Pro-Team GoCartVac Service Manual
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Pro-Team GoCartVac Service Manual

Pro-team gocartvac: supplementary guide
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GoCartVac
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Summary of Contents for Pro-Team GoCartVac

  • Page 1 GoCartVac ™ Service Manual...

  • Page 2: Table Of Contents

    Replace Battery Control Module (BCM) ........18 Remove Motor/BCM Assembly From Vacuum ......19 Replace Motor/BCM Assembly Into Vacuum .

  • Page 3: Battery Safety

    (vented) or diffused through the container walls. The VRLA batteries specified for this equipment are designed to minimize gas produced. The gasses released or diffused must not be allowed to accumulate. The GoCartVac enclosure has been designed to ensure proper ventilation of battery gasses.

  • Page 4: Full Vacuum Parts

    103623 Electrified Hose, 1 " x 20' Long, 2-Wire 102715 Replacement Swivel Elbow Cuff, Black 106550 Switch Replacement 106284 Kit, Vacuum Attachment Hardware for Cart 106219 Kit, Power Receptacle Cord 106211 Box, Sound w/Corner Rails 106213 Cart Assembly 106214 Kit, Mounting Hardware...

  • Page 5: Remove Charger Panel

    Remove side panel closest to power switch by pushing in and pulling up at the same time. Place cover into tray of cart. Continue pulling up until panel is removed. Place aside. (Continued on page 5) www.pro-team.com 800.541.1456...
  • Page 6 Grab each end of the charging harness and work back and forth as you pull apart. Slide the charger’s black/red connector apart from the other two. Unplug charger from receptacle. www.pro-team.com 800.541.1456 (Continued from page 4) Using grip in panel pull up until panel is clear from cart.

  • Page 7: Replace Charger Panel

    Slide red and black connector of charger into other two red and black connectors from batteries and vacuum. Attach the charging harness terminal to the three connectors of the charger, batteries and vacuum. (Continued on page 7) www.pro-team.com 800.541.1456...
  • Page 8 If on tightly the four flanges are visible above the cover. www.pro-team.com 800.541.1456 (Continued from page 6) Put cover in place on top of cart. Push until snaps into place.

  • Page 9: Remove Vacuum Panel

    Remove Vacuum Panel REMOVE VACUUM PANEL 1. Remove Charger Panel (Page 4) Slide the remaining two red/black connectors apart from each other. Disconnect plug from vacuum. Carefully remove vacuum panel from cart. www.pro-team.com 800.541.1456...

  • Page 10: Replace Vacuum Panel

    Confirm that the panel is rest- ing on the bottom of the cart and that the corner molding and panel are even at the top. Plug cable from cover of cart into vacuum.

  • Page 11: Remove Diffuser

    Remove Diffuser REMOVE DIFFUSER 1. Remove Charger Panel (Page 4) 2. Remove Vacuum Panel (Page 8) Remove vacuum from panel using Phillips screwdriver to remove two screws and washers. Turn vacuum upside down. Remove cap by twisting counter-clockwise. Using a 5/16 socket or flat head screwdriver, remove two screws holding plastic diffuser to motor.

  • Page 12: Replace Diffuser

    Replace diffuser by placing the side with ridges away from motor. Turn vacuum right side up and place cloth and paper filter into vacuum body. Lay panel on top of vacuum aligning mounting holes in vacuum with holes in panel. www.pro-team.com 800.541.1456 Attach diffuser to motor with two screws.

  • Page 13: Remove Receptacle

    Using fingers or flathead screwdriver, loosen receptacle from vacuum. Locate and remove top horizontal connector on battery control module (BCM) (white wire from receptacle) with needlenose pliers. Remove two screws holding receptacle to vacuum body with Philip’s screwdriver. Remove receptacle from vacuum. www.pro-team.com 800.541.1456...

  • Page 14: Replace Receptacle

    REPLACE RECEPTACLE Thread wires of new or existing receptacle through hole in vacuum body. Attach receptacle to vacuum body with two screws using a Phillips screwdriver. Connect the white receptacle wire onto the top hori- zontal BCM connection labeled “Switch.”...

