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Kirby G10D Service Manual
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Kirby G10D Service Manual

Domestic edition, 120 v
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Summary of Contents for Kirby G10D

  • Page 2 Service Manual MODEL Gl0D 120 V 50-60 Hz. Printed in USA•© 2015 The Kirby Company• P 1 246515 REV. B 11/15...
  • Page 3 4.2.I Troubleshooting Matrix 4.2.2 Assembly of Unit and Section References Micron Magic HEPA Filtration System 4.2.3 Electrical Guide - 120 Volt - Kirby Unit 4.3.l Basic Electrical Design Common Electrical Failures-Cause and Troubleshooting Guide 20 Motor Will Not Run 4.4.1 4.4.2...
  • Page 4 TABLE OF CONTENTS SECTION 5 Service Details and Instructions Use of This Section 5.1.1 Warnings, Cautions. and Noles 5.1.2 Arrangement of Illustrated Parts List and Exploded Views 5.1.3 Relationship of Text to Theory Illustrations and Exploded Views Power Unit Checkout Power Unit Disassembly - General 5.3.1 Cover As embly Removal...
  • Page 5 TABLE OF CONTENTS SECTION 6 Slide Bracket Service Instructions Slide Bracket Assembly Service 6.1.1 Slide Bracket As embly Component Replacement 6.1.2 Handle Pivot Spring Assembly 6.1.3 Final Assembly of Unit SECTION 7 Outer Bag Service Instructions 7 .1 Outer Bag Assembly Service 7.
  • Page 6 NOTES...
  • Page 8 NOTES...
  • Page 9 SECTION 4 - 120 V TROUBLESHOOTING USE OF THIS SECTION 4.1.1 Warnings, Cautions, and Notes Observe all Warnings, Caution • otes in this section as well as those sections which you will be referred. 4.1.2 Arrangement of the Troubleshooting Section The troubleshooting section is arranged in two parts;...
  • Page 10 SECTION 4 - 120 V TROUBLESHOOTING TROUBLESHOOTING GUIDE When the problem appears electrical in nature, and the information contained 4.2.1 TroubleShooting Matrix in the following table does not correct The following matrix guides the user the problem. proceed to Section 4.4 to the probable cause and a solution 10 for information on conducting an electrical resistance check.
  • Page 11 SECTION 4 - 120 V TROUBLESHOOTING TROUBLESHOOTING TABLE PROBLEM PROBABLE CAUSE SOLUTION Armature/carbon 1. Mot0r bind Replace motor ( 5.6. l ) or failed brushes spark motor component ( 5.6.2 - 5.6.7) 2. Carbon bru h stuck in holder 2. Replace carbon bru h assembly ( 5.6.3) Armature or field coil failure 3.
  • Page 12 SECTION 4 - 120 V TROUBLESHOOTING TROUBLESHOOTING TABLE PROBLEM PROBABLE CAUSE SOLUTION Reset or replace motor seal Base pan dirty inside Motor eal pinched/leaking ( Fig. 38 ) ( 5.6.8 A ) 2. Replace horn gasket ( 5.3.3) Hom gasket t0m J 2.
  • Page 13 SECTION 4 - 120 V TROUBLESHOOTING TROUBLESHOOTING TABLE PROBLEM PROBABLE CAUSE SOLUTION Ad j ust primar y drive belt Primary drive belt ti g ht 17. Drive ystem assembly rattles on wind down ( 5.4.4 F I and F 2 ) Primary drh·...
  • Page 14 SECTION 4 - 120 V TROUBLESHOOTING TROUBLESHOOTING TABLE SOLUTION PROBLEM PROBABLE CAUSE Remove brush roll ends to clean. Brush roll bind 22. Brush roll belt breaks or replace brush roll ( 8.1 E ) Motor runs backwards Motor brush leads reversed. Correct brush lead routing ( Fig.
  • Page 15 TROUBLESHOOTING 4.3.1 Basic Electrical Design 4.2.2 Assembly of Unit Section References The Kirby unit is powered by a two speed Once the problem has been serviced. universal motor. Basic circuit elements a semble the unit. Repair assembly include a motor field, armature. main power references are given below.
