Simplicity SYNERGY X9.4 Service Manual Download

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071807

VI. Figures

Manual Reset

Thermo Circuit

Breaker

Direct

Air

Motor

Valve

Micro

Switch

Winged

Rocker

Switch

LED Connector

Handle Connection

Yellow

White

Red

Black

Brown

Blue

Green/Y

ellow Stripe

Black

Red

Black/Red Stripe

Black

Red

Black

Black/Red Stripe

Short Lead

Long Lead

Main Circuit Board Connector

Jacketed

Wire

Yellow

Black

Red

Jacketed

Wire

Green Ground

Hall

Sensor

Connector

19 7 16

Top of Connector

113

To PCB

11 12 13 14 15 16

Clean Air Motor

Fiber

Glass

Jacketed Wire

White

Black

Black/White

Blue

Blue or

Yellow

White

Black

NOTE: The following are required for Direct Air

Motor operation:

1. Power to the vacuum.

2. Handle seated in vacuum and secure.

3. Tools activation dial/rotational valve handle

turned to Tools “OFF” (micro switch closed).

4. Winged rocker switch disengaged (nozzle

cover off vacuum or handle out of the upright

position).

5. Headlights “ON”. (Head lights “ON” means

the clean air motor is providing power through

the PC board to the lights.)

NOTE: Back of Connector is Numbered

R. Main Body Wire Harness .5 and . Models

Summary of Contents for SYNERGY X9.4

Page 1: ...Service Manual for X9 5 and Older Models...

Page 2: ...t Air Motor Will Not Run Headlights are on 22 C Nozzle Suction Power is Weak 24 C 1 There is no suction at the hose 24 C 2 There is no suction at the nozzle 24 D Excessive Vibration 25 E Agitator brus...

Page 3: ...ended when plugged in Unplug from outlet when not in use 2 Turn off all controls before unplugging 3 Do not attempt to service vacuum while plugged in 4 Before handling PC board discharge static elect...

Page 4: ...headlights should be on This assures that the fuses on the PC board are working and there is power in the tap wire See Figure B PCB Layout and Belt Idler Assembly NOTE All the above conditions must be...

Page 5: ...et fiber the air flow may not be restricted enough to cause the motor to build up heat To test the FBI system 1 The air flow must be completely blocked off 2 Place the tool activation dial rotational...

Page 6: ...t the lights in the handle switches are on The lights in the handle main power switch will come on any time the power cord is plugged into an outlet and the main power switch is turned ON The light in...

Page 7: ...ure B PCB Layout and Belt Idler Assembly Belt Idler Assembly Belt Idler Assembly PC Board PC Board 5 and 6 4 and older Brush Roll AFI Fuse NOTE The PC Boards in the 5 and 6 do not have adjustment pods...

Page 8: ...through the dust compartment is installed remove it at this time 2 Remove the wire harness connector from the dust compartment and the micro switch from the wiring harness A Step 4 Turn the vacuum ov...

Page 9: ...ring harness is being changed 1 Remove the screw from the PC board 2 Disconnect the wiring harness and remove the PC board 3 Remove the screw in the metal plate and the metal plate from the dust compa...

Page 10: ...e agitator brushroll with a 7 16 socket driver Figure D Agitator Brushroll Assembly B Step 4 Slide off the end caps Figure D Agitator Brushroll Assembly B Step 5 Pry off the belt pulley with a standar...

Page 11: ...rt the belt into the nozzle base tray C Step 4 Turn the vacuum over and pull the belt into the nozzle base tray Loop belt around the agitator brushroll making sure the ribs of the belt line up with th...

Page 12: ...ng the Spring Assist Assembly WARNING If the vacuum is not in upright position injury may occur or vacuum may be damaged Always wear safety glasses during repair E Step 1 Remove the 5 five mounting sc...

Page 13: ...acuum in the upright position and remove the 2 two screws from the spring assist bar 2 Lay the vacuum flat Remove the 3 three screws from the direct air motor inlet duct cover and 1 one screw from eac...

Page 14: ...he ground wire if necessary 6 Remove the 2 two screws from each of the nozzle base tray pivot brackets G Step 4 Figure H Clean Air Motor Placement 1 Lift the dust compartment up out of the nozzle base...

Page 15: ...Step 7 Attach the inlet duct cover with 3 three screws H Step 8 Note the layout of the idler assembly and the motor drive pulley See Figure E Belt Placement Loop the new belt over the motor drive pull...

Page 16: ...and the micro switch from the wiring harness I Step 4 Turn the vacuum over depress the handle release and lay the vacuum flat Remove the nozzle cover I Step 5 WARNING If the vacuum is not in the uprig...

Page 17: ...nt do not push all the way down shaft side first then fan side keeping the motor level as it goes in 5 Check the back of the vacuum to ensure the scroll housing is not catching on the rubber seal 6 Ro...

