indicator tube tube not pic tured from the bulkhead and lift off the bulkhead 6 Remove 4 bag housing screws and remove bag housing 5 Remove upper motor mount 7 Disconnect motor crimps from motor and remove motor 8 ...

Page 19: ...se assembly Pull the air duct system air duct hose and lower wire harness out of the motor housing 10 Remove 2 lower air duct screws from inside motor housing then remove the foam that covers wire harness 9 Note Rotate brass fitting so it cannot be trapped by the lower duct Insert new power nozzle wire harness in motor housing locking brass fitting into position as shown 11 ...

Page 20: ...s Wire harness should remain behind lower duct assembly Reinstall foam as shown 12 Connect wires as shown Red to red White to white 14 Note The two black wires are threaded up through the wand guide Replace vacuum motor as shown 15 Note motor must be properly seated It is properly seated when the motor can no lon ger rotate easily The bulkhead will not fully seat over the motor housing if the moto...

Page 21: ...unt 16 Pull wires up through housing one on each side 18 Reinstall bag lockout switch 19 17 Tuck wires below bulkhead leaving the bag full indicator tube out to insert into the bulkhead as shown If the bulkhead does not seat firmly onto the motor housing you must adjust the motor until the motor is properly installed Continued on page 21 ...

Page 22: ...kout switch Do not remove power nozzle motor ProCare models do not have a power nozzle lockout switch 23 Disconnect all wire connections 22 To replace lower wire harness remove 8 baseplate screws and turn vacuum back over to remove base cover 21 Attach bag housing Insert 4 bag housing screws Upper wire harness replacement now complete 20 Continued on page 22 ...

Page 23: ...other end of the hose and position in the base assembly Replace the cover air duct and screw 26 Thread the air duct hose into the motor housing turning counter clockwise 25 Remove screw that holds the cover and air duct 24 Connect wires as shown and verify orientation of switches 27 BLACK WHITE RED BLUE Continued on page 23 ...

Page 24: ...e powerhead should go back to normal operation 6 Turn the vacuum on in position number one I The vacuum motor should be on Pull out the wand and cover the end of the wand with your hand This will simulate blockage and the bag full light should come on Take your hand off the end of the wand and the light should turn off If your vacuum passes these tests your vacuum is ready to use Attach new blue a...

Page 25: ...er Press brass tab inside bracket down so it is flush with brush 2 Disconnect wire from carbon brush 1 Using pliers or fingers carefully grasp tab and remove carbon brush from bracket 3 Carefully bend brass tab slightly upward with small flat tip screwdriver 2 Re connect wire Replace locking tabs Bend tabs downward 3 Insert carbon brush into bracket 1 ...

Page 26: ...ver Brush Retainer Phillips Screw Brush Roll Retainer Motor 14 Brush Roll Air Duct Base Cover Seal Lower Hose to Air Duct Rear Wheel Clamp Phillips Screw Air Duct Hose Sleeve Brush Roll Drive Belt Front Roller Axle Shaft Motor Vibration Grommet Motor Phillips Screw Formed Wire Brace Vinyl Bumper Base Cover Phillips Screw Front Roller Baseplate Safety Lockout Switch XP models only ...

Page 27: ...ottom view Additional components a Install sleeve and hose b Install duct cover c Install electronic components Vacuum Operation Indicator Board circuit breaker and power nozzle lockout switch lockout switch XP models only not pictured d Attach jumper wire to Vacuum Operation Indicator Board e Make sure components are properly seated in the base 3 a b d Insert braces 1 ...

Page 28: ...ves on the power nozzle base Wheel clamps are then put into place and screwed down Power nozzle cover will then be placed on top of the base 2 Place axle sleeve onto motor axle making sure the shoulder is facing the motor housing Put wheel onto motor housing axle 1 Flip the unit and fasten cover to power nozzle base using 8 screws 3 ...

Page 29: ...rews from base plate Turn vacuum over and pull base cover off powerhead 1 Unclip circuit board and move aside 2 Pull off air duct cover Pull out hose sleeve Replace with new sleeve Sleeve must sit in groove to be properly seated Reverse steps to reassemble 4 Unscrew air duct cover 3 ...

Page 30: ...EPLACEMENT To Reassemble Repeat steps in reverse Remove 8 screws from base plate 1 Turn vacuum over and pull base cover off powerhead 2 Remove right and left rear wheel clamps 3 Lift bag housing from powerhead and remove wheel 4 Remove old pivot bearing Install new pivot bearing 5 ...

Page 31: ...tent springs 1 Use needle nose pliers to remove detent spring if there is adequate spring to grab 2 If there is not enough detent spring to remove with pliers use a flat head screwdriver to pry out broken spring 3 Place new detent spring into spring slot in vacuum power head as shown 4 Push down on detent spring until fully seated 5 ...

