Kirby G5 Service Manual
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Kirby G5 Service Manual

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SERVICE MANUAL FOR THE KIRBY G5
SECTION 4
4.1
4.1.1
4.1.2
4.2.
4.2.2
4.2.3
4.2.4
4.3
4.4
4.4.2
4.4.3
4.4.5
4.5.

TABLE OF CONTENTS

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Summary of Contents for Kirby G5

  • Page 1: Table Of Contents

    SERVICE MANUAL FOR THE KIRBY G5 TABLE OF CONTENTS FOREWORD Troubleshooting SECTION 4 Troubleshooting Guide Use of This Section Warnings, Caution, and Notes 4.1.1 4.1.2 Arrangement of the Troubleshooting Section 4.2. Kirby GS Troubleshooting Guide 4.2. l Troubleshooting Matrix 4.2.2...
  • Page 2 SECTION 5 Service Details and Instructions Use of This Section 5.1.1 Warnings, Cautions, and Notes 5.1.2 Arrangement of Illustrated Parts List and Exploded Views Relationship of Text to Theory Illustrations and 5.1.3 Exploded Views Power Unit Checkout Power Unit Disassembly - General 5.3.l Cover Assembly Removal 5.3.2...
  • Page 3 SECTION 6 Slide Bracket Service Instructions Slide Bracket Assembly Service 6.1.1 Slide Bracket Assembly Component Replacement 6.1.2 Handle Pivot Spring Assembly 6.1.3 Final Assembly Unit SECTION 7 Outer Bag Service Instructions Outer Bag Assembly Service 7.1.1 Bag Top Assembly Service 7.1.2 Removal/Installation of Bag to Mini Emtor SECTION 8...
  • Page 4 NOTES...
  • Page 5 SECTION 2 -120 THE SERVICE CENTER/DEPARTMENT OPERATION TOOLS AND METERS Tools required include: Screwdrivers - Flat - Assorted Sizes Screwdriver - Phillips - Assorted Sizes Pliers - Assorted Impact Screwdriver Bench Vice File Round Rattail 8" long File - 1/4" pillar - 6" long Tap Wrench Threading Tap 6 Threading Tap 8 x 3 2...

  • Page 6: Troubleshooting

    SECTION 4 -120 VT TROUBLESHOOTING USE OF THIS SECTION 4.1.1 Warnings, Cautions, and Notes - Observe all Warnings, Cautions, and Notes in this section as well as those sections to which you will be referred. 4.1.2 Arrangement of the Troubleshooting Section - The troubleshooting section is arranged in two parts, first.
  • Page 8 SECTION 4 -120 VT TROUBLESHOOTING Troubleshooting Table PROBLEM PROBABLE CAUSE SOLUTION 5. Armature/carbon . Motor binds Replace motor (5.6. l) or !-----------;-------------�------ --- · brushes spark defective motor component (5.6.2-5.6.7) Carbon brush stuck in holder 2. Replace carbon brush assembly (5.6.3) Defective armature or field 3.
  • Page 9 SECTION 4 -120 VT TROUBLESHOOTING Troubleshooting Table PROBLEM PROBABLE CAUSE SOLUTION 11. Base pan dirty Motor seal pinched/leaking 1 . Reset or replace motor seal inside. (5.6.8 A.) Hom gasket tom . Replace horn gasket (5.3.3) Headlight bulb Bulb defective 1.
  • Page 10 SECTION 4 -120 VT TROUBLESHOOTING Troubleshooting Table SOLUTION PROBLEM PROBABLE CAUSE 17. Drive system Primary drive belt tight Adjust primary drive belt assembly rattles ( 5.4.4 F.1 and F.2 ) on wind down Primary drive sprocket loose Replace drive sprocket. Remove clip and sprocket off shaft 18.
  • Page 11 SECTION 4 -120 VT TROUBLESHOOTING Troubleshooting Table PROBLEM PROBABLE CAUSE SOLUTION 22. Brush roll belt Brush roll binds Remove brush roll ends to breaks. clean, or replace brush roll Motor runs backwards Brush leads reversed. Correct brush lead routing (Fig. 30 5.6.7 L) 23.

  • Page 12: Assembly Of Unit And Paragraph References

    4.2.4 GS Bag Top (7.1.1) If attachments are not seated properly and the switch levers are not activated, 4.3 Electrical Guide-120 Volt-Kirby the motor will not come on when the Model GS Cleaner on/off rear foot pedal is depressed.
  • Page 13 SECTION 4 -120 VT TROUBLESHOOTING CIRCUIT SHOWN IS LOW SPEED OPERATION HEADLIGH T ALL SWITCH INTERLOCKS ARE "ON" r -------------- , °' - - - - - - - - - -, ➔ ➔ >>-____.!,_ _____ SWITCH --- --- � ::�>------,-' ----...-.�...

