Upright Service Manual - Pro
Contents
1. 38 Impact Bumper Installation 39 FINAL VACUUM ASSEMDIY ceini seres n a e aaa 40 View Upright Vacuum Clearing Hose and Wand Obstructions eeeeeeececceeeeeeeeeeeeeeeeees 41 42 at www pro team com www pro team com 866 888 2168 XP HEPA MODEL Bag C Bag Cover 29 Over Rel Latch Oo Release elease Latc Latch ui sa Release Re ease Button ill T lg 55 Button prings GA it Springs Bag Cover Latch Plate Bag Cover Latch Plate Bag Cover Phillips Screws gt Latch Sprin Duct Crossover pang Bag Cover Bag Cover i Transition Duct Bag Latch Spring Cover Upper Seal Lower Crossover Duct Bag Cover Nozzle Crossover Plate Seal Cou Transition Duct Bag Cover Inlet Seal Lower Transition Duct Seal Bag Cover Nozzle Plate Nozzle Plate Bag Cover Nozzle Plate Bag Cover Gasket Phillips Screws Phillips Screws www pro team com 866 888 2168 Bag Cover DISASSEMBLY 1 Tilt bag cover forward to open Remove 4 2 To release XP transition duct remove 2 dig Phillips screws to release from bag cover wg Phillips screws from bag cover nozzle Base nozzle plate model duct crossover has 4 Phillips screws Lift transition duct duct crossover from bag cover2. To determine obstruction location remove wand from port Figure C Turn on vacuum and place hand over wand opening to check for proper suction If no suction exists blockage is at location A or B as shown in Figure B and proceed to Step 3 If there is proper suction the blockage is at location C or D as shown in Figure B and proceed to Step 5 DS Open Bag Housing Cover Fic 1 and replace Intercept Micro Filter A full filter will restrict airflow Remove hose from the bag housing cover by using the quick release tabs Fic 2 Look into upper hose and wand Shake or insert broom handle to clear any visible debris Replace hose and wand on vacuum Figure B If blockage is not in the wand or upper hose disconnect the lower air duct hose on the back of the power nozzle Fic 3 Visually check the lower air duct hose for debris and remove To check for unobstructed air flow turn on vacuum and place hand over opening on lower air duct If you feel proper suction reconnect lower air duct and resume vacuuming If blockage port Dr is not in lower air duct hose proceed to step 6 0 00 Wand opening With bottom air duct hose and upper hose and wand disconnected carefully insert a broom handle or any similar item like a short length of hose pipe etc approximately 14 inches into wand guide on top of vacuum housing Figure D to dislodge obstruction or debris D
3. Handle Nut Plate Filter Lock Out Switch Bag Housing Assembly d gt Left Right Wand Guide or both Duct Assembly APPLIES TO XP MODELS ONLY Motor Housing a Feed bag switch wires through bag housing b Align duct with opening in bag housing APPLIES TO XP MODELS ONLY c Bag housing assembly should fit neatly onto bulkhead d Insert bag housing screws and tighten e Attach harness connectors to switch and place switch into position 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 www pro team com 866 888 2168 Motor Housing APPLIES TO Completed ih XP MODELS ONLY Motor Housing APPLIES TO Completed i Motor Housing XP MODELS BASE MODEL HEPA MODEL Upper ZN Upper Left Wand Guide Motor gt APPLIES TO XP MODELS ONLY Mount a U pper Right Wand Guide APPLIES TO Motor XP MODELS ONLY Includes f Wi ires A Main Power Supply Harness si Lockout 105754 Wire TE AIS okey Harness Kit Motor Mount yy Switch Includes A D f G Kw C Bag Full Lower Air Duct ZI Indicator Seal Sensor Air Duct Assembly B Jumper Harness Left Panel Motor Housing Sound Foam Rear Panel Motor Housing Front Panel Sound Foam Motor Housing Sound Foam E Power Hou
4. 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 prope suction reconnect lower air duct and resume vacuuming If blockage is not in lower air duct hose proceed to step 5 Carefully insert a broom handle or any similar item like a short length of hose pipe etc approximately 14 inches into guide on top of vacuum housing Figure D to dislodge obstruction or debris Debris should then drop or move into the lower air duct where you can then remove it with your hand Reconnect the lower air duct and upper hose assembly Close bag hous ing cover and power on the vacuum Proleam leaning for Health Since 1987 P O Box 7385 Boise Idaho 83707 866 888 2168 www pro team com 106243 Revised 12 12
