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ProTeam GoCartVac, Service Manual

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ProTeam GoCartVac Service Manual Download Page 42

40

www.pro-team.com   866.888.2168

Remove/Replace Charger Receptacle

REMOVE CHARGER RECEPTACLE

REPLACE CHARGER RECEPTACLE

Squeeze together the sides of 

the receptacle.

3.

Push through hole while continuing 

to squeeze sides.

4.

Push new receptacle through the cover of the 

enclosure. 

1.

1. Remove Charger Panel 

(Page 4)

2. Remove Cover of Electrical Enclosure 

(Page 38)

2. Replace Cover onto Electrical Enclosure 

(Page 39)

3. Replace Charger Panel 

(Page 6)

Summary of Contents for GoCartVac

Page 1: ...GoCartVac Service Manual...

Page 2: ......

Page 3: ...tor 29 Batteries Harness Safety Notice Precautions 30 Battery Termination Schematic 31 Disassemble Reassemble GoCart 32 Remove Replace Fusible Link 33 Remove Replace Red Jumper Wire 34 Remove Replace...

Page 4: ...inals of batteries should avoid wearing metal rings or watchbands It is a good practice to remove all metallic items such as watches bracelets and personal jewelry when working on or around battery te...

Page 5: ...t Swivel Elbow Cuff Black 17 106550 Switch Replacement 18 106284 Kit Vacuum Attachment Hardware for Cart 19 106219 Kit Power Receptacle Cord 20 106211 Box Sound w Corner Rails 21 106213 Cart Assembly...

Page 6: ...by pulling straight up carefully ATTENTION Pull up carefully as cord is attached to vacuum 1 Place cover into tray of cart 2 Remove side panel closest to power switch by push ing in and pulling up at...

Page 7: ...Continued from page 4 Grab each end of the charging harness and work back and forth as you pull apart 5a 5b Slide the charger s black red connector apart from the other two 6a 6b Unplug charger from...

Page 8: ...s from batteries and vacuum 4a 4b Attach the charging harness terminal to the three connectors of the charger batteries and vacuum 5 2 Slide panel into cart by placing side without molding into empty...

Page 9: ...page 6 Slide remaining side panel into cart by placing both sides into empty channels of molding Confirm that the panel is resting on the bottom of the cart and that the corner molding and panel are e...

Page 10: ...888 2168 Remove Vacuum Panel REMOVE VACUUM PANEL Slide the remaining two red black connectors apart from each other 2a 2b Disconnect plug from vacuum 3 Carefully remove vacuum panel from cart 1 Remov...

Page 11: ...of the vacuum to the red black connector from the batteries 3 Plug cable from cover of cart into vacuum 4 2a Slide panel into cart by placing side without molding into empty channel of molding from s...

Page 12: ...to remove two screws and washers 3 Remove cap by twisting counter clockwise 4 Remove both cloth and paper filters 5 Using a 5 16 socket or flat head screwdriver remove two screws holding plastic diffu...

Page 13: ...dy 3 Secure lid on vacuum by turning clockwise 4 Lay vacuum flat with mounting holes up 5 Lay panel on top of vacuum align ing mounting holes in vacuum with holes in panel 6 Attach vacuum to back pane...

Page 14: ...remove top horizontal connector on battery control module BCM white wire from receptacle with needlenose pliers 4 Locate black wire with white connector from receptacle on BCM and remove with needleno...

Page 15: ...ttach receptacle to vacuum body with two screws using a Phillips screwdriver 3 Connect the black receptacle wire to the vertical BCM location marked Switch with needlenose pliers or fingers 4 Connect...

Page 16: ...able and remove from BCM 5 8b Holding outer nut unscrew the inner nut from the threads on the cable Remove cable from vacuum 8a Locate black wire of power cable on BCM Remove w needlenose pliers or fi...