  • Page 15: Remove Power Cable

    Holding outer nut, unscrew the inner nut from the threads on the cable. Remove cable from vacuum. 2. Remove Vacuum Panel (Page 8) Locate white wire from power cable and remove from BCM. 3. Remove Diffuser (Page 10) Locate black wire of power cable on BCM.

  • Page 16: Replace Power Cable

    Attach the white wire from switch receptacle to the top connector (marked with SWITCH). If all needed changes are complete: 7. Replace Diffuser (Page 11) www.pro-team.com 800.541.1456 8. Replace Vacuum Panel (Page 9) Replace Power Cable Thread wires through inner nut and tighten nut.

  • Page 17: Remove/Replace Thermal Switch

    Remove/Replace Thermal Switch REMOVE THERMAL SWITCH 1. Remove Charger Panel (Page 4) 2. Remove Vacuum Panel (Page 8) 3. Remove Diffuser (Page 10) Locate and remove thermal switch connector from BCM. REPLACE THERMAL SWITCH Connect male connector of new or existing thermal switch to motor wire.

  • Page 18: Remove Battery Control Module (Bcm)

    REMOVE BCM 1. Remove Charger Panel (Page 4) 2. Remove Vacuum Panel (Page 8) 3. Remove Diffuser (Page 10) Remove all wires connected to BCM. www.pro-team.com 800.541.1456 Remove Battery Control Module (BCM) Remove screw holding BCM to compression ring with either a flathead screwdriver or 5/16 socket.

  • Page 19: Replace Battery Control Module (Bcm)

    8. Replace Diffuser (Page 11) Connect black wire of power cable to “-36” on PC board. 9. Replace Vacuum Panel (Page 9) Connect female connector of thermal switch to “MOTOR” on BCM. Attach the black wire from the motor to the bottom horizontal connector (marked with MTR+).

  • Page 20: Remove Motor/Bcm Assembly From Vacuum

    REMOVE MOTOR/BCM ASSEMBLY FROM VACUUM 1. Remove Charger Panel (Page 4) 2. Remove Vacuum Panel (Page 8) Use flathead screwdriver to remove 3 washer cover caps. Push well nut into vacuum using screwdriver. Remove motor from vacuum body. www.pro-team.com 800.541.1456 3.

  • Page 21: Replace Motor/Bcm Assembly Into Vacuum

    Press dome filter onto bottom of motor. Align motor as shown in picture (BCM close to power cable hole). Ensure well nut is flush against vacuum body. Place motor into vacuum body. Press well nuts into holes in vacuum body.
  • Page 22 REPLACE MOTOR/BCM ASSEMBLY INTO VACUUM Replace Z-washers and screws. Press washer cover/cap over washer. Replace receptacle. Follow Steps 1 through 5 on Page 13. www.pro-team.com 800.541.1456 (Continued from page 20) Tighten screw on Z-washer until well nut has tightened against vacuum wall.

  • Page 23: Remove Motor Brushes

    Remove Motor Brushes REMOVE MOTOR BRUSHES 1. Remove Charger Panel (Page 4) 2. Remove Vacuum Panel (Page 8) 3. Remove Diffuser (Page 10) 4. Remove Motor/BCM Assembly (Page 19) Remove screw and wire retaining clamp on motor with 5/16" socket.

  • Page 24: Remove Motor Brushes

    Remove Motor Brushes REMOVE MOTOR BRUSHES (Continued from page 22) Remove two screws and bracket over the motor brushes. Remove motor brush. Remove 2nd motor brush in same way. www.pro-team.com 800.541.1456...

  • Page 25: Replace Motor Brushes

    With end of flathead screwdriver, push wire clip back into place. If all changes are complete: 5. Replace Motor/BCM Assembly (Page 20) 6. Replace Diffuser (Page 11) 7. Replace Vacuum Panel (Page 9) 8. Replace Charger Panel (Page 6) www.pro-team.com 800.541.1456...