5. 17 9 Remove 2 lower air duct screws from inside 10 Cut lower wire harness between the motor housing motor housing then remove the foam that covers ag and the base assembly Pull the air duct system wire harness air duct hose and lower wire harness out of the motor housing N Note Rotate brass fitting so it cannot be trapped by the lower duct 1 1 Insert new power nozzle wire harness in D motor housing locking brass fitting into position as shown Continued on page 19 www pro team com 866 888 2168 18 Wire Harness WIRE HARNESS REPLACEMENT CONTINUED FROM PAGE 18 Zi Me LO Qn Install upper wire harness and connect the vacuum 1 2 Install lower duct assembly and foam Tighten 2 bag full sensor screws Wire harness should remain behind lower duct assembly Reinstall foam as shown 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 motor is not properly installed Continued on page 20 www pro team com 866 888 2168 Wire Harness WIRE HARNESS REPLACEMENT CONTINUED FROM PAGE 19 16 Replace sound foam and install the motor mount 1 7 Tuck wires below bulkhead leaving the bag full i D 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 m
6. 5 Slide handle tube through opening in strain relief 6 Plug in new cord and slide handle tube into handle D Align holes on strain relief and handle tube D sleeve on motor housing Press firmly down on han Insert new ratchet fastener in hole and push flush dle to ensure it is fully seated Install cord retension clip next to power cord Install screw and tighten 7 Use flathead screwdriver to reattach carry handle gg to handle tube Ensure proper alignment of carry handle by verifying bag cover closure www pro team com 866 888 2168 Handle and Power Cord HANDLE INSTALLATION 1 Insert the handle tube into the channel on the bag gg 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 2 Insert ratchet fastener into cord clasp opening by gg pushing with thumb to connect cord to handle www pro team com 866 888 2168 IMPACT BUMPER INSTALLATION 1 Using a Phillips Head screwdriver remove screw gg from cord wrap bracket Discard screw only ilil PEAY TETT Insert impact bumper assembly into cord wrap 3 bracket Note Screw should be inserted inside spring from original assembly Do not over tighten 2 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 s
7. Service Manual Upright leaning for Health Since 1987 Proleam Table of Contents BAG COVER Index sioni ai Rab Lai aaa 2 ATTENTION DAS iii ail 3 Before servicing any part or BAG HOUSING proceeding with any repair Index 4 procedure on any ProTeam vacuum Disassembly sise 5 ip a Bag Lockout Switch Replacement i 6 Hose Gap Collar Repair 54scrstriti unes Ann 7 Quick Release Clip Replacement 8 Bag Housing to Motor Housing Assembly 9 MOTOR HOUSING NING OX oo os fo tec etek esehs E E 10 DISASSEMDIY scccesssanansssassssaaessannssevevsavsasnnedseaneasvelceddececausseaccdacedcesdgecees 11 14 Wand Gudes spip EE EE E AE 15 ELECTRICAL Wire Harness Replacement 16 23 MOTOR Carbon Brushes ssssssessssssssnsosrssererene RIA 24 POWER NOZZLE NING OX AE E E OOE 25 ASSEMBLY zione adipe RESSE 26 Power Nozzle to Body Assembly 27 Hose Sleeve Replacement ini 28 Pivot Bearing Replacement Wheel Replacement 29 Detent Spring ReplaceMEnt i 30 HOSE AND POWER CORD Index siae E 31 HANDLE WING OX CR RS 32 Assembly sca e EE Ea EREE ai 33 35 Handle New Power Cord amp Strain Relief Replacement 36 37 Handle and Power Cord Installation
8. ebris should then drop or move into the lower air duct hose where you can then remove it with your hand Lower __ air DR Fic 3 Figure C Figure D Reconnect the lower air duct hose and upper hose assembly and turn on the vacuum Wand port N www pro team com 866 888 2168 Troubleshooting CLEARING HOSE AND WAND OBSTRUCTIONS HEPA MODELS Figure A Lower air duct Figure D www pro team com 866 888 2168 CLEARING THE BRUSH ROLL Obstructions such as hair string and throw rugs may cause the red brush indicator light to be illuminated and the power nozzle to shut off 1 Turn off vacuum and unplug power cord from outlet 3 3 On underside of vacuum pull out or cut away obstructions on the brush roll Figure A Press the reset button on top side of powerhead Plug in power cord and restart motor Figure A CLEARING HOSE amp WAND Obstructions in hoses and wands may reduce or eliminate suction SONS Turn off vacuum and unplug power cord from 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
