Upright Service Manual
Table of Contents ATTENTION Before servicing any part or proceeding with any repair procedure on any ProTeam vacuum, ALWAYS disconnect the vacuum from power source. BAG COVER Index ...................................................................................................... 2 Disassembly ............................................................................................ 3 BAG HOUSING Index ....................................................................................................
Bag Cover BASE/HEPA MODEL XP/HEPA MODEL Bag Cover Release Latch Bag Cover Release Latch Release Button Springs Release Button Springs Bag Housing Cover Bag Housing Cover Bag Cover Latch Plate Bag Cover Latch Plate Bag Cover Latch Spring Phillips Screws Duct Crossover Bag Cover Transition Duct/Bag Cover Upper Seal Bag Cover Latch Spring Transition Duct Bag Cover Lower Crossover Duct/Bag Cover Nozzle Plate Seal Crossover Duct Inlet Seal Phillips Screws Lower Transition Duct Seal Bag Cover Nozzl
Bag Cover DISASSEMBLY 1. Tilt bag cover forward to open. Remove (4) Phillips screws to release from bag cover nozzle plate. 2. To release XP transition duct remove (2) Phillips screws from bag cover nozzle. Base model duct crossover has (4) Phillips screws. 3. Lift transition duct/duct crossover from bag cover nozzle plate and remove. 4. Using a flathead screwdriver pry upward on bag cover latch spring to release. 5. Insert flathead screwdriver beneath bag cover latch plate to release.
Bag Housing Completed Bag Housing Bag Housing Seal Gasket Phillips Screw Handle Nut Plate Filter Lock-Out Cover 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.
Bag Housing DISASSEMBLY 1. Remove screw on carry handle. Slide tube away from base. Unplug power cord. 2. Remove cover screw. 3. Remove switch cover and filter lockout switch. To remove the switch cover, insert a flathead screwdriver under switch lever and gently pry upward. 4. Remove crimps by pressing locking tab on locked connector. To Reassemble. Repeat steps in reverse. 5. 5 Remove 4 screws located near bottom of bag housing (2 front, 2 back). Remove bag housing. www.pro-team.com 866.888.
Bag Housing BAG LOCKOUT SWITCH REPLACEMENT 1. Open filter bag housing. Remove filter bag. 2. Remove cover screw. 3. Remove switch cover and filter lockout switch. To remove the switch cover, insert a flathead screwdriver under switch lever and gently pry upward. 4. Remove crimps by pressing locking tab on locked connectors. Reverse steps to reassemble. www.pro-team.com 866.888.
Bag Housing HOSE CAP COLLAR REPAIR – XP Models Only 1. To inspect the collar, attach the quick release cuff to the bag cover collar. Lift the vacuum by the hose cuff. The collar 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. 2.
Bag Housing QUICK RELEASE CLIP REPLACEMENT 1. Aligh tabs. Push ends together. www.pro-team.com 866.888.2168 2. Snap into place.
Bag Housing to Motor Housing ASSEMBLY (a) Feed bag switch wires through bag housing. (b) Align duct with opening in bag housing (APPLIES TO XP MODELS ONLY). Bag Housing Cover (c) Bag housing assembly should fit neatly onto bulkhead. (d) Insert bag housing screws and tighten. Switch Cover Phillips Screw (e) Attach harness connectors to switch and place switch into position. Filter Lock-Out Switch Cover Bag Housing Gasket Seal (f) Fasten switch cover with screw.
Motor Housing APPLIES TO XP MODELS ONLY Completed Motor Housing Completed Motor Housing APPLIES TO XP MODELS ONLY BASE MODEL HEPA MODEL Bulkhead Phillips Screw for Wand Guide Upper Motor Mount Motor (Includes Wires) Lower Motor Mount Lower Air Duct Phillips Screw Left Panel Motor Housing Sound Foam Front Panel Motor Housing Sound Foam Upper Left Wand Guide APPLIES TO XP MODELS ONLY Upper Right Wand Guide APPLIES TO XP MODELS ONLY A.
Motor Housing DISASSEMBLY 1. Remove handle and power cord. Open bag housing cover. Remove Intercept Micro® Filter. 2. Remove switch cover screw. 3. Remove switch cover and filter lockout switch. To remove the switch cover, insert a flathead screwdriver under switch lever and gently pry upward. 4. Remove crimps by pressing locking tab on connector. (Continued on page 12) 11 www.pro-team.com 866.888.
Motor Housing DISASSEMBLY (CONTINUED FROM PAGE 11) 5. Remove (4) bag housing screws and bag housing. 6. Remove the bag full indicator tube (tube not pictured) from the bulkhead and lift off the bulkhead. 7. Remove upper motor mount. Lift motor from housing. 8. Disconnect motor crimps from motor and from lower air duct. Remove motor. (Continued on page 13) www.pro-team.com 866.888.
Motor Housing DISASSEMBLY 9. 11. (CONTINUED FROM PAGE 12) Remove (2) lower air duct screws from inside motor housing then remove the foam that covers wire harness. 10. Housing should look like this after the foam and air duct are removed. Turn vacuum over and remove (8) screws. 12. Slide duct flex hose from powerhead. (Continued on page 14) 13 www.pro-team.com 866.888.
Motor Housing DISASSEMBLY 13. (CONTINUED FROM PAGE 13) Remove (2) wheel clamp screws on left and right wheels. 14. Remove wheels and pivot bearings. Pull wire harness through body housing. To Reassemble. Repeat steps in reverse. 15. Remove exhaust filter. www.pro-team.com 866.888.
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 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 Latch Hole Switch Guide Latch 2. 15 Switch Installation.
Wire Harness WIRE HARNESS REPLACEMENT 1. Remove handle and power cord. Open bag housing cover. Remove Intercept Micro Filter. 2. Remove switch cover screw. 3. Remove switch cover and filter lockout switch. To remove the switch cover, insert a flathead screwdriver under switch lever and gently pry upward. 4. Remove crimps by pressing locking tab on connector. www.pro-team.com 866.888.
Wire Harness WIRE HARNESS REPLACEMENT (CONTINUED FROM PAGE 16) 5. Remove (4) bag housing screws and remove bag housing. 6. Remove the bag full indicator tube (tube not pictured) from the bulkhead and lift off the bulkhead. 7. Remove upper motor mount. 8. Disconnect motor crimps from motor and remove motor. (Continued on page 18) 17 www.pro-team.com 866.888.
Wire Harness WIRE HARNESS REPLACEMENT (CONTINUED FROM PAGE 17) 9. Remove (2) lower air duct screws from inside motor housing then remove the foam that covers wire harness. 10. Cut lower wire harness between the motor housing and the base assembly. Pull the air duct system, air duct hose and lower wire harness out of the motor housing. Note: Rotate brass fitting so it cannot be trapped by the lower duct. 11.
Wire Harness WIRE HARNESS REPLACEMENT (CONTINUED FROM PAGE 18) lower duct assembly and foam. Tighten (2) 12. Install screws. Wire harness should remain behind lower 13. Install upper wire harness and connect the vacuum bag full sensor. 15. Replace vacuum motor as shown. duct assembly. Reinstall foam as shown. RED 14. WHITE Connect wires as shown – Red to red. White to white. Note: The two black wires are threaded up through the wand guide. Note: motor must be properly seated.
Wire Harness WIRE HARNESS REPLACEMENT (CONTINUED FROM PAGE 19) 16. Replace sound foam and install the motor mount. 18. Pull wires up through housing – one on each side. 17. 19. 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. Reinstall bag lockout switch. (Continued on page 21) www.pro-team.com 866.888.
Wire Harness WIRE HARNESS REPLACEMENT (CONTINUED FROM PAGE 20) 20. Attach bag housing. Insert (4) bag housing screws. Upper wire harness replacement now complete. 22. Disconnect all wire connections. 21. To replace lower wire harness remove (8) baseplate screws and turn vacuum back over to remove base cover. wire ties. Remove the circuit breaker and 23. Remove power nozzle lockout switch. Do not remove power nozzle motor. *ProCare models do not have a power nozzle lockout switch.
Wire Harness WIRE HARNESS REPLACEMENT (CONTINUED FROM PAGE 21) 24. Remove screw that holds the cover and air duct. 25. Thread the air duct hose into the motor housing, turning counter clockwise. WHITE RED BLUE BLACK the hose sleeve into the other end of the hose 26. Put and position in the base assembly. Replace the cover, air duct, and screw. www.pro-team.com 866.888.2168 27. Connect wires as shown and verify orientation of switches.
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. 2. Install Intercept Micro Filter. 3. Plug in vacuum and turn vacuum on in the number two (II) position. 4. Powerhead motor should be running. Release vacuum from upright locked position. 5.
Motor REMOVING CARBON BRUSHES 1. Disconnect wire from carbon brush. 2. INSTALLING CARBON BRUSHES 1. Insert carbon brush into bracket. www.pro-team.com 866.888.2168 2. Remove both locking connectors with small flat tip screwdriver. Press brass tab (inside bracket) down so it is flush with brush. 3. Using pliers (or fingers), carefully grasp tab and remove carbon brush from bracket Carefully bend brass tab slightly upward with small flat tip screwdriver. 3. Re-connect wire.
Power Nozzle Fully Assembled Power Nozzle Upright Lock Detent Spring Power Nozzle Cover Circuit Breaker Brush Retainer Phillips Screw Vacuum Operation Indicator Board Safety Lockout Switch XP models only Air Duct Cover Motor Vibration Grommet Brush Roll Retainer Motor Phillips Screw 14" Brush Roll Motor Brush Roll Drive Belt Air Duct Base Cover Seal Formed Wire Brace Lower Hose to Air Duct Air Duct Hose Sleeve Phillips Screw Baseplate Rear Wheel Clamp Front Roller Front Roller Axle Shaft B
Power Nozzle ASSEMBLY 1. 2. Insert braces. Install motor, brush roll, and belt. Be careful. Do not attempt to over-tighten screws. d b a Fully assembled power nozzle (bottom view). 3. 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.
Power Nozzle to Body Assembly ASSEMBLY 1. Place axle sleeve onto motor axle, making sure the shoulder is facing the motor housing. Put wheel onto motor housing axle. 3. Flip the unit and fasten cover to power nozzle base using (8) screws. 27 2. Wheel axles on the motor housing should be placed in the grooves 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. www.pro-team.com 866.888.
Power Nozzle HOSE SLEEVE REPLACEMENT 1. Remove (8) screws from base plate. Turn vacuum over and pull base cover off powerhead. 2. Unclip circuit board and move aside. 3. Unscrew air duct cover. 4. 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. www.pro-team.com 866.888.
Power Nozzle PIVOT BEARING REPLACEMENT/WHEEL REPLACEMENT 1. Remove 8 screws from base plate. 2. Turn vacuum over and pull base cover off powerhead. 3. Remove right and left rear wheel clamps. 4. Lift bag housing from powerhead and remove wheel. To Reassemble. Repeat steps in reverse. 5. 29 Remove old pivot bearing. Install new pivot bearing. www.pro-team.com 866.888.
Power Nozzle DETENT SPRING REPLACEMENT 1. Place vacuum on flat surface in unlocked position exposing detent springs. 2. Use needle nose pliers to remove detent spring if there is adequate spring to grab. 3. If there is not enough detent spring to remove with pliers use a flat head screwdriver to pry out broken spring. 4. Place new detent spring into spring slot in vacuum power head as shown. 5. Push down on detent spring until fully seated. www.pro-team.com 866.888.
Hose and Power Cord WAND AND HOSE APPLY TO XP MODELS ONLY Power Cord with Strain Relief Hose Assembly with Cuffs Strain Relief Clasp Handle Assembly Screw for XP Model Quick Release Hose Clip Carry Handle with Tool Caddy for XP Model Quick Release Hose Cuff Handle Assembly Screw for Base Model Wand Carry Handle with Tool Caddy for Base Model 31 Cord Retention Clip www.pro-team.com 866.888.
Handle Handle with Over Mold and Decal On/Off Rocker Switch Cord Wrap Bracket Cord Wrap Phillips Screw Cord Wrap Bracket Compression Spring Washer Handle Bezel with Screws (XP version pictured) Cord Wrap Bracket Compression Spring Handle Assembly Phillips Screw Handle Tube with Wire Harness, Rivet Nut and Plug Rivet Handle Tube Bushing and Screw www.pro-team.com 866.888.
Handle HANDLE ASSEMBLY fig. 1 1. fig. 2 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) fig. 3 2. Remove screw at base of handle and remove from handle tube (fig. 3). fig. 4 3. Feed handle wire harness through new handle and replace screw at the base of the handle (fig. 4). (Continued on page 34) 33 www.pro-team.com 866.888.
Handle HANDLE ASSEMBLY (CONTINUED FROM PAGE 33) front of switch I 0 II position II must be on the bottom before attaching wires to spades Feed wires through opening on handle bezel. short brown long blue Using the diagram provided above, attach wires to switch. Orient the switch box with the II 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.
Handle HANDLE ASSEMBLY 7. (CONTINUED FROM PAGE 34) Switch must remain flat to the handle bezel when installed into handle body as shown. 8. Press the switch into place in the handle bezel. The II position should be closest to the front of the bezel. A 9. Lay the long red, brown and blue wires between the circular shoulders and gently place handle bezel into handle. 10. B Slide tab A into handle slot B and press firmly into place at C.
Handle and Power Cord NEW CORD AND STRAIN RELIEF REPLACEMENT 1. Use a flathead screwdriver and hammer to push the strain relief towards the handle. Snap off remaining strain relief. 2. Remove screw from carry handle and remove carry handle. 4. 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. Cord Retension Clip 3. Unscrew cord retension clip and set aside. Slide handle tube away from base.
Handle and Power Cord NEW CORD AND STRAIN RELIEF REPLACEMENT 5. Slide handle tube through opening in strain relief. Align holes on strain relief and handle tube. Insert new ratchet fastener in hole and push flush. 7. Use flathead screwdriver to reattach carry handle to handle tube. Ensure proper alignment of carry handle by verifying bag cover closure. 37 6. (CONTINUED FROM PAGE 36) Plug in new cord and slide handle tube into handle sleeve on motor housing.
Handle and Power Cord HANDLE INSTALLATION 1. 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. 2. Insert ratchet fastener into cord clasp opening by pushing with thumb to connect cord to handle. 3. www.pro-team.com 866.888.
Handle IMPACT BUMPER INSTALLATION Old Washer 1. Using a Phillips Head screwdriver, remove screw from cord wrap bracket. Discard screw only. 3. Insert impact bumper assembly into cord wrap bracket. Note: Screw should be inserted inside spring from original assembly. Do not over tighten. 39 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 shown above. www.pro-team.com 866.888.
Final Vacuum Assembly ASSEMBLY Hose Assembly with Cuffs 1. Install all 3 filters: (a) Intercept Micro Filter (b) Motor Intake Filter (c) Exhaust Filter 2. Install Power Cord and Handle with Over Mold and Decal. Attach with Handle Tube Bushing and Carry Handle with Tool Caddy. WAND AND HOSE APPLY TO XP MODELS ONLY Handle with Over Mold and Decal Quick Release Hose Cuff 3. Wrap Power Cord around Cord Wrap Post.
Troubleshooting CLEARING HOSE AND WAND OBSTRUCTIONS – XP MODELS RE E T E T S RE S 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. Turn off vacuum and unplug power cord from outlet. 1. 2. On underside of vacuum, pull out, or cut away, obstructions on the brush roll. (Figure A) 3. Press the reset button on top side of powerhead. Plug-in power cord, and restart motor (Figure A).
Troubleshooting CLEARING HOSE AND WAND OBSTRUCTIONS – HEPA MODELS CLEARING THE BRUSH ROLL RE S E T RE S E T Figure A 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. Turn off vacuum and unplug power cord from outlet. 1. 2. On underside of vacuum, pull out, or cut away, obstructions on the brush roll. (Figure A). 3. Press the reset button on top side of powerhead. Plug-in power cord, and restart motor.
P.O. Box 7385, Boise, Idaho 83707 • 866.888.2168 www.pro-team.