  • Page 16 SECTION 4 - 120 V TROUBLESHOOTING Sentria 1 T S!--Ov\/N LOW SPEED OPER,AT 1 0N LED CIRCUIT BOARD A_L SW TCH l'-JT=RLOCl(S ARE "0"-J' SNITCH LEFT BRUS�, Figure 1 Schematic Diagram SWITCH ARMATURE r--... FIELD SWITCH Figure 2 Block Diagram...
  • Page 17 Mini Emtor bag assembly. This ervice manual is available through the Kirby Distributor Service Center or the Unplug the cord. The cleaner should be in [ntemational Warehouse in your location. the on condition and ready for the Open Circuit Isolation Check.
  • Page 21 SECTION 4 - 120 V TROUBLESHOOTING 2. To perform the high potential test the 4. Measure between field terminals #6 and cleaner must be in the on condition. There #7. There should be no continuity with must be an accessory on the front mounting the high speed plunger out, and there (floor nozzle) and an accessory on the side should be continuity with the plunger in.
  • Page 22 DWG# 1431 AVALIR MULTI-SURFACE SHAMPOO SYSTEM SCN# 1431 TAG PART MODEL DESCRIPTION NO . 306714 TANK ASSEMBLE CSS CAP, MSSS TANK AVALIR 308914 SUDS SCREEN MSSS-MOLDED 316214 10/PK G3/AV Filter Sponge - C.S.S.Tank Assembly 307389S MSSS NOZ ASSY W/LABEL AVL 303114S BELT BAFFLE STRIP - CSS 305214...
  • Page 23 SCN# 1431 IW3# 1431 AVALIR MULTI-SUREACE SHAMFro SYSTEM ei - 3...
  • Page 24 CARPET SHAMPOO Multi-Surface Shampoo System (MSSS) Troubleshooting Guide: Steiz # Causes: Corrections: Owners Manual Page # Baffle Strip on underside of MSSS missing Replace Baffle Strip Black Marks on Carpeting r· • . r-.--.' Select Carpet setting Suds control valve not set correctly Suds Screen missing or Foam Sponge clogged Clean Foam sponge or replace Suds Screen Not Enough suds...
  • Page 25 Troubleshooting Guide: CARPET SHAMPOO Multi-Surface Shampoo System (MSSS) Replace MSSS tank. fNo suds Gasket (tank) alignment issue Contact the Engineering Lab or Fred Jackson for details Brushroll not properly seated on end cap !Shield or Brushroll Melted Properly seat brushroll into end cap holders. holders.
  • Page 26 HARD FLOOR Multi-Surface Shampoo System (MSSS) Troubleshooting Guide: Correction: Causes: Owners Manual Page# Step# Sitmet1,m:ii: Replace MSSS tank. Contact the Engineering Lab or Fred Jackson Gasket (tank) alignment issue �- \ Ot]' � � for details ���- � No Suds Suds Screen missing or Foam Sponge Clean Foam sponge or replace Suds Screen clogged...
  • Page 28 NOTES...
  • Page 29 SECTION 5 - 120 V SERVICE DETAILS AND INSTRUCTIONS USE OF THIS SECTION � 7 arnings, Cautions, and Notes 5.1.J Observe all Warnings. Cautions, and Notes. 5.1.2 Arrangement of Illustrated Parts Lists and Exploded Views The parts list and related exploded views are provided in Section 9. Item numbers on the exploded views relate to the parts list contained in Tables 1 through 12.
  • Page 30 SERVICE DETAILS AND INSTRUCTIONS Power Unit Troubleshoot D. Operate switch pedal and observe power unit operation. If the Kirby Unit requires service, checkout as f o llows: E. lf the power unit does not energize properly, inspect the power cord for A.
  • Page 32 SECTION 5 -120 V SERVICE DETAILS AND INSTRUCTIONS 5. If the fan blade require 2. Remove rwo screws from top of fan case. replacement, refer to Section 5.6.2. 6. Prior lo rhe reas embly of fan case, 3. Remove rwo remaining screws from clean old sealant from joining lower end of the fan case.