Page 17: ...f up to washer and outer nut Tighten all with crescent wrench 3 Attach the white wire from power cord to the middle connector marked with 36V 4 Attach the white wire from switch receptacle to the top...

Page 18: ...connector of new or existing thermal switch to motor wire 1 Connect female connector of thermal switch to MOTOR on BCM 2 1 Remove Charger Panel Page 4 2 Remove Vacuum Panel Page 8 3 Remove Diffuser P...

Page 19: ...6 888 2168 17 REMOVE BCM Remove all wires connected to BCM 4 Remove screw holding BCM to compression ring with either a flathead screwdriver or 5 16 socket Remove BCM 5 1 Remove Charger Panel Page 4 2...

Page 20: ...thermal switch to MOTOR on BCM 3 Reconnect black wire of receptacle to SWITCH on BCM 4 Attach the black wire from the motor to the bottom horizontal connector marked with MTR 5 Attach the white wire...

Page 21: ...e 3 washer cover caps 6 Use Phillips screwdriver to remove screw and Z washer Remove all three 7 1 Remove Charger Panel Page 4 2 Remove Vacuum Panel Page 8 3 Remove Diffuser Page 10 4 Remove Receptacl...

Page 22: ...lace motor into vacuum body 2 Align motor as shown in picture BCM close to power cable hole 3 Press well nuts into holes in vacuum body Rotating as pushing in may ease assembly 4 Ensure well nut is fl...

Page 23: ...crews 7 Tighten screw on Z washer until well nut has tightened against vacuum wall 8 Press washer cover cap over washer 9 Replace power cable Follow Steps 1 through 6 on Page 15 10 Replace receptacle...

Page 24: ...ently wedge between center of motor brush and clip Turn screwdriver counter clockwise to push out the wire clip under the motor brush insulation Do not press downward on the clip or use exces sive for...

Page 25: ...om page 22 Remove two screws and bracket over the motor brushes 7a 7b Remove motor brush Remove 2nd motor brush in same way Tip brush upward and slide connec tor out 8 TIP New carbon brushes give off...

Page 26: ...nder the top insulation 1a 1b Replace brush brackets with screws 2 With end of flathead screwdriver push wire clip back into place 3 Replace screw and wire retaining clamp on each side of motor 4 If a...

Page 27: ...onnect thermal switch s other wire to MOTOR on BCM 2 Connect remaining motor wire to MTR on BCM Go to Page 21 Step 1 11 3 Remove thermal switch connector from BCM 5 If all changes are complete 4 Repla...

Page 28: ...rd 7 Remove ring over top of motor 9 Remove remaining 3 screws which attach compression ring to motor 8 1 Remove Charger Panel Page 4 2 Remove Vacuum Panel Page 8 3 Remove Diffuser Page 10 4 Remove Mo...

Page 29: ...ws which attach the ring to the motor Leave out a screw which is not under a wire clamp where the BCM was attached 2 Re attach PC board in remaining hole on compression ring 3 Reconnect remaining moto...

Page 30: ...ing tetraseal over top of motor 1 Press down on seal until flush with motor flange 2 Replace compression ring BCM and re wire per Steps 1 through 5 on Page 27 3 If all changes are complete 4 Replace M...

Page 31: ...lace compression ring tetraseal and BCM on new motor per Steps 1 through 3 on Page 28 1 Reconnect thermal switch to motor wire 2 1 Remove Charger Panel Page 4 2 Remove Vacuum Panel Page 8 3 Remove Dif...

Page 32: ...internal impedance and thus are capable of delivering high currents if externally short circuited The resultant heat can cause severe burns and is a potential fire hazard Remove all metallic items su...

Page 33: ...Battery Termination Schematic www pro team com 866 888 2168 31 Refer to this schematic for removing and replacing of battery wires Red Jumper 105844 Power Harness 105834 M2 M1 Fusible Link 105842...

Page 34: ...eassemble GoCart DISASSEMBLE GOCART Remove remaining side panel and molding 3 1 Remove Charger Panel Page 4 2 Remove Vacuum Panel Page 8 REASSEMBLE GOCART 1 Replace Vacuum Panel Page 9 2 Replace Charg...

Page 35: ...ry B1 and using the red terminal end of the fus ible link a Place 7 16 bolt through ring of harness and battery terminal b Place 7 16 nut on end of bolt c Tighten assembly with either two 7 16 insulat...

Page 36: ...Safety Precautions on Page 30 2 On negative terminal of battery B1 and using the black terminal end of the red jumper harness Follow a thru e on Step 1 of Replace Fusible Link on Page 33 1 On positive...

Page 37: ...Link on Page 33 1 On positive terminal of battery B2 and using the red terminal end of the power harness follow a thru e on Step 1 of Replace Fusible Link on Page 33 2 REMOVE POWER HARNESS REPLACE POW...

Page 38: ...ove all wire harnesses from the batteries using insulated wrenches See Safety Notice and Personal Safety Precautions on Page 30 1 3 Reassemble GoCart Page 32 1 Disassemble GoCart Page 32 Place new bat...

Page 39: ...rs from existing charger 2a 2b Place new Charger in cut out location on panel 1 Position so that the fan vents are toward the handle of the panel Push screws through holes in panel and charger 2 Place...

Page 40: ...sure REMOVE COVER OF ELECTRICAL ENCLOSURE Remove the 4 screws holding the cover of the electrical enclosure 2 Pull open the cover to expose wires and components 3 Remove the black red and green wires...

Page 41: ...cal Enclosure www pro team com 866 888 2168 39 REPLACE COVER ONTO ELECTRICAL ENCLOSURE Push crimped end of green black and red wire from switch onto terminals of receptacle 1 Using the four screws sec...

Page 42: ...E Squeeze together the sides of the receptacle 3 Push through hole while continuing to squeeze sides 4 Push new receptacle through the cover of the enclosure 1 1 Remove Charger Panel Page 4 2 Remove C...

Page 43: ...s nuts and washers holding electrical enclosure to panel with Phillips screwdriver and 3 8 end wrench 3a 3b Remove black wire with Phillips screwdriver from power receptacle 4 Remove red wire with Phi...

Page 44: ...of receptacle 1 Using Phillips screwdriver put bare end of black wire from switch into gold terminal of receptacle 2 Place enclosure over switch and receptacle 3 Place washer and nut star washer over...

Page 45: ...s Page 41 Squeeze together sides of switch 4 While continuing to squeeze pull switch from hole in panel 5 Push new switch assembly through cut out in the panel such that the line on state is closest t...

Page 46: ...ce flanged receptacle in the side panel cut out with ground pin down Attach with screws Tighten to 5 in lbs 1 Using Phillips screwdriver put bare end of green ground wire back into ground terminal of...

Page 47: ...ELBOW CUFF REPLACE SWIVEL ELBOW CUFF 1 Bend down until the cuff is loose from the hose 3a 3b Push the smaller end of new elbow cuff into hose until the textured part of the elbow is against the hose 1...

Page 48: ...Switch in Hose Handle REMOVE SWITCH 1 Remove top cover 3 Lift up and remove angled tube 4 Lift out and remove switch and BCM 5 2 Remove the 8 screws which hold the handle together COPPER CONTACTS Use...

Page 49: ...s are closest to the switch and not against handle wall 3 Ensure stub tube is inserted into angle tube Place angled tube into handle 4 Confirm copper rings on angled tube are against the metal clips o...

Page 50: ...dle 1 Remove eight Phillips screws from hose handle then remove top half of housing Tools needed Phillips Head Screw Driver not included in kit Replace top half of hose handle and tighten screws Follo...

Page 51: ...Electrical Diagram www pro team com 800 541 1456 49...

Page 52: ...P O Box 7385 Boise Idaho 83707 866 888 2168 www pro team com 106591 Revised 6 12...

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