9. els D Pull wire harness through body housing 15 Remove exhaust filter www pro team com 866 888 2168 Motor Housing WAND GUIDE For XP Models Only Note Use care in prying open latches with screwdriver so as not to break tabs Unsnap latches closest to fingers first 1 Separate left wand guide from right wand guide by gg inserting two fingers between two guides Use a flat tip screwdriver with opposite hand to unsnap lock latches and pry open wand guides using your two fingers Left Wand Guide Lock Latches Right Wand Guide 2 Switch Installation Seat switch into the left wand gg guide Snap lock latches together all the way up both sides of the wand guides www pro team com 866 888 2168 Wire Harness WIRE HARNESS REPLACEMENT Remove handle and power cord Open bag housing mg cover Remove Intercept Micro Filter 3 Remove switch cover and filter lockout switch 4 Remove crimps by pressing locking tab gg To remove the switch cover insert a flathead gg on connector screwdriver under switch lever and gently pry upward Continued on page 17 www pro team com 866 888 2168 16 Wire Harness WIRE HARNESS REPLACEMENT CONTINUED FROM PAGE 16 Remove the bag full indicator tube tube not pic tured from the bulkhead and lift off the bulkhead Continued on page 18 www pro team com 866 888 2168 Wire Harness WIRE HARNESS REPLACEMENT CONTINUED FROM PAGE
10. g Install new pivot mg bearing www pro team com 866 888 2168 Power Nozzle DETENT SPRING REPLACEMENT Use needle nose pliers to remove detent spring if there is adeguate spring to grab Place vacuum on flat surface in unlocked position exposing detent springs Place new detent spring into spring slot in vacuum power head as shown If there is not enough detent spring to remove with pliers use a flat head screwdriver to pry out broken spring Push down on detent spring until fully seated www pro team com 866 888 2168 Hose and Power Cord WAND AND HOSE APPLY TO XP MODELS ONLY Power Cord with Strain Relief Hose Assembly with Cuffs Strain Relief Clasp Assembly Screw for XP Model Quick Release Hose Clip Carry Handle with Tool Caddy for XP Model Handle Assembly Screw for Base Model Carry Handle with Tool Caddy for Base Model Cord Retention Clip www pro team com 866 888 2168 Handle with Over Mold and Decal On Off Rocker Switch Cord Wrap Bracket Cord Wrap Phillips Screw i 1 LN ee te tg Wrap Bracket Compression Spring Washer Handle Bezel with Screws Cord Wrap Bracket Compression Spring XP version pictured Handle Assembly Phillips Screw lo Tube with Wire Harness Rivet Nut and Plug Rivet Handle Tube Bushing and Screw www pro team com 866 888 2168 HANDLE ASSEMBLY 1 Use a flathead screwdriver fig 1 to pry bottom of sw
11. hown above www pro team com 866 888 2168 Final Vacuum Assembly ASSEMBLY Install all 3 filters a Intercept Micro Filter Hose Assembly with Cuffs b Motor Intake Filter WAND AND HOSE APPLY TO c Exhaust Filter XP MODELS ONLY Install Power Cord and Handle with Rana Over Mold and Decal Attach with Handle Tube Bushing and Carry Handle with Tool Caddy Wrap Power Cord around Cord Wrap Post Cord Wrap Screw Power Cord Handle Tube Bushing Handle Assembly Screw cp Carry Handle with Tool Caddy Cord Wrap Post 2 2 E ER SG Sy www pro team com 866 888 2168 Troubleshooting CLEARING HOSE AND WAND OBSTRUCTIONS XP MODELS CLEARING THE BRUSH ROLL Obstructions such as hair string and throw rugs may cause the red brush indi cator light to be illuminated and the power nozzle to shut off sg 1 Turn off vacuum and unplug power cord from outlet On underside of vacuum pull out or cut away obstructions on the brush 2 roll Figure A Figure A Airflow path and possible obstruction locations Press the reset button on top side of powerhead Plug in power cord and 3 Am restart motor Figure A CLEARING HOSE amp WAND Obstructions in hoses and wands may reduce or eliminate suction Familiarize yourself with air flow path and possible obstruction locations Figure B release tabs ni L
12. itch from the handle body Disconnect all wires from switch gg posts by depressing locking tab on base of crimps fig 2 2 Remove screw at base of handle and remove from 3 Feed handle wire harness through new handle and gg handle tube fig 3 gg replace screw at the base of the handle fig 4 Continued on page 34 www pro team com 866 888 2168 HANDLE ASSEMBLY CONTINUED FROM PAGE 33 4 Feed wires through opening on handle bezel front of switch back of switch position II must be on the bottom before attaching wires to spades Using the diagram provided above attach wires to switch Orient the switch box with the Il position on the down side a Attach the first plug on the brown wire to the middle left spade b Attach the first plug on the blue wire to the lowest left spade Wait to attach the last blue plug c Wrap the second brown plug underneath blue and attach to the middle right spade d Attach the last blue plug to the upper right spade The bottom right spade will remain unattached e Connect the red wire to the top right spade 6 When finished with steps a through e your final Mag Wire connection configuration should appear as above www pro team com 866 888 2168 Install the switch into the handle bezel Place the long BLUE BROWN then RED wires between the screw bosses in that order as shown BROWN and BLUE wire loops must be positioned above the screw bosses on