  • Page 33 SECTION 5 - 120 V SERVICE DETAILS AND INSTRUCTIONS C. Wheel Shaft and Ratchet Lock 6. While ratchet lock and spring are Service: compressed, install wheel shaft to I. Inspect wheel shaft components for fan case by inserting teeth of ratchet breaks or cracks and center shaft for pedal onto teeth of ratchet lock.
  • Page 34 Detailed service The drive system as embly is a sealed unit information on the drive system assembly and should only be erviced at Kirby. is provided in Section 5.4.2. However, wheel covers and wheels may be replaced without removing drive system A.
  • Page 35 SECTION 5 - 120 V SERVICE DETAILS AND INSTRUCTIONS Lift B. Carefully power switch foot pedal REMOVE DRIVE up and out of power unit until sufficient DRIVE BELT SYSTEM clearance is available to slide power ASSEMBLY switch actuating rod out of foot pedal. �...
  • Page 36 SECTION 5 - 120 V SERVICE DETAILS AND INSTRUCTIONS B. Remove ID pedal assembly by 5.4.3 Rear Axle Assembly Service removing screw in bottom of the drive system assembly. and lifting up A. After N/D pedal and bracket cam and pulling out. assemblies are removed from drive system, loosen both axle retainer crews C.
  • Page 37 SECTION 5 -120 V SERVICE DETAILS AND INSTRUCTIONS teelh of clutch half o, erload gear. Lnstall G. If there is a growling noise in neUlral bushing and washers with washer side mode, inspect axle surface for wear. If against drive bevel gear. In tall ax.Je worn.
  • Page 38 SECTION 5 - 120 V SERVICE DETAILS AND INSTRUCTIONS Q. Install the ID pedal and bracket cam lnsert left axle bushing into the left assemblies on the drive system assembly bushing sleeve of the drive system by positioning the bracket cam finger casting, with tab pointing up, and right between the drive bevel gear and the ide of axle angled away from drive...
  • Page 39 SECTION 5 - 120 V SERVICE DETAILS AND INSTRUCTIONS I. If belt is too tight, loo en screws and CONNECTOR shift drive system assembly to left (ratchet side) and re-tighten screws. 2. Using moderate downward pre sure. belt should deflect 3/8" to l/2" between gear .
  • Page 40 SECTION 5 -120 V SERVICE DETAILS AND INSTRUCTIONS 5.6.1 Motor Unit Assembly Removal Remove the motor unit a sembly as follows: EADLIGHT See Figure 21. Turn the power unit over and remove the two crew from the BASE recessed hole in power unit. (See CAUTION at end of this section).
  • Page 41 SECTION 5 -120 V SERVICE DETAILS AND INSTRUCTIONS !NOTE C. Remove static wire assembly from the All work conducted on the motor should be left rear motor hold-down screw. done with the switch actuating rod removed. D. See Figure 23. Remove exhaust duct 5.6.2 Fan Replacement sere".
  • Page 42 SECTION 5 - 120 V SERVICE DETAILS AND INSTRUCTIONS 2. See Figure 25. Install spacer/seal i.AOfOR a .embly with flat side of eal ORIVi: '<E1 AIN::� SCR::\', toward spacer shoulder and tapered side of seal toward bearing plate. MOTOR UNIT ASSEMBLY SPACER/ SEA L ASSEMBLY...
  • Page 43 SECTION 5 -120 V SERVICE DETAILS AND INSTRUCTIONS 5.6.5 Armature Assembly and Front MOTOR UNIT Bearing Replacement A. See Figure 26. Using Tl 54, snap ring expander pliers No. 0200. remove motor drive clip at rear of armature shaft. B. Remove motor sprocket gear from rear of armature shaft.
  • Page 44 SECTION 5 - 120 V SERVICE DETAILS AND INSTRUCTIONS G. To replace rear bearing, remove bearing F. lnstall armature assembly. using rear bearing puller. part no TI 27 A. To install bearing, press or lightly tap on Install bearing plate See Figure 29.