Page 18: ...ust compartment and the micro switch from the wiring harness J Step 4 Turn the vacuum over depress handle release and lay flat Remove the nozzle cover J Step 5 WARNING If the vacuum is not in the upri...

Page 19: ...compartment do not push all the way down shaft side first then fan side keeping the motor level as it goes in 5 Check the back of the vacuum to ensure the scroll housing is not catching on the rubber...

Page 20: ...heel 2 Remove the e clip on the outside of the wheel hub Slide the rear wheel from the shaft L Step 3 1 Remove the e clip holding the tilt lock pivot shaft to the nozzle base tray this e clip is locat...

Page 21: ...nds are in good condition continue to Step 4 4 If faulty connectors are found replace the wiring harness 5 Reassemble the vacuum and retest A Step 4 1 Plug the power cord in and turn the switches on 2...

Page 22: ...e clean air motor 2 Disconnect the blue yellow lead that connects to the thermal switch 3 Place a meter or test light to the blue yellow lead and the ground lead on the PC board connector 4 With the v...

Page 23: ...lights B 1 Step 1 1 Remove the dust cover then lay the vacuum face down 2 Remove the nozzle cover 5 screws 3 Place vacuum in the upright position and remove the 2 two screws from the assist spring 4 L...

Page 24: ...and upper portion of the back path may be removed to gain access to the micro switch 3 Turn the vacuum on and press the micro switch Figure K Location of Micro Switch 4 If the direct air motor starts...

Page 25: ...volts 3 If the voltage is within normal limits the micro switch is faulty 4 If voltage is low then the problem is in the handle connector or the handle wiring B 2 Step 8 1 Unplug the direct air motor...

Page 26: ...roll as required C 2 Step 3 Remove the dust cover and turn the vacuum ON in carpet mode The bag should inflate assuring the air path is open and the direct air motor is working C 2 Step 4 If suction i...

Page 27: ...gitator brushroll and retest Models 5 and newer 1 Remove the nozzle cover and install the hall sensor test plug If test plug is not installed the direct air motor will only run 2 to 3 seconds and then...

Page 28: ...onditions are met continue to F Step 2 4 If jam test fails remove the sock and start the test again 5 If test fails a second time troubleshoot the source as either the PC Board or the Hall Sensor Asse...

Page 29: ...he motor cover See Figure M Agitator brushroll Jam Screw FBI Screw Position 3 Remove the left plug from the motor cover A gray colored adjustment screw should be visible through the hole 4 The slot of...

Page 30: ...om the motor cover A gray colored airflow adjustment screw should be visible through the hole 4 The slot of the screw should be in the Eleven o clock position If not adjust it to the Eleven o clock po...

Page 31: ...belt idler must turn this is where the hall sensor is installed NO Install belt See II Maintenance Procedures C Replacing Belt YES Go to A Step 4 A Step 4 If the direct air motor still will not run m...

Page 32: ...Hook 2 Screw 13 Handle Mount Screw 3 Handle Pin 14 Handle Tube Base Connector 4 E Clip 15 Handle Tube 5 Power Cord 16 Handle to Body Harness 6 Upper Cord Hook Base 17 Metal Handle Retainer 7 Upper Cor...

Page 33: ...5 6 23 Direct Air Motor Inlet Seal 24 Direct Air Motor Assembly 25 Direct Air Cleaning Fan 26 Fan Washer 27 Direct Air Motor Shroud Seal 28 Internal Wire Harness 29 Dust Cover Catch 30 Pivot Bushing C...

Page 34: ...brushroll Assembly 18 External Retaining Ring 19 Small Overmolded Wheel Assembly 20 Height Adjust Axle 21 Height Adjust Axle Cover 22 Baseplate Assembly W Seals 23 Nozzle base tray 24 Top Agitator br...

Page 35: ...Handle Harness Power Cord NOTE Light ON in switches on handle only indicates that there is power to the switches The lights will come on any time the power cord is plugged into an outlet and the swit...

Page 36: ...To PCB 11 12 13 14 15 16 20 19 18 17 1 2 3 4 5 6 10 9 8 7 5 M Clean Air Motor M Fiber Glass Jacketed Wire White White Black B la c k Black White B l u e Blue or Yellow W hite Black NOTE The following...

Page 37: ...5 6 10 9 8 7 M Clean Air Motor M Fiber Glass Jacketed Wire White White Black B la c k Black White B l u e Blue or Yellow W hite Black 5 NOTE The following are required for Direct Air Motor operation...

Page 38: ...h to replace vacuum bag Vacuum nozzle Twin LED headlamps Furniture guard Brushroll jam indicator Full bag clog indicator Exhaust filter cover Quick release cord hook Telescopic wand 5 to 1 stretch hos...

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Simplicity SYNERGY X9.4, Service Manual

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