Page 32: ...ool Caddy for Base Model Handle Assembly Screw for Base Model Power Cord with Strain Relief Quick Release Hose Cuff Quick Release Hose Clip Hose Assembly with Cuffs WAND AND HOSE APPLY TO XP MODELS ONLY Cord Retention Clip Handle Assembly Screw for XP Model Carry Handle with Tool Caddy for XP Model ...

Page 33: ...t Nut and Plug Rivet Handle with Over Mold and Decal Cord Wrap Bracket Handle Bezel with Screws XP version pictured Cord Wrap Phillips Screw Cord Wrap Bracket Compression Spring Washer Cord Wrap Bracket Compression Spring Handle Assembly Phillips Screw Handle Tube Bushing and Screw Handle ...

Page 34: ...he base of the handle fig 4 3 Use a flathead screwdriver fig 1 to pry bottom of switch from the handle body Disconnect all wires from switch posts by depressing locking tab on base of crimps fig 2 1 fig 1 fig 2 Remove screw at base of handle and remove from handle tube fig 3 2 fig 3 fig 4 Continued on page 34 Handle ...

Page 35: ...the upper right spade The bottom right spade will remain unattached e Connect the red wire to the top right spade 5 I 0 II position II must be on the bottom before attaching wires to spades long blue long brown short brown short blue red back of switch front of switch BLUE B L U E B L U E R E D R E D R E D R E D R E D B R O W N B R O W N BR O W N B ROW N When finished with steps a through e your f...

Page 36: ...b A into handle slot B and press firmly into place at C Be sure all switch wires are routed between screw bosses to ensure that the wires do not get damaged Insert screws into bezel fig 5 10 A C Press the switch into place in the handle bezel The II position should be closest to the front of the bezel 8 Switch must remain flat to the handle bezel when installed into handle body as shown 7 Handle B...

Page 37: ...ry handle and remove carry handle 2 Feed new strain relief clasp over the new power cord Slide strain relief up to the groove on the power cord and snap strain relief clasp into place NOTE Use care when sliding the strain relief clasp over the handle tube bushing so as not to damage bushing 4 Handle and Power Cord Unscrew cord retension clip and set aside Slide handle tube away from base Unplug ol...

Page 38: ...chet fastener in hole and push flush 5 Plug in new cord and slide handle tube into handle sleeve on motor housing Press firmly down on han dle to ensure it is fully seated Install cord retension clip next to power cord Install screw and tighten 6 Use flathead screwdriver to reattach carry handle to handle tube Ensure proper alignment of carry handle by verifying bag cover closure 7 Handle and Powe...

Page 39: ...asp opening by pushing with thumb to connect cord to handle 2 Insert the handle tube into the channel on the bag housing and press downward until it is 2 3 inches inside the channel It will be correctly inserted when the handle bushing hole in the handle tube aligns with the nut plate hole in the bag housing 1 3 ...

Page 40: ...et Discard screw only 1 2 Insert impact bumper assembly into cord wrap bracket Note Screw should be inserted inside spring from original assembly Do not over tighten 3 Place new washer on new screw and insert into impact bumper Place old washer on end of screw Note Make sure spring is installed as shown above Old Washer Handle ...

Page 41: ...Decal Attach with Handle Tube Bushing and Carry Handle with Tool Caddy Wrap Power Cord around Cord Wrap Post Hose Assembly with Cuffs Wand Carry Handle with Tool Caddy Cord Wrap Post a b c Handle Tube Bushing Handle Assembly Screw Cord Wrap Screw Power Cord Quick Release Hose Cuff Handle with Over Mold and Decal 1 2 3 WAND AND HOSE APPLY TO XP MODELS ONLY Final Vacuum Assembly ...

Page 42: ...rom the bag housing cover by using the quick release tabs FIG 2 Look into upper hose and wand Shake or insert broom handle to clear any visible debris Replace hose and wand on vacuum If blockage is not in the wand or upper hose disconnect the lower air duct hose on the back of the power nozzle FIG 3 Visually check the lower air duct hose for debris and remove To check for unobstructed air flow tur...

Page 43: ...rom outlet Open Bag Housing Cover Figure B and replace Intercept Micro Filter A full filter will restrict airflow Disconnect the lower air duct hose on the back of the power nozzle Figure C Visually check the lower air duct hose for debris and remove To check for unobstructed air flow turn on vacuum with bag housing cover closed and place hand over opening on lower air duct Figure C If you feel pr...

Page 44: ...P O Box 7385 Boise Idaho 83707 866 888 2168 www pro team com 106243 Revised 12 12 ...

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