  • Page 45 SECTION 5 - 120 V SERVICE DETAILS AND INSTRUCTIONS 0. Install Fan. MOTOR HOUSING plate is clean. Apply thin, visible 2. See Figure 25. Install spacer/seal a sembly with flat side of eal toward spacer shoulder and tapered side of eal toward bear i ng plate. Install mylar fan washer.
  • Page 46 SECTION 5 -120 V SERVICE DETAILS AND INSTRUCTIONS E. Now install the right brush cartridge 2. Install motor mount screws. assembly. Tilt brush cartridge and insert a. Install rear motor mount cartridge tab into slot in motor housing. screws first. Be sure that static Seat cartridge securely in channel.
  • Page 47 SECTION 5 - 120 V SERVICE DETAILS AND INSTRUCTIONS 2. Insen two screws into rear legs of slide bracket casting to base pan in front of rear wheel wells. Tighten screws to 16-20 in-lbs. 3. Refer to Section 5.5.F. Install tie wrap around top 1ight slide bracket casting leg to secure headlight lead wires against tube insulation.
  • Page 48 SECTION 5 - 120 V SERVICE DETAILS AND INSTRUCTIONS SentriaTM BRUSH LEAD LEFT LED CIRCUIT P/N 602989A BOARD ASSEMBLY .----ARMATURE �-- MATCHES "B' ON P/N 114789 MOTOR HOUSING SWITCH/HDL JUMPER P/N 607189A --- POWER SWITCH P/N 110590 --- BRUSH LEAD RIGHT P/N 602889A MATCHES "O"...
  • Page 49 SECTION 6 -120 V SLIDE BRACKET SERVICE INSTRUCTIONS Slide Bracket Assembly Service E . Refer ro Figures 31 and 32 as needed to assemble. Assembly is as follows: 6.1.l. Slide Bracket Assembly Component I. If new roller bearing assemblie are Replacement to be in tailed.
  • Page 50 SECTION 6 - 120 V SLIDE BRACKET SERVICE INSTRUCTIONS ♦ Slide is equipped with a centering spring. Install with pring facing downward, toward slide bracket casting. When assembled. the spring should rest in the rectangular shaped cut-out in the slide FACE UP TO CENTER bracket casting.
  • Page 51 SECTION 6 - 120 V SLIDE BRACKET SERVICE INSTRUCTIONS See Figure 35. Remove two screws E. Using other side of the TT-150 tool, from bracket tab. Remove handle in tall tool to po ition handle pivot pivot assembly. spring assembly with "FACE UP TO SET HANDLE PIVOT"...
  • Page 52 SECTION 6 - 120 V SLIDE BRACKET SERVICE INSTRUCTIONS 3. Apply inward pressure on trim strips at rear of cover hell while tightening rear screws. Tighten screws to 12-16 in-lbs. 4. Fasten cover to fan case with two flat head screw . Tighten screws to 28-30 in-lbs.
  • Page 53 SECTION 7 - 120 V OUTER BAG SERVICE INSTRUCTIONS 7.1.2 Removal/Installation of Bag Outer Bag Assembly Service to Mini Emtor 7.1.1 Bag Top Assembly Service A. To remove outer bag assembly from A. See Figure 36. Remove the bag top Mini Emtor.
  • Page 54 SECTION 7 - 120 V OUTER BAG SERVICE INSTRUCTIONS OUTER BAG --_; BAG CLAMP STRAP MINI EMTOR Figure 37. Bag Clamp Strap Position G. Lock the strap and ensure that all the teeth on the end opposite the cross bar lock are ecured by the ribs of the lock.
  • Page 55 SECTION 8 - 120 V BELT LIFTER, ATTACHMENT HOSE AND HEADLIGHT SERVICE Belt Lifter Replacement Hook should point toward top of nozzle when belt lifter is turned Remove power nozzle assembly from counter-clockwi e to its fullest extent. power unit. Remove rug plate, brush roll and belt Re-install brush roll and belt.
