Simplicity SYNERGY X9.5 Service Manual
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Simplicity SYNERGY X9.5 Service Manual

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Service Manual for X9.5 and Older Models

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Summary of Contents for Simplicity SYNERGY X9.5

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

  • Page 2: Table Of Contents

    Table of Contents I. Common Issues ................2 VI. Figures A. Direct Air Motor.................. 2 A. Correct Handle Installation ..............4 A.1. Direct Air Motor will not run............ 2 B. PCB Layout and Belt Idler Assembly..........5 A.2. Direct Air Motor is making a squealing sound...... 2 C.
  • Page 3 IMPORTANT SAFETY INSTRUCTIONS When using or servicing any electrical appliance, basic precautions should always be followed, including the following: WARNING: To reduce the risk of fire, electrical shock, or injury: 1. Do not leave vacuum unattended when plugged in. Unplug from outlet when not in use. 2.

  • Page 4: Common Issues

    I. Common Issues A. Direct Air Motor A.1. Direct Air Motor will not run. Check the following: 1. The main switch must be “ON” and the floor/carpet switch must be in the carpet position. 2. The tools activation dial/rotational valve handle must be in the tools “OFF” position. 3.

  • Page 5: Full Bag Indicator (Fbi)

    B. Full Bag Indicator (FBI) B.1. Full bag light will not come “ON”. The full bag indicator is controlled by temperature. As the bag fills, the air flow is restricted causing the motor to work harder building up heat in the motor compartment. At a set point, this heat build up causes the FBI to illuminate. It may take up to 2 minutes for the FBI light to illuminate.

  • Page 6: General Issues

    C. General Issues: C.1 Why does the dust cover gap open when the lower motor is turned “ON”? The direct air motor pulls more air into the dust compartment than the clean air motor can push out. This could be caused by the following: 1.

  • Page 7: Identifying Models By Pcb Layout Or Belt Idler Assembly

    C. General Issues - continued C.3. Identifying Models by PCB Layout or Belt Idler Assembly Figure B. PCB Layout and Belt Idler Assembly .5 and .6 .4 and older Brush Roll PC Board PC Board Fuse Belt Idler Assembly Belt Idler Assembly NOTE: The PC Boards in the .5 and .6 do not have adjustment pods because they have a hall sensor on the belt idler assembly.

  • Page 8: Maintenance Procedures

    II. Maintenance Procedures A. Disassembly Instructions A. Step 1. Figure C. Location of Nozzle Cover Screws 1. Remove the handle and dust cover. 2. Place the vacuum face down on the bench. 3. Remove the base plate by removing the 2 (two) screws. 4.
  • Page 9 A. Disassembly Instructions - Continued A. Step 8. 1. .4 models and older - Remove the direct air motor by lifting up and rotating, and then disconnect the leads. 2. .5 models and newer - Remove screw holding direct air motor in place and lift up. A.

  • Page 10: Removing The Brush Strips

    B. Removing the Brush Strips B. Step 1. 1. Remove the base plate by removing the 2 (two) screws. 2. Remove the agitator/brushroll. 3. If the belt un-loops itself from the motor shaft, the nozzle cover may need to be removed by removing the 5 (five) mounting screws on the underside of the nozzle base tray.

  • Page 11: Replacing The Belt

    C. Replacing the Belt C. Step 1. 1. Remove the base plate by removing the 2 (two) screws. 2. Remove the agitator/brushroll. 3. Remove the 5 (five) mounting screws on the underside of the nozzle base tray. (See Figure C. Location of Nozzle Cover Screws) C.

  • Page 12: Replacing The Led Light Board

    D. Replacing the LED Light Board D. Step 1. Remove the 5 (five) mounting screws on the underside of the nozzle base tray. (See Figure C. Location of Nozzle Cover Screws) D. Step 2. Remove the 3 (three) screws holding the light board onto the nozzle base tray - the middle screw may have the ground wire attached.

  • Page 13: Replacing The Main Pc Board

    F. Replacing the Main PC Board Note: Static electricity is a potential problem and could damage the PC board if a charge is transferred from yourself to the board during handling and installation. Keep the board in the anti-static packaging until ready to install. It is best to use anti-static protection such as a grounding wrist strap.

  • Page 14: Replacing The Clean Air Motor

    G. Replacing the Clean Air Motor G. Step 1. Figure F. Clean Air Motor Wiring 1. Remove the handle and the dust cover. Blue Wire White Wire 2. Place the vacuum face down on the bench. 3. Remove the base plate by removing the 2 (two) screws. 4.

  • Page 15: Installing The Motor Cover

    H. Installing the Motor Cover Note the proper location of the two cables passing from the clean air motor compartment to the direct air motor compartment. They should be stored in the channel of the rib wall before the motor cover is reinstalled. If not, the rib wall could pinch and damage the cables.

  • Page 16: Removing And Replacing The Direct Air Motor

    I. Removing and Replacing the Direct Air Motor Step 1. 1. Remove the handle and the dust cover. 2. Place the vacuum face down on the bench. 3. Remove the base plate by removing the 2 (two) screws. 4. Remove the agitator/brushroll. 5.
  • Page 17 I. Removing and Replacing the Direct Air Motor - Continued Step 9. The direct air motor is located in the lower motor compartment (nearest the nozzle). To remove the direct air motor place a hand on each side of motor and lift up and rotate the motor toward the dust compartment.

  • Page 18: Replacing The Direct Air Motor Fan

    J. Replacing the Direct Air Motor Fan J. Step 1. 1. Remove the handle and the dust cover. 2. Place the vacuum face down on the bench. 3. Remove the base plate by removing the 2 (two) screws. 4. Remove the agitator/brushroll. 5.
  • Page 19 J. Replacing the Direct Air Motor Fan- Continued J. Step 10. 1. Replace the fan. 2. Note the placement of the washer(s) on the fan. The placement of these washers is critical to allow the fan to tighten properly on the motor shaft. 3.

  • Page 20: Replacing The Rear Wheels

    K. Replacing the Rear Wheels NOTE: When replacing the wheels or hubcaps for .4 and older models, the entire wheel/axle set needs to be replaced. K. Step 1. Remove the rear wheel hubcaps by depressing the 3 lock tabs on the inside of the wheel. K.

  • Page 21: General Troubleshooting

    III. General Troubleshooting A. Vacuum has no power. A. Step 1. 1. If there are lights in the handle switches there is power to the handle, continue to Step 2. 2. If there are no lights in the handle switches, there is no power to the vacuum or the power cord is faulty. a.
  • Page 22 A. Vacuum has no power. - Continued A. Step 5. 1. Disassemble the vacuum and disconnect the PC board. 2. Using a test light or meter, test connector 10 (thermal lead) and either 5 or 6 (ground) on the main connector on the wire harness.

  • Page 23: Direct Air Motor Will Not Run

    B. Direct Air Motor Will Not Run 1. If nozzle cover is installed, the vacuum must be out of the upright position before the direct air motor will run. 2. If the nozzle cover is not installed, the direct air motor should run in the upright position. 3.

  • Page 24: Direct Air Motor Will Not Run: Headlights Are On

    B.2. Direct Air Motor Will Not Run: Headlights are on B.2. Step 1. 1. Check the position of tools activation dial/rotational valve handle. Tool dial must be in “OFF” position. Rotate the tool dial fully counter clockwise and then back to full clockwise or “OFF” position. 2.

  • Page 25: Proper Position For Tools Activation Dial/Rotational Valve Handle

    B. Direct Air Motor Will Not Run - continued B.2. Step 7. If all switches appear to be good: 1. Check the brown wire on the wing rocker switch as follows. Place one lead of the multi-meter on the brown wire from the micro switch.

  • Page 26: Nozzle Suction Power Is Weak

    C. Nozzle Suction Power is Weak 1. Bag may be full or contain fine particles such as drywall dust or talc. 2. Filters may be dirty and need replaced. C.1. There is no suction at the hose C.1. Step 1. The tool activation dial/rotational valve handle should be in the tools “ON”...

  • Page 27: Excessive Vibration

    D. Excessive Vibration 1. Check the direct air fan for damage. Replace if necessary. (See II. Maintenance Procedures, J. Replacing the Direct Air Motor Fan) 2. The agitator/brushroll may be out of balance. 3. To test the agitator/brushroll for balance: Models .4 and older: 1.

  • Page 28: Agitator/Brushroll Jam Test

    F. Agitator/brushroll Jam Test F. Step 1. 1. Turn the vacuum on. Turn the carpet/floor switch to carpet. Run the vacuum over a sock or towel to jam the agitator/ brushroll. NOTE: Be sure to use thick enough sock or towel material so it doesn’t wrap around the agitator/brushroll. 2.

  • Page 29: Trouble Shooting - .4 And Older Models Only

    IV. Trouble Shooting - .4 and Older Models Only A. Full Bag Indicator (FBI) Comes On Too Soon or Not At All If the light comes on too soon, the bag may be full or contain fine particles such as drywall dust or talc. If the light does not come on at all, the bag may be full of fluffy material.

  • Page 30: Agitator/Brushroll Jam Light Comes On Too Soon Or Not At All

    B. Agitator/brushroll Jam Light Comes On Too Soon or Not At All If the sensor is coming on too soon, the customer may be vacuuming one extra plush carpet. Set the height adjustment to higher level and retest. If the sensor still comes on too soon, it may be out of calibration and need adjusting. - See Adjusting the Agitator/brushroll Jam Indicator below.

  • Page 31: Trouble Shooting - .5 And .6 Models Only

    V. Trouble Shooting - .5 and . Models Only A. Direct Air Motor Starts But Shuts Off in 2 or 3 Seconds NOTE: Any time the nozzle cover is removed the direct air motor will run with the vacuum in the upright position. A.

  • Page 32: Handle Assembly

    VI. Figures N. Handle Assembly Description Description Handle Assembly Lower Cord Hook Screw Handle Mount Screw Handle Pin Handle Tube Base Connector E-Clip Handle Tube Power Cord Handle to Body Harness Upper Cord Hook Base Metal Handle Retainer Upper Cord Hook Steel Rod Pin Spring Switch Carpet/Floor...

  • Page 33: Body Assembly

    O. Body Assembly Dust Cover Assembly Printed Dust Cover Dust Cover Latch Body Assembly Dust Cover Latch Body Dust Cover Latch Latch Cover Dust Cover Lever HEPA Bag Carrying Handle Motor Cover Seal Direct Air Filter Cover Direct Air Motor Filter Motor Cover Internal Air Path Secondary Filter...

  • Page 34: Nozzle Assembly

    P. Nozzle Assembly Lens Right Lens Left Nozzle Bumper Nozzle Cover Assembly Nozzle Badge Nozzle Cover Printed Indicator Light Adjust Lens Retaining Ring Height Adjust Assembly 10 Screws 11 Rear Wheel Hub Cap 12 Nozzle Inlet Duct Cover 13 Large Overmolded Wheel Assembly 14 E-Clip 15 Axle-Rear Wheel 16 Reflector/Headlight Assembly...

  • Page 35: Handle Wiring

    Q. Handle Wiring 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 switch is turned “ON” Handle regardless of whether the handle is installed in the Harness...

  • Page 36: Main Body Wire Harness .5 And .6 Models

    R. Main Body Wire Harness .5 and . Models Handle Connection 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.

  • Page 37: Main Body Wire Harness .4 And Older Models

    S. Main Body Wire Harness .4 and Older Models Handle Connection 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.

  • Page 38: Description Of Vacuum

    T. Description of Vacuum Main on / off power switch ComfortGrip" handle Carpet / hardwood floor switch Quick release cord hook 34' power cord ReadyReach™ tools Carrying handle Combination dusting / Tool upholstery brush activation dial 5-to-1 Bag compartment latch stretch hose (to replace vacuum bag) Telescopic wand...

This manual is also suitable for:

Synergy x9.6Synergy x9.4

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