  • Page 14: Common Electrical Defects-Cause And Troubleshooting Guide

    SECTION 4 -120 VT TROUBLESHOOTING Common Electrical Defects - Cause should come on. If it does not come on, do not depress the rear on-off and Troubleshooting Guide switch and do not remove the nozzle A troubleshooting video and this service or bag.
  • Page 15 SECTION 4 -120 VT TROUBLESHOOTING Chart 4.4.1 Open Circuit Isolation Sequence (120 Volt) Continuity Procedure Comment (yes/no) Step 1: Unit functions properly. Problem is in Attach one of the multimeter probes � upply _ voltage, po � er � ord, or an to point 1 (upper switch prong) and mtermment open circuit the other to point 12 (lower switch...

  • Page 16: Defect In The Motor Field

    SECTION 4 -120 VT TROUBLESHOOTING Check for the following resistance: 4.4.2 Defect in the Motor Field Motor Field A high resolution ohm-meter can be Terminals Resistor Resistance Reading used to help find a motor field problem. 5 and 7 .444/.510 Equipment 7 and 8 Ohm-meter.

  • Page 18: High Potential Test Of Finished Units

    SECTION 4 -120 VT TROUBLESHOOTING High Potential Test of Finished Units 2. To perform the high potential test the cleaner must be in the on condition. Purpose: There must be an accessory in the The high potential test is one method front mounting (like a nozzle) and an of checking the electrical insulation accessory on the side exhaust port (like...
  • Page 19 NOTES...

  • Page 20: Service Details And Instructions

    - Theory Illustrations Throughout the text. line drawings of the GS Kirby appear that as­ sociate accompanying procedural steps with the unit. Text refer­ ences, the location or the illustration and its title clarify its use.

  • Page 22: Fan Case Assembly And Wheel Shaft Main Assembly Removal

    SECTION 5 -120 VT SERVICE DETAILS AND INSTRUCTIONS 2. Insert flat bladed screw driver in slot and 2. Remove two screws from top of fan case. lift. 3. Remove two remaining screws from 3. Apply downward pressure to top of scuff lower end of the fan case.

  • Page 24: Base Pan

    Remove bent The drive system assembly is a sealed unit and ring by pulling up with pliers. should only be serviced at Kirby. However, wheel covers and wheels may be replaced ! OTE without removing drive system assembly from power unit as follows: Do not remove or grind the rivets.

  • Page 26: Rear Axle Assembly Service

    SECTION 5 -120 VT SERVICE DETAILS ANO INSTRUCTIONS away pedal pivot for freedom of move- 5.4.3 Rear Axle Assembly Service 1:1ent. Shifting malfunction or extremely A. After N/D pedal and bracket cam assem­ tight breakaway pedal will require replace­ blies are removed from drive system, ment of N/D pedal, bracket cam or rear loosen both axle retainer screws and posi­...
  • Page 27 SECTION 5 -120 VT SERVICE DETAILS AND INSTRUCTIONS I. See Figure 18. Position axle so that left side M. Place the left bearing just to the right of the of axle has the greatest distance from the left bearing tabs and the clutch half over­ axle drive balls to the end of axle.

  • Page 28: Install Drive System Assembly

    SECTION 5 -120 VT SERVICE DETAILS AND INSTRUCTIONS the bottom of the N/D pedal body into the 5.5 Headlight Cap/Slide Bracket Assembly, and Handle Pivot Spring hole in the bottom of the drive system cast­ ing . Removal R. Align the threaded hole in the N/D pedal For detailed service information on the compo­...

  • Page 29: Motor Unit Assembly Service

    SECTION 5 -120 VT SERVICE DETAILS AND INSTRUCTIONS C. Disconnect remaining headlight cap electri­ See Figure 21. Tum the power unit over cal lead from the power switch. and remove the two screws from the re­ cessed holes in power unit. (See CAU­ D.

  • Page 30: Fan Replacement

    SECTION 5 -120 VT SERVICE DETAILS AND INSTRUCTIONS EXHAUST MOTOR UNIT DUCT ASSEMBLY OPEN END FAN PULLEY WRENCH HOLE Figure 23. Exhaust Duct and Grill Removal Figure 24 Fan Removal E. While holding base pan down, remove mo­ tor assembly by gently lifting up and out D.