  • Page 56 SECTION 8 -120 V BELT UFTER, ATTACHMENT HOSE AND HEADLIGHT SERVICE 8.3 Headlight Lens And LED Service Attachment Hose Swivel Tube Or Suction Blower Connector Materials Needed: Replacement • EL-164309 - Headlight LED circuit board Static Mat with ground wire. Wrist Strap !NOTE with cable (PIN 166906 ESD Kit) Repair method described in Sections A and...
  • Page 57 SECTION 8 - 120 V HEADLIGHT SERVICE Procedure: 7. Using the release latch on the harness connector, r e move the Board from the 1. Place the Senoia Power Unit on the wire harness. Static Mat. 8. Gently bend one of the snap latches on 2.
  • Page 58 NOTES...
  • Page 59 SECTION 9 - 120 V ILLUSTRATED PARTS LIST AND EXPLODED VIEWS Figure 39 Base Pan Assembly and Cord Set Table 1 Base Pan As embly and Cord Set Figure 40 Motor Assembly Table 2 Motor Assembly Figure 41 Fan Case Assembly Table 3 Fan Ca e Assembly Figure 42...
  • Page 60 AVALIR a�E PAN �..SSEMBLY SC N # � POLYMER BASE � �� Figure 39. Base Pan Assembly and Cord et...
  • Page 61 rnG# AVAI.iIR BASE PAN ASSEMBLY SCN# PARI' MJDEL DFSCRIPI'ION (J.IT. 604314S BASE PAN SUB ASSY AVALIR G3/AV Hom Gasket - Exhaust 5/PK 601996S 100689A 10/PK G3/AV Rivet - Exhaust Hom Gasket G 3 /A V 106397 Exhaust D..lct Black Screw-Pwr 8\,,7/BPI (LI) /Ex.Duct Alum Base 10/PK I.J..
  • Page 62 Il'JG# AVfl.LTR MJIOR ASSEMBLY SCN# SCN# AVALIR. FAN CASE ASSEMBLY IW3# 1 3� 14--_£...
  • Page 63 IW3# AVALIR '.PW CASE ASSEMBLY SCN# 42 1 PART DE9CRIPI'IC N M)])EL (JrY GS/AV 119797S Fan case Assanbl y GS/AV 2/PK 125297A Nozzle 1.ock Lever Assembly 10/PK SOS/AV 1211 Nozzle IDck Screw 10/PK SOS/AV N:>zzle I.ock Spring 121297S 1'fozzle Attacbrrent Shaft 5/PK G3/AV 121689S...
  • Page 64 AW,.J..D.. �IGHT CAP /SLIDE BRACKEI' ASSY. JJAUft SCN# 1041 1043 �16 s--i , - s Figure 42. Headlight Cap/Slide Bracket/Handle Pivot Spring Assembly...
  • Page 65 1043 AVALIR HR?\DLIGHT CAP/SLIDE BRAO<Er ASSY. 1041 SCN# ]J;q(3# PAR!' DFSCRIPI'ICN M:IDEL (JIT 10/PK 505/AV Screw-Hdlt/Rear Axl/Plt-Pvt CStg/RCover 102168A 5/ PK SE/AV Lens - Headlight Cap 108506S SE/AV 11/10 LED Circuit Boa.rd W/Iead Wires 164309 SF./AV LED Circuit Board W/Iead Wires 11/10 164309 SE/AV...
  • Page 66 I:WG# AVN.iffi CXJVER SHELL ASSEMBLY Srn# �5 - - -7 �/ \�// Figure 43. Cover Shell Assembly...
  • Page 67 SCN# AVALIR CDVER SHELL ASSEMBLY PART MJDEL DESCRIPTION SE/AV 135606A Cbver Shell w/Reg. card Less Trim Strips Left Trim Strip-Cover Shell Elegnt black 630914 630814 Right Trim strip-Cover Shell Elgnt Black SCUff Plate - us 1112l4 943114 Scuff Plate - Exp::>rt G3/AV 233405S Tone Screw /Scuff Plate (Btrn...
  • Page 68 SCN# 1213 AVALIR TRANSMISSION !1AG# 1213 � Figure 44. Power Drive Assembl y...