13. locking tab W switch To remove the switch cover insert wg on locked connectors Reverse steps to a flathead screwdriver under switch lever reassemble and gently pry upward www pro team com 866 888 2168 Bag Housing HOSE CAP COLLAR REPAIR XP Models Onl To inspect the collar attach the quick Clean the quick release cuff and bag release cuff to the bag cover collar Lift cover with rubbing alcohol to ensure a the vacuum by the hose cuff The collar secure grip should support the weight of the vacuum If not the collar will fail and separate from the bag cover The collar will need to be removed from the quick release cuff and re glued into the bag cover If this collar test fails Proceed to Step 2 Apply a continuous bead of adhesive around the entire perimeter of the detached collar Care should be taken to avoid drips and runs IMPORTANT you have only a few seconds to apply the bead of glue and seat the collar into the bag cover IMPORTANT use only Loctite adhesive 454 3 Quickly insert collar into bag cover evenly wg pressing firmly for 20 seconds to ensure an adequate bond www pro team com 866 888 2168 Bag Housing QUICK RELEASE CLIP REPLACEMENT Snap into place www pro team com 866 888 2168 Bag Housing to Motor Housing ASSEMBLY Bag Housing Cover Switch Cover Phillips Screw Filter Lock Out Bag Housing gt Switch Cover Gasket Seal f
14. nozzle plate and remove Using a flathead screwdriver pry upward on bag cover latch spring to release Insert flathead screwdriver beneath bag cover latch plate to release Make sure rounded points clear holes in bag cover Using thumb to hold in place insert flat head screwdriver into bag cover near top to release bag cover release latch To Reassemble Repeat steps in reverse www pro team com 866 888 2168 Bag Housing Completed Bag ai Bag Housing Seal Gasket Phillips Screw a or ao om Switch Filter Lock Out Switch Rivet for Bag Housing Assembly Bag Housing Assembly with Riveted Hinge and Bag Cover Nozzle Plate www pro team com 866 888 2168 Bag Housing DISASSEMBLY 1 Remove screw on carry handle Slide tube away 2 Remove cover screw from base Unplug power cord 3 Remove switch cover and filter lockout switch 4 Remove crimps by pressing locking tab on mm To remove the switch cover insert a flathead wg locked connector screwdriver under switch lever and gently pry upward To Reassemble Repeat steps in reverse 5 Remove 4 screws located near bottom of bag gg housing 2 front 2 back Remove bag housing www pro team com 866 888 2168 Bag Housing BAG LOCKOUT SWITCH REPLACEMENT Open filter bag housing 2 Remove cover screw dl Remove filter bag 3 Remove switch cover and filter lockout 4 Remove crimps by pressing
15. otor is properly installed 18 Pull wires up through housing one on each side 19 Reinstall bag lockout switch Continued on page 21 www pro team com 866 888 2168 20 Wire Harness WIRE HARNESS REPLACEMENT CONTINUED FROM PAGE 20 20 Attach bag housing Insert 4 bag housing screws 21 To replace lower wire harness remove 8 D baseplate screws and turn vacuum back over to remove base cover o 000 22 Disconnect all wire connections 2 Remove wire ties Remove the circuit breaker and Ai y power nozzle lockout switch Do not remove power nozzle motor ProCare models do not have a power nozzle lockout switch Continued on page 22 www pro team com 866 888 2168 Wire Harness WIRE HARNESS REPLACEMENT CONTINUED FROM PAGE 21 1 8 v f S 09 04 o 00 2 Wire Harness WIRE HARNESS REPLACEMENT CONTINUED FROM PAGE 22 LOCKOUT SWITCH ON XP MODELS ONLY 28 Attach new blue and black wires 29 Replace base cover and screws To Reassemble Reverse Steps 29 through 1 to finish reassembly TO PERFORM A FUNCTION TEST 1 Reinstall handle assembly and cord Install Intercept Micro Filter Plug in vacuum and turn vacuum on in the number two Il position Powerhead motor should be running Release vacuum from upright locked position MS re The brush roll motor should stop and the red warning light should light up Release the switch and the