  • Page 26: Remove/Replace Motor Assembly

    REMOVE MOTOR ASSEMBLY 1. Remove Charger Panel (Page 4) 2. Remove Vacuum Panel (Page 8) 3. Remove Diffuser (Page 10) 4. Remove Motor/BCM Assembly (Page 19) REPLACE MOTOR ASSEMBLY Connect one of the thermal switch wires to new motor wire. It does not matter which wire.

  • Page 27: Remove Compression Ring

    Remove Compression Ring REMOVE COMPRESSION RING 1. Remove Charger Panel (Page 4) 2. Remove Vacuum Panel (Page 8) 3. Remove Diffuser (Page 10) 4. Remove Motor/BCM Assembly (Page 19) Remove horizontal motor connector from BCM. Remove remaining 3 screws which attach compression ring to motor.

  • Page 28: Reassemble Compression Ring

    Re-attach PC board in remaining hole on compression ring. Reconnect remaining motor wire to “MTR+” on BCM. www.pro-team.com 800.541.1456 Reassemble Compression Ring Replace three of the screws which attach the ring to the motor. Leave out a screw which is not under a wire clamp (where the BCM was attached).

  • Page 29: Remove/Reassemble Tetraseal

    If all changes are complete: 4. Replace Motor/BCM Assembly (Page 20) 5. Replace Diffuser (Page 11) 6. Replace Vacuum Panel (Page 9) 7. Replace Charger Panel (Page 6) Remove tetraseal by pulling up and over the top of motor.

  • Page 30: Remove/Reassemble Motor

    REMOVE MOTOR 1. Remove Charger Panel (Page 4) 2. Remove Vacuum Panel (Page 8) 3. Remove Diffuser (Page 10) 4. Remove Motor/BCM Assembly (Page 19) Disconnect thermal switch from motor wire. REASSEMBLE MOTOR Replace compression ring, tetraseal and BCM on new motor per Steps 1 through 3 on Page 28.

  • Page 31: Batteries/Harness Safety Notice/Precautions

    (vented) or diffused through the container walls. The VRLA batteries specified for this equipment are designed to minimize gas produced. The gasses released or diffused must not be allowed to accumulate. The GoCartVac enclosure has been designed to ensure proper ventilation of battery gasses.

  • Page 32: Battery Termination Schematic

    Battery Termination Schematic – Fusible Link Red Jumper (105842) (105844) – – Power Harness (105834) Refer to this schematic for removing and replacing of battery wires. www.pro-team.com 800.541.1456...

  • Page 33: Disassemble/Reassemble Gocart

    DISASSEMBLE GOCART 1. Remove Charger Panel (Page 4) Remove remaining side panel and molding. REASSEMBLE GOCART 1. Replace Vacuum Panel (Page 9) Remove remaining side panel and molding. 2. Remove Vacuum Panel (Page 8) 2. Replace Charger Panel (Page 6) 3.

  • Page 34: Remove/Replace Fusible Link

    Torque to 25-30 in-lbs. e) Place protector over the battery terminal. 3. Resassemble GoCart (Page 32) www.pro-team.com 800.541.1456 Remove/Replace Fusible Link On negative terminal of battery B2, and using the black terminal end of the fusible link: Follow a) thru e) of...

  • Page 35: Remove/Replace Red Jumper Wire

    Follow a) thru e) on Step 1 of Replace Fusible Link on Page 33. If only replacing red jumper, Follow a) thru e) on Step 1 of Replace Fusible Link on Page 33. www.pro-team.com 800.541.1456...

  • Page 36: Remove/Replace Power Harness

    Step 1 of Replace Fusible Link on Page 33. 3. Reassemble GoCart (Page 32) www.pro-team.com 800.541.1456 Remove/Replace Power Harness 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.

  • Page 37: Replace Batteries/Harness

    Remove all wire harnesses from the batteries using insulated wrenches. See Safety Notice and Personal Safety Precautions on Page 30. 3. Reassemble GoCart (Page 32) Place new batteries in cart as shown. To replace all harnesses follow directions on Page 35. www.pro-team.com 800.541.1456...

  • Page 38: Remove/Replace Charger

    Place new Charger in cutout location on panel. Place the washer and then the nut/star washer over the screws. Tighten screw to 10 in-lbs. www.pro-team.com 800.541.1456 Remove/Replace Charger Remove the screws, nuts and washers from existing charger. Position so that the fan vents are toward the handle of the panel.

  • Page 39: Remove Cover Of Electrical Enclosure

    REMOVE COVER OF ELECTRICAL ENCLOSURE 1. Remove Charger Panel (Page 4) Remove the 4 screws holding the cover of the electrical enclosure. Remove the black, red and green wires from the receptacle terminals. Pull open the cover to expose wires and components. www.pro-team.com 800.541.1456...

  • Page 40: Replace Cover Onto Electrical Enclosure

    REPLACE COVER ONTO ELECTRICAL ENCLOSURE Push crimped end of green, black and red wire from switch onto terminals of receptacle. www.pro-team.com 800.541.1456 Replace Cover of Electrical Enclosure Using the four screws secure cover to enclosure.

  • Page 41: Remove/Replace Charger Receptacle

    Squeeze together the sides of the receptacle. REPLACE CHARGER RECEPTACLE Push new receptacle through the cover of the enclosure. 2. Replace Cover onto Electrical Enclosure (Page 39) 3. Replace Charger Panel (Page 6) Push through hole while continuing to squeeze sides. www.pro-team.com 800.541.1456...

  • Page 42: Remove Electrical Box & Connections

    Remove 4 screws, nuts and washers holding electrical enclosure to panel with Phillips screwdriver and 3/8” end wrench. Remove black wire with Phillips screwdriver from power receptacle. www.pro-team.com 800.541.1456 Remove Electrical Box and Connections Remove red wire with Phillips screwdriver from power receptacle.

  • Page 43: Reassemble Electrical Box & Connections

    Using Phillips screwdriver put bare end of black wire from switch into gold terminal of receptacle. Place four screws through panel into threaded screw locations in corners. 6. Replace Cover onto Electrical Enclosure (Page 39) 7. Replace Charger Panel (Page 6) www.pro-team.com 800.541.1456...

  • Page 44: Remove/Replace Power Switch

    If all changes are complete: 2. Reassemble Electrical Box and Connections (Page 42) 3. Replace Cover onto Electrical Enclosure (Page 39) 4. Replace Charger Panel (Page 6) www.pro-team.com 800.541.1456 Remove/Replace Power Switch While continuing to squeeze, pull switch from hole in panel.

  • Page 45: Remove/Replace Power Receptacle

    4. Replace Cover onto Electrical Enclosure (Page 39) 5. Replace Charger Panel (Page 6) Remove 2 screws holding receptacle to panel and remove receptacle. Using Phillips screwdriver put bare end of green ground wire back into ground terminal of receptacle. www.pro-team.com 800.541.1456...

  • Page 46: Remove/Replace Swivel Elbow Cuff

    REPLACE SWIVEL ELBOW CUFF Push the smaller end of new elbow cuff into hose until the textured part of the elbow is against the hose. www.pro-team.com 800.541.1456 Remove/Replace Swivel Elbow Cuff Place one hand on hose (close to cord strain...

  • Page 47: Remove Switch In Hose Handle

    Remove Switch in Hose Handle REMOVE SWITCH Remove top cover. Lift out and remove switch and BCM. Remove the 8 screws which hold the handle together. Lift up and remove angled tube. www.pro-team.com 800.541.1456...

  • Page 48: Reassemble Switch In Hose Handle

    Confirm metal rings on angled tube are against the metal clips on BCM. www.pro-team.com 800.541.1456 Reassemble Switch in Hose Handle Place switch with the ON position ( ( I I ) ) facing the nozzle.

  • Page 49: Electrical

    Electrical www.pro-team.com 800.541.1456...
  • Page 50 5118 N. Sawyer Ave., Boise, Idaho 83714 • 800.541.1456 www.pro-team.com #106591 Revised 11/07...

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