  • Page 69 1213 r:w3# AVALIR TRANSMISSICN 1213 S0\1# PART DESCRIPI'ICN t,ODEL (:JN G3/AV Rear Axle AsS'f w/GearAsy/Clip/Bshg 555211A G3/AV Clip-Mtr. Sprocket Gear/Re.ar Axle 102095 10/PK 601689A 110314 FOOT PEDAL 550505 Prinary Sproc Gear(No Clip)Trans Lt Grey SE/AV 10/PK G3/AV Bushing - Rear Axle 550889S 552312G Power Drive Systan Assy(Transmissian)
  • Page 71 AVALIR FiroR NOZZLE ASSEMBLY [MG# SQiI # PART M:DEL DESCRIPI'ON (lfY N:>ZZLE BCMl?ER 14041.4 ID./AV 141381A Rug Plate latch Rivet 10/PK SF:2/AV Floor Nozzle Assy less B:rush Roll & Belt 1416128 SF,/AV Belt Lifter Assy - Chrone (Ma:in Nozzle) 159206 Belt Lifter Hook 144291 HI/AV...
  • Page 72 SCN# AVALJR HANDLE FDRK ASSEMBLY r:m3# 1--+ � � _ A +- 9 +-11 � A Figure 46. Handle Fork and Grip Assembly...
  • Page 73 r:w3# SCN# AVALIR HANDLE FORK ASSEMBLY PART ':rnG MJDEL DFSCRIP'I'ION HANDLE GRIP 173114 latch Plate Handle Fork G3/AV 672189 173814 CDRD HCOK 10/PK Spring - Cord Hook SWi vel 174167A DBO/AV 175014G HANDLE FORK ASSY AVALIR...
  • Page 74 A\lAL:ffi MINI EMIOR AND R/:\G ASSEMBLY SCN# DivG# 12 w/24 1 O w/2 Figure 47. Cloth Bag and Mini Emtor Assembly...
  • Page 75 AVALIR MINI EMIDR AND FAG ASSEMBLY SCN# r:w:;# PART 1-.U. DESCRIPI'ICN M:>DEL (JIT MINI EM-'IOR - 1 PIEX:E 188814 SF./AV 190309 Snap Fill Tube for 1 Pc Mini Ent.or 25/PK HI. / AV 191182S Fill Tube Tie 190408 G6/AV F Style Top Adaptor/snap 90 D=gree G6/SE BAG ASSY-S'IRAIGHT ZIPPER 190014 191814...
  • Page 76 SCN# 1341 rw3# 1341 AVALIR ATrn.rnMENT • - -16 � OOJ]I� )) � � �mmm o � Figure 48. Attachments...
  • Page 77 1341 AVALIR A'.ITACE I:W:,# SCN# 1341 PART M:IDEL DESCRIPI'ICN (JfY 201314 roRTABLE HANDLE 'JlSY AVAL. 210711 WHEEL - SURFACE NJZZLE 210814S W/C BROSH ASS'£ AVALIR SUCTION BI..OiJE a:NNECIDR 210014 213814 INFI.A'I/DEFIA'IOR AVMJR. 214114 UTILITY TOOL AVALIR 215414 � IDZ 'JlSY - AVALIR 212414 UPHOI.SI'ERY TOOL AVALIR 218190...
  • Page 78 SCN# 1431 � 1431 AVALIR MOLTI-�CE SHAMRX> SYS'TIM Figure 49. Carpet Shampoo Sy tern...
  • Page 79 1431 AVALIR MULTI-�CE SYSTEM 1431 SCN# � SHAMfO'. PARI' DESCRIPI'ION M)D EL 'mNK ASSEMBLY CSS 306714 308914 MSSS 'mNK AVALIR 316214 StIDS SCREEN MSSS-M:>IDED m/AV 307389S Filter Sponge - C.S.S. Tank Assembly 10/PK 303114S MSSS NOZ ASSY W/LABEL AVL 305214 BELT BAFFLE STRIP - CSS 319714 OJVER-WASTE T.RAY CSS...