Pro-Team GoCartVac User manual

GoCartVac™

Service Manual

Table of Contents

Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Full Vacuum Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Remove Charger Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Replace Charger Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

Remove Vacuum Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Replace Vacuum Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Remove Diffuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Replace Diffuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Remove Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Replace Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Remove Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Replace Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Remove/Replace Thermal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Remove Battery Control Module (BCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Replace Battery Control Module (BCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Remove Motor/BCM Assembly From Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Replace Motor/BCM Assembly Into Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21

Remove Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-23

Replace Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Remove/Replace Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Remove Compression Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Reassemble Compression Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Remove/Reassemble Tetraseal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Remove/Reassemble Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Batteries/Harness Safety Notice/Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Battery Termination Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Disassemble/Reassemble GoCart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Remove/Replace Fusible Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Remove/Replace Red Jumper Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Remove/Replace Power Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Replace Batteries/Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Remove/Replace Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Remove Cover of Electrical Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Replace Cover onto Electrical Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Remove/Replace Charger Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Remove Electrical Box & Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Reassemble Electrical Box & Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Remove/Replace Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Remove/Replace Power Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Remove/Replace Swivel Elbow Cuff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Remove Switch in Hose Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Reassemble Switch in Hose Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

www.pro-team.com 800.541.1456

ATTENTION

Before servicing any part

or proceeding with any

repair procedure on any

ProTeam vacuum,

ALWAYS disconnect

the vacuum from

the power source.

2www.pro-team.com 800.541.1456

Battery Safety

WARNING: Risk of electric shock

Read complete instructions prior to installation and operation.

1. Observe all safety regulations. Electrical wiring should be performed in accordance with all applicable national,

state and local codes to prevent damage to equipment and ensure personnel safety.

2. Hazardous voltages exist within enclosure. Installation and service should be performed only by trained

service personnel.

3. WARNING – Risk of explosive gasses. Working in the vicinity of a lead-acid battery is dangerous. Batteries generate

explosive gasses during normal battery operation. During normal charging operation, some hydrogen gas is

released (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.

4. WARNING – Risk of battery terminal shorting. The batteries specified for use in this equipment have very low internal

impedance and thus are capable of delivering high currents if externally short circuited. The resultant heat can cause

severe burns and is a potential fire hazard.

5. Particular caution should be used when replacing batteries. The person working near the open terminals of batteries

should avoid wearing metal rings or watchbands. It is a good practice to remove all metallic items such as watches,

bracelets and personal jewelry when working on or around battery terminals.

6. As a further precaution, when installing batteries or working on them, insulating gloves should be worn and

only insulated tools should be used to prevent accidental short circuits. Handle recharged batteries carefully as

they may be hot.

7. The batteries are interconnected with a Fusible Link for added safety. In the event this link is to be replaced,

only use Pro-Team approved replacement parts. Do not handle plug, batteries or appliance with wet hands.

8. Replacement batteries should be carefully inspected to installation. Particular attention should be given to ensure

that none of the cell cover seals have been broken, no battery case damage is evident and no visible sign of

battery leakage exists. If batteries leak fluid, change color, shape or change in any other way, DO NOT use them.

Battery Recycling - The Environmental Protection Agency requires the recycling of sealed lead batteries. Proper disposal and recycling

of batteries mandatory under the Mercury-Containing Rechargeable Battery Management Act, 42 U.S.C 14301-14336 (“Battery Act”).

The Charge Up to Recycle! Program offers various recycling plans for communities, retailers, businesses and public agencies. For more

information about the Charge Up to Recycle! Program, or for information about a local collection site visit www.rbrc.com or call RBRD’s

toll free number 1-800-8-BATTERY

Full Vacuum Parts

www.pro-team.com 800.541.1456 3

1314

No. Part Name

1 104273 Twist Cap (Black)

2 100431 496 Sq. In. Intercept Micro Filter

3 100564 Micro Cloth Filter

4 106282 Power Cord Replacement, Complete

5 106583 Plastic Diffuser w/Connection Screw

Set (2 screws)

6 100335 Compression Ring w/Connection Screws

100378 Compression Ring Connection Screws

7 100014 Tetraseal

103731 Carbon Brush Set for 36V motor

8 103732 36V Motor w/Crimps, Replacement

103617 Complete 36V Motor Assembly w/Seal,

Compression Ring and Relay

(includes: #6,7,8,9)

9105496 Battery Control Module

10 100368 Motor Mounting System Set

11 103916 Receptacle, 2-Wire w/Crimps

12 104272 Receptacle Screw Set

13 100030 Dome Filter w/Foam Media

14 100343 Foam Filter Media for Dome Filter

101220 High Filtration Disk (Optional)

15 103623 Electrified Hose, 11/4" x 20' Long, 2-Wire

16 102715 Replacement Swivel Elbow Cuff, Black

17 106550 Switch Replacement

18 106284 Kit, Vacuum Attachment Hardware for Cart

19 106219 Kit, Power Receptacle Cord

20 106211 Box, Sound w/Corner Rails

21 106213 Cart Assembly

22 106214 Kit, Mounting Hardware

23 103718 Hose Wrap, Blk

24 106241 Kit, Receptacle for Box Assembly

25 106215 Kit, Box Assembly

26 106277 Harness, Charging w/Connectors

27 106216 Kit, Battery Wiring Harness

28 106280 Lead, Wire, Battery, Fusible Link,

Replacement #8AWG, w/Terminals

29 106279 Lead, Wire, Battery, Red, #8AWG,

w/Terminals

30 106278 Harness, Battery

31 106217 Kit, Receptacle

32 106281 Switch Assembly w/Crimps

33 106218 Kit, Charger, 36V, 18.5A, w/Terminals

34 106276 Battery, Lead Acid, 12V, 37AH

35 106283 Kit, Attachment Hardware for Charger

and Box Assembly

36 103476 Thermal Protector

37 106297 Wheel Set, Rear

38 106298 Wheel Set, Front

101678 50' Extension Cord (Not Shown)

4www.pro-team.com 800.541.1456

Remove Charger Panel

REMOVE CHARGER PANEL

Remove cover of cart by pulling straight up

carefully. ATTENTION: Pull up carefully as cord

is attached to vacuum.

1. Place cover into tray of cart.

Remove side panel closest

to power switch by pushing

in and pulling up at the

same time.

3. Continue pulling up until

panel is removed.

Place aside.

(Continued on page 5)

Remove Charger Panel

www.pro-team.com 800.541.1456 5

REMOVE CHARGER PANEL (Continued from page 4)

Grab each end of the charging harness and work

back and forth as you pull apart.

5a. 5b.

Slide the charger’s black/red connector apart from

the other two.

6a. 6b.

Unplug charger from receptacle.

7. Using grip in panel pull up until panel is clear

from cart.

6www.pro-team.com 800.541.1456

Replace Charger Panel

REPLACE CHARGER PANEL

Connect plug of battery charger into

receptacle.

3. Slide red and black connector of charger

into other two red and black connectors

from batteries and vacuum.

4a.

4b.

Attach the charging harness terminal to the

three connectors of the charger, batteries

and vacuum.

Slide panel into cart by placing side without molding

into empty channel of molding from side panel. Confirm

that the panel is resting on the bottom of the cart and

that the corner molding and panel are even at the top.

(Continued on page 7)

Place corner molding

on one side of charger

panel.

Replace Charger Panel

www.pro-team.com 800.541.1456 7

REPLACE CHARGER PