ProTeam GoCartVac Service Manual
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ProTeam GoCartVac Service Manual

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Summary of Contents for ProTeam GoCartVac

  • Page 1 GoCartVac ® Service Manual...

  • Page 3: Table Of Contents

    Before servicing any part Replace Vacuum Panel ....................9 or proceeding with any repair procedure on any Remove Diffuser ...................... 10 ProTeam vacuum, Replace Diffuser ....................... 11 ALWAYS disconnect Remove Receptacle ....................12 the vacuum from Replace Receptacle ....................13 the power source.

  • Page 4: 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 5: Full Vacuum Parts

    Full Vacuum Parts Part Name 104273 Twist Cap (Black) 100431 496 Sq. In. Intercept Micro Filter 100564 Micro Cloth Filter 106282 Power Cord Replacement, Complete 105044 Motor Shroud/Diffuser w/Screw Set: 2 screws 100335 Compression Ring w/Connection Screws 100378 Compression Ring Connection Screws 100014 Tetraseal 103732...

  • Page 6: Attention Remove Charger Panel

    Remove Charger Panel REMOVE CHARGER PANEL Remove cover of cart by pulling straight up Place cover into tray of cart. carefully. ATTENTION: Pull up carefully as cord is attached to vacuum. Remove side panel closest Continue pulling up until to power switch by push- panel is removed.

  • Page 7: Remove Charger Panel

    Remove Charger Panel REMOVE CHARGER PANEL (Continued from page 4) 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. Using grip in panel pull up until panel is clear Unplug charger from receptacle.

  • Page 8: Replace Charger Panel

    Replace Charger Panel REPLACE CHARGER PANEL Place corner molding Slide panel into cart by placing side without molding on one side of charger into empty channel of molding from side panel. Confirm panel. that the panel is resting on the bottom of the cart and that the corner molding and panel are even at the top.

  • Page 9: Replace Charger Panel

    Replace Charger Panel REPLACE CHARGER PANEL (Continued from page 6) Put cover in place on top of cart. Align hole in cover over top of vacuum. Slide remaining side panel into cart by placing both sides into empty channels of molding. Confirm that the panel is resting on the bottom of the cart and that the corner molding and panel are even at the top.

  • Page 10: Before Servicing Any Part 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 866.888.2168...

  • Page 11: Or Proceeding With Any Replace Vacuum Panel

    Replace Vacuum Panel REPLACE VACUUM PANEL Place corner molding on one side of vacuum panel. Slide panel into cart by placing side without molding into empty channel of molding from side 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.

  • Page 12: Repair Procedure On Any Remove Diffuser

    Remove Diffuser REMOVE DIFFUSER 1. Remove Charger Panel (Page 4) 2. Remove Vacuum Panel (Page 8) Remove vacuum from panel using Phillips Remove cap by twisting Remove both screwdriver to remove two screws and washers. counter-clockwise. cloth and paper filters. Turn vacuum upside down.

  • Page 13: Proteam Vacuum, Replace Diffuser

    Replace Diffuser REPLACE DIFFUSER Replace diffuser by placing the side with ridges Attach diffuser to motor with away from motor. two screws. Turn vacuum right side up Secure lid on vacuum by Lay vacuum flat with mounting and place cloth and paper turning clockwise.

  • Page 14: Remove Receptacle

    Remove Vacuum Receptacle REMOVE VACUUM RECEPTACLE 1. Remove Charger Panel (Page 4) 2. Remove Vacuum Panel (Page 8) 3. Remove Diffuser (Page 10) Inside vacuum locate and remove top horizontal connector on battery control module (BCM) (white wire from receptacle) with needlenose pliers. Locate black wire with white connector from receptacle Remove two screws holding receptacle to vacuum on BCM and remove with needlenose pliers.

  • Page 15: Replace Receptacle

    Replace Receptacle REPLACE RECEPTACLE Thread wires of new or existing Push receptacle until flush against body of vacu- receptacle through hole in vacuum body. Attach receptacle to vacuum body with two screws Connect the black receptacle wire to the vertical using a Phillips screwdriver.

  • Page 16: Remove Power Cable

    Remove Power Cable REMOVE POWER CABLE 1. Remove Charger Panel (Page 4) 2. Remove Vacuum Panel (Page 8) 3. Remove Diffuser (Page 10) Locate white wire from receptacle Locate white wire from power Locate black wire of power cable and remove from BCM. cable and remove from BCM.

  • Page 17: Replace Power Cable

    Replace Power Cable REPLACE POWER CABLE Thread wires of new or existing cable through hole Thread wires through inner nut and tighten nut. in vacuum body. Screw strain relief up to washer and outer nut. Attach the white wire from power cord to the Tighten all with crescent wrench.

  • Page 18: 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 Disconnect the other end of the thermal swich from BCM. from motor wire. REPLACE THERMAL SWITCH Connect male connector of new or existing Connect female connector of thermal switch to...

  • Page 19: Remove Battery Control Module (Bcm)

    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. Remove screw holding BCM to compression ring with either a flathead screwdriver or 5/16 socket. Remove BCM.

  • Page 20: Replace Battery Control Module (Bcm)

    Replace Battery Control Module (BCM) REPLACE BCM Screw new or existing BCM to motor Connect black wire of Connect female connector of compression ring with either a flat- power cable to “-36” on thermal switch to “MOTOR” head screwdriver or 5/16 socket. PC board.

  • Page 21: Remove Motor/Bcm Assembly From Vacuum

    Remove Motor/BCM Assembly from Vacuum REMOVE MOTOR/BCM ASSEMBLY FROM VACUUM 1. Remove Charger Panel (Page 4) 3. Remove Diffuser (Page 10) 5. Remove Power Cable (Page 14) 2. Remove Vacuum Panel (Page 8) 4. Remove Receptacle (Page 12) Use flathead screwdriver to remove 3 washer Use Phillips screwdriver to remove screw and cover caps.

  • Page 22: Replace Motor/Bcm Assembly Into Vacuum

    Replace Motor/BCM Assembly into Vacuum REPLACE MOTOR/BCM ASSEMBLY INTO VACUUM TIP: Recommend using new well nuts each time. Old well nuts warp over time. Press dome filter onto bottom of motor. Place motor into vacuum body. Align motor as shown in picture (BCM Press well nuts into holes in vacuum body.
  • Page 23 Replace Motor/BCM Assembly into Vacuum REPLACE MOTOR/BCM ASSEMBLY INTO VACUUM (Continued from page 20) Replace Z-washers and screws. Tighten screw on Z-washer until well nut has tightened against vacuum wall. Press washer cover/cap over washer. Replace power cable. Follow Steps 1 through 6 on Page 15.

  • Page 24: 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. Use end of flathead screwdriver, gently wedge between center of motor brush and clip.
  • Page 25 Remove Motor Brushes REMOVE MOTOR BRUSHES (Continued from page 22) Remove two screws and bracket over the motor brushes. TIP: New carbon brushes give off small sparks briefly once motor is engaged while brushes finish aligning. This is normal. Remove motor brush. Remove 2nd motor brush in same way.

  • Page 26: Replace Motor Brushes

    Replace Motor Brushes REPLACE MOTOR BRUSHES Obtain new motor brushes and slide into place with wire clip/tab going under the top insulation. Replace brush brackets with screws. With end of flathead screwdriver, push wire clip back into place. If all changes are complete: 5.

  • Page 27: Remove/Replace Motor Assembly

    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) Remove thermal switch connector Remove thermal switch from BCM. from motor wire. REPLACE MOTOR ASSEMBLY Connect one of the thermal switch wires to new Connect thermal switch’s other wire to...

  • Page 28: 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 thermal switch Remove PC Board. connector from BCM.

  • Page 29: Reassemble Compression Ring

    Reassemble Compression Ring REASSEMBLE COMPRESSION RING Place new or existing compression ring Replace three of the screws which attach the ring to the over top of motor such that cut outs in motor. Leave out a screw which is not under a wire clamp ring are aligned with motor brushes.

  • Page 30: Remove/Reassemble Tetraseal

    Remove/Reassemble Tetraseal REMOVE TETRASEAL 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 compression ring per Steps 5 Remove tetraseal by pulling up and through 9 on Page 27. over the top of motor.

  • Page 31: Remove/Reassemble Motor

    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. Remove compression ring and tetraseal per Steps 5 and 6 on Page 28. REASSEMBLE MOTOR Replace compression ring, tetraseal Reconnect thermal switch to motor wire.

  • Page 32: 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 33: 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 866.888.2168...

  • Page 34: Disassemble/Reassemble Gocart

    Disassemble/Reassemble GoCart DISASSEMBLE GOCART 1. Remove Charger Panel (Page 4) 2. Remove Vacuum Panel (Page 8) Remove remaining side panel and molding. REASSEMBLE GOCART 1. Replace Vacuum Panel (Page 9) 2. Replace Charger Panel (Page 6) 3. Replace Side Panel into Cart www.pro-team.com 866.888.2168...

  • Page 35: Remove/Replace Fusible Link

    Remove/Replace Fusible Link REMOVE FUSIBLE LINK – Please Read Safety Precautions on Page 2 1. Disassemble GoCart (Page 32) Remove fusible link from batteries using insulated wrenches. See Safety Notice and Personal Safety Precautions on Page 30. REPLACE FUSIBLE LINK On positive terminal of battery B1, and On negative terminal of battery B2, using the red terminal end of the fus-...

  • Page 36: Remove/Replace Red Jumper Wire

    Remove/Replace Red Jumper Wire REMOVE RED JUMPER WIRE 1. Disassemble GoCart (Page 32) Remove red jumper wire from batteries using insulated wrenches. See Safety Notice and Personal Safety Precautions on Page 30. REPLACE RED JUMPER WIRE On negative terminal of battery B1, On positive terminal of battery B3, and using the black terminal end of and using the red terminal end of...

  • Page 37: Remove/Replace Power Harness

    Remove/Replace Power Harness REMOVE POWER HARNESS 1. Disassemble GoCart (Page 32) Remove power harness wire from batteries using insulated wrenches. See Safety Notice and Personal Safety Precautions on Page 30. REPLACE POWER HARNESS On negative terminal of battery B2, On positive terminal of battery B2 and and using the black terminal end of using the red terminal end of the power the power harness follow...

  • Page 38: Replace Batteries/Harness

    Replace Batteries/Harness REPLACE BATTERIES 1. Disassemble GoCart (Page 32) Remove all wire harnesses from the Place new batteries in cart as shown. batteries using insulated wrenches. To replace all harnesses follow See Safety Notice and Personal directions on Page 35. Safety Precautions on Page 30.

  • Page 39: Remove/Replace Charger

    Remove/Replace Charger REMOVE CHARGER 1. Remove Charger Panel (Page 4) Remove the screws, nuts and washers from existing charger. REPLACE CHARGER Place new Charger in cut- Position so that the fan vents are toward out location on panel. the handle of the panel. Push screws through holes in panel and charger.

  • Page 40: Remove Cover Of Electrical Enclosure

    Remove Cover of Electrical Enclosure REMOVE COVER OF ELECTRICAL ENCLOSURE 1. Remove Charger Panel (Page 4) Remove the 4 screws holding the cover Pull open the cover to expose wires of the electrical enclosure. and components. Remove the black, red and green wires from the receptacle terminals.

  • Page 41: Replace Cover Onto Electrical Enclosure

    Replace Cover of Electrical Enclosure REPLACE COVER ONTO ELECTRICAL ENCLOSURE Push crimped end of green, black and Using the four screws secure red wire from switch onto terminals cover to enclosure. of receptacle. www.pro-team.com 866.888.2168...

  • Page 42: Remove/Replace Charger Receptacle

    Remove/Replace Charger Receptacle REMOVE CHARGER RECEPTACLE 1. Remove Charger Panel (Page 4) 2. Remove Cover of Electrical Enclosure (Page 38) Squeeze together the sides of Push through hole while continuing the receptacle. to squeeze sides. REPLACE CHARGER RECEPTACLE Push new receptacle through the cover of the enclosure.

  • Page 43: Remove Electrical Box & Connections

    Remove Electrical Box and Connections REMOVE ELECTRICAL BOX & CONNECTIONS 1. Remove Charger Panel (Page 4) 2. Remove Cover of Electrical Enclosure (Page 38) Remove 4 screws, nuts and washers holding electrical enclosure to panel with Phillips screwdriver and 3/8” end wrench.

  • Page 44: Reassemble Electrical Box & Connections

    REASSEMBLE ELECTRICAL BOX AND CONNECTIONS Using Phillips screwdriver put bare Using Phillips screwdriver put bare end of end of red wire from switch into black wire from switch into gold terminal silver terminal of receptacle. of receptacle. Place enclosure over switch and Place four screws through panel into receptacle.

  • Page 45: Remove/Replace Power Switch

    REMOVE POWER SWITCH 1. Remove Charger Panel (Page 4) 2. Remove Cover of Electrical Enclosure (Page 38) 3. Remove Electrical Box and Connections (Page 41) Squeeze together sides of switch. While continuing to squeeze, pull switch from hole in panel. REPLACE POWER SWITCH Push new switch assembly through cut-out in the...

  • Page 46: Remove/Replace Power Receptacle

    Remove/Replace Power Receptacle REMOVE POWER RECEPTACLE 1. Remove Charger Panel (Page 4) 2. Remove Cover of Electrical Enclosure (Page 38) Using Phillips screwdriver remove green Remove 2 screws holding receptacle to ground wire from receptacle. panel and remove receptacle. REPLACE POWER RECEPTACLE Place flanged receptacle Using Phillips screwdriver put in the side panel cut-out,...

  • Page 47: Remove/Replace Swivel Elbow Cuff

    Remove/Replace Swivel Elbow Cuff REMOVE SWIVEL ELBOW CUFF Place one hand on hose (close to cord strain relief) and one on the elbow cuff. Bend down until the cuff is loose from the hose. 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.

  • Page 48: Remove Switch In Hose Handle

    Remove Switch in Hose Handle REMOVE SWITCH Remove the 8 screws which hold the handle together. Remove top cover. Lift up and remove angled tube. COPPER CONTACTS. Use pencil eraser to clean away any build up. Lift out and remove switch and BCM. www.pro-team.com 866.888.2168...

  • Page 49: Reassemble Switch In Hose Handle

    Reassemble Switch in Hose Handle REASSEMBLE SWITCH Place new switch/BCM in handle. Place switch with the ON position ( I ) facing the stub tube. Place BCM such that wires are closest Ensure stub tube is inserted into angle tube. to the switch and not against handle Place angled tube into handle.

  • Page 50: Stub Tube Replacement

    Stub Tube Replacement Tools needed: Phillips Head Screw Driver (not included in kit). Remove eight Phillips screws Remove stub tube from top Remove stub tube from plastic from hose handle then half of hose handle. adapter by pressing button and remove top half of housing.

  • Page 51: Electrical Diagram

    Electrical Diagram www.pro-team.com 800.541.1456...
  • Page 52 P.O. Box 7385, Boise, Idaho 83707 • 866.888.2168 www.pro-team.com #106591 Revised 6/12...

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