16. powerhead should go back to normal operation Ox 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 www pro team com 866 888 2168 REMOVING CARBON BRUSHES Disconnect wire from carbon 2 Remove both locking connec Using pliers or fingers carefully gg brush gg tors with small flat tip screw gg grasp tab and remove carbon driver Press brass tab inside brush from bracket bracket down so it is flush INSTALLING CARBON BRUSHES With brush Insert carbon brush into 2 Carefully bend brass tab slightly Re connect wire Replace D bracket gg upward with small flat tip gg locking tabs Bend tabs screwdriver downward www pro team com 866 888 2168 Power Nozzle Calo Assembled Power Nozzle Upright Lock Detent Nozzle Circuit Breaker Safety Lockout Switch Brush Retainer XP models only Phillips Screw Ia Brush Roll Retainer T 14 Brush Roll Air Duct Base Cover Seal Formed Wire Brace Front Roller I wn Roller E Base Cover Phillips Screw Axle Shaft l Vinyl Bumper www pro team com 866 888 2168 Power Nozzle ASSEMBLY 1 Insert braces 2 Install motor brush roll and bel
17. sing Nozzle Switch High Filtration Harness Filter Exhaust Motor KA Housing Rear Wheel n a gt WwW LP Pivot Bearing A Filter Cartridge Cover D Power Nozzle K cn Switch Harness C HEPA Media Exhaust Filter Rear Wheel i Filter Cartridge Cover www pro team com 866 888 2168 Motor Housing DISASSEMBLY Remove handle and power cord Open bag housing cover Remove Intercept Micro Filter 3 Remove switch cover and filter lockout switch gg To remove the switch cover insert a flathead screw driver under switch lever and gently pry upward Remove crimps by pressing locking tab on connector Continued on page 12 www pro team com 866 888 2168 Motor Housing DISASSEMBLY CONTINUED FROM PAGE 11 bag full indicator tube tube not bulkhead and lift off the 7 Remove upper motor mount Lift motor from mg housing www pro team com 866 888 2168 Motor Housing DISASSEMBLY CONTINUED FROM PAGE 12 S S U ae 9 Remove 2 lower air duct screws from inside 1 0 Housing should look like this after the foam and motor housing then remove the foam that covers D air duct are removed wire harness 12 Slide duct flex hose from powerhead Continued on page 14 www pro team com 866 888 2168 Motor Housing DISASSEMBLY CONTINUED FROM PAGE 13 1 3 Remove 2 wheel clamp screws on left and 14 Remove wheels and pivot bearings D right whe
18. t Be careful Do x gg not attempt to over tighten screws Fully assembled power nozzle bottom 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 www pro team com 866 888 2168 Power Nozzle to Body Assembly ASSEMBLY Place axle sleeve onto motor axle 2 Wheel axles on the motor housing should be placed in the grooves on the making sure the shoulder is facing gg power nozzle base Wheel clamps are then put into place and screwed the motor housing Put wheel down Power nozzle cover will then be placed on top of the base onto motor housing axle www pro team com 866 888 2168 Power Nozzle HOSE SLEEVE REPLACEMENT IM We Ca k www pro team com 866 888 2168 Power Nozzle PIVOT BEARING REPLACEMENT WHEEL REPLACEMENT 2 Turn vacuum over and pull base cover gg off powerhead 4 Lift bag housing from powerhead and remove D wheel To Reassemble Repeat steps in reverse 5 Remove old pivot bearin
19. the handle bezel as shown Continued on page 35 34 HANDLE ASSEMBLY CONTINUED FROM PAGE 34 7 Switch must remain flat to the handle bezel when 8 Press the switch into place in the handle bezel wg installed into handle body as shown gg The II position should be closest to the front of the bezel 9 Lay the long red brown and blue wires between 10 Slide tab A into handle slot B and press firmly B the circular shoulders and gently place handle into place at C Be sure all switch wires are routed bezel into handle between screw bosses to ensure that the wires do not get damaged Insert screws into bezel fig 5 www pro team com 866 888 2168 Handle and Power Cord NEW CORD AND STRAIN RELIEF REPLACEMENT 1 Use a flathead screwdriver and hammer to push the 2 Remove screw from carry handle and remove carry gg strain relief towards the handle Snap off remaining gg handle strain relief 3 Unscrew cord retension clip and set aside Slide 4 Feed new strain relief clasp over the new power D handle tube away from base Unplug old power gg cord Slide strain relief up to the groove on the cord 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 Continued on page 37 www pro team com 866 888 2168 Handle and Power Cord NEW CORD AND STRAIN RELIEF REPLACEMENT CONTINUED FROM PAGE 36
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