  • Page 32: Armature Assembly And Front Bearing Replacement

    SECTION 5 -120 VT SERVICE DETAILS AND INSTRUCTIONS Excessive force may cause breakage of 5.6.6 Field Assembly Replacement field terminals. A. Remove fan, brush holder assemblies, H. Tighten power switch screw to 4-6 in-lbs. power switch, bearing plate assembly, and when installing.
  • Page 34 SECTION 5 -120 VT SERVICE DETAILS AND INSTRUCTIONS with drive system linkage.Tighten cartridge securely in channel. Tighten screws to 22-26 in-lbs. brush cartridge screw to 4-6 in-lbs. b. Install the static discharge wire con­ F. Install right brush lead wire from brush car­ nector end to the static washer tab tridge to lower switch terminal noted "O"...
  • Page 35 SECTION 5 -120 VT SERVICE DETAILS AND INSTRUCTIONS LIGHT WI RE WISOCKET PIN 603889/\ POWER l TCH DIN l l 0590 OR 0589S P/N I I BRUSH LE/\D RI G-iT PIN 602889/\ M/\TCHES "O" OR "/\" ON MOTOR HOUSING. SPECIFICATIONS MOTOR FIELD 103989 LOW SPEED...

  • Page 36: Slide Bracket Service Instructions

    SECTION 6-120 VT SLIDE BRACKET SERVICE INSTRUCTIONS SLIDE BRACKET ASSEMBLY D. Remove guide blocks, slide adjusting SERVICE wedge, roller bearing assemblies, and slide. 6.1.1 Slide Bracket Assembly Component E. Refer lo Figures 31 and 32 as needed ro as­ semble. Assembly is as follows: Replacement Service is limited to disassembly and l .

  • Page 38: Final Assembly Unit

    SECTION 6-120 VT SLIDE BRACKET SERVICE INSTRUCTIONS be as far forward as possible without exert­ 6.1.3 Final Assembly Unit ing pressure on the linkage. A. Install cover shell. !CAUTION 1. Assure proper assembly of trim strips to cover before installation. Installation of handle pivot spring as­...
  • Page 39 NOTES...

  • Page 40: Outer Bag Service Instructions

    SECTION 7 -120 VT OUTER BAG SERVICE INSTRUCTIONS OUTER BAG ASSEMBLY SERVICE B. To install outer bag to Mini Emtor, unzip the bag, unfold rubber seal at bottom of 7.1.1 Bag Top Assembly Service bag so that wide lip is pointing toward top of bag and stitching securing bag to rubber A.
  • Page 41 NOTES...

  • Page 42: Belt Lifter, Attachment Hose, And Headlight Service

    SECTION 8 -120 VT BELT LIFTER, ATTACHMENT HOSE, AND HEADLIGHT SERVICE Belt Lifter Replacement side of casting when viewed from the rear of the nozzle. Remove rug nozzle assembly from power unit. Turn brush roll end caps so both are at the same setting.
  • Page 44 NOTES...
  • Page 45 NOTES...

  • Page 46: Illustrated Parts List And Exploded Views

    SECTION 9 - 120 VT ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Figure 39 Base Pan Assembly and Cord Set Table l Base Pan Assembly and Cord Set Figure 40 Motor Assembly Motor Assembly Table 2 Figure 41 Fan Case Assembly Fan Case Assembly Table 3 Headlight Cap/Slide Bracket/Handle Pivot...
  • Page 48 SECTION 9 - 120 ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Table 1. Base Pan Assembly and Cord Set Base Pan Assembly 604397S 601989S 0 - Ring - Horn Adapter (5 pack) 100689S Rivet - Horn Adapter (25 pack) Exhaust Duct 106397 104197S Grill - Exhaust Duct (5 pack)
  • Page 49 SECTION 9 • 120 ILLUSTRATED PARTS LIST AND EXPLODED VIEWS /• '-,.,: � £/ � ---- ,, , � ,., I -� i._\ 3? --- ,.,,., ,.,,., � � � �' ,.,,., � � Figure 40. Motor Assembly...
  • Page 50 5.6.7 Assembly of Motor A. Install field coil with terminal block side positioned in open side of motor housing with terminals pointing toward rear bearing well. Install two field screws and nuts. Tighten screws to 16-20 in-lbs. Install static washer in motor housing rear bearing well.
  • Page 51 SECTION 9 - 120 ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Table 2. Motor Assembly 103989 Field Coil - 120 VT 100196S Motor Housing w/Tolerance Ring Screw (Torx) - Motor Field (IO p ack) 232295S Nut - Field Screw and Bearing Plate (25 pack) 600589S Brush Holder w/Brush (10 pack) 107189A...
  • Page 52 SECTION 9 - 120 VT ILLUSTRATED PARTS LIST AND EXPLODED VIEWS \,,,,,,, � ,.,,,,,,, � ✓, /� � .._ ,.,.. r ,,. '----,,, 7 18-:1' Figure 41. Fan Case Assembly...
  • Page 53 SECTION 9 - 120 ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Table 3. Fan Case Assembly Fan Case Assembly l 19797S 1211 S Screw Nozzle Lock (10 pack) Nozzle Lock pack) Spring - 1212S 125297A Lever - ozzle Lock (2 pack) 610097S Bezel - Power Switch (5 pack) 121689S...
  • Page 54 SEC T ION 9 - 120 V T ILLUSTRATED PARTS LIST AND EXPLODED VIEWS ��, f-�+ �/4 {� ------1I ! .,,, ,:'/� •_/ .__-=-- Figure 42. Headlight Cap/Slide Bracket/Handle Pivot Spring Assembly...
  • Page 55 SECTION 9 - 120 VT ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Table 4. Headlight Cap/Slide Brar.ket/Handle Pivot Spring Assembly 160097 Headlight Cap - Casting Lens - Headlight Cap 108597 109289S Light bulb (10 pack) Headlight Frame Bracket 161797 232497S Screw (Torx) - Headlight Pivot to Slide Bracket (10 pack) 161389 Headlight Pivot Casting 161689S...
  • Page 57 SECTION 9 120 VT ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Table 5. Cover Shell Assembly 135689A Cover Less Trim Strips 630997S Left Trim Strip - Cover (5 pack) 630897S Right Trim Strip - Cover (5 pack) 111297 Scuff Plate - 120 VT 233497S Screw (Torx)- Scuff Plate - Rear (10 pack) 232395S...
  • Page 59 SECTION 9 - 120 VT ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Table 6. Power Drive Assembly 5523970 Power Drive Assembly w/Rear Wheels 555997S Hubcap - Rear Wheel (10 pack) Rear Wheel 556297 Clip - Rear Wheel (25 pack) 601689S 554189S Primary Drive Belt (5 pack) 110397S Foot Pedal (5 pack)
  • Page 60 SECTION 9 - 120 VT ILLUSTRATED PARTS LIST AND EXPLODED VIEWS €Jim- ,,.. Figure 45. Floor ozzle Assembly...
  • Page 61 SECTION 9 - 120 VT ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Table 7. Floor Nozzle Assembly 1416970 Nozzle Assembly (Less Brush and Belt) Label - Belt Lifter (5 pack) 673697S 232596S Screw (Torx) - Belt Lifter (10 pack) 159297S Belt Lifter Body Assembly 144681S Flat Washer - Belt Lifter (10 pack) 314890S...
  • Page 62 SECTION 9 - 120 VT ILLUSTRATED PARTS LIST AND EXPLODED VIEWS " Figure 46. Handle Fork and Grip Assembly...
  • Page 63 SECTION 9 - 120 VT ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Table 8. Handle Fork and Grip Assembly Handle Fork Assembly 1750970 672189 Latch Plate Screw - Latch Plate (25 pack) 170489S 174397S Label - Handle Fork pack) Strain Relief - Rear Cover (5 pack) 170597S 675189S Retainer Ring - Strain Relief...
  • Page 64 SECTION 9 - 120 VT ILLUSTRATED PARTS LIST AND EXPLODED VIEWS ,,.. ,,,. 1 ,,.. ,,,. ,,..,,.. _,.,,.. / / r.:::---____,, � Figure 47. Cloth Bag and Mini Emtor Assembly...
  • Page 65 SECTION 9 - 120 ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Table 9. Cloth Bag and Mini Emtor Assembly 187997G Bag/Mini Emtor Assembly 190097 Bag Assembly (w/Latch Only) 191897 Bag Top Cover 196497S Latch - Cloth Bag (5 pack) 196597S Bag Clamp Strap (5 pack) 199497S Fill Tube/Mini Emtor Assembly 197394...
  • Page 66 SECTION 9 - 120 VT ILLUSTRATED PARTS LIST AND EXPLODED VIEWS » � � � ",/ � rffi" � � D O» fl-- Figure 48. Attachments...
  • Page 67 Venturi - Spray Gun (5 pack) 256697S 285697S Strap - Kaddy Assembly (5 pack) 285597S Push Nut - Kaddy Strap (5 pack) Cover - Portable Handle (5 pack) 200797S 207097S GS Attachment Set - Service * 270897A GS Kirby Carton Top (20/cs) * Not Jllustrated...
  • Page 68 SECTION 9 - 120 VT ILLUSTRATED PARTS LIST AND EXPLODED VIEWS 21 r- - - --, �� Figure 49. Carpet Shampoo System...
  • Page 69 SECTION 9 - 120 VT VIEWS ILLUSTRATED PARTS LIST AND EXPLODED Table 11. Carpet Shampoo System CSS Nozzle Assembly 303197S Belt Lifter Body Assembly 159297S Label - Belt Lifter (5 pack) 673697S 304297S Warning Label, CSS (5 pack) 314890S Spring Washer (10 pack) 144291 Belt Lifter Hook 144681S...
  • Page 72 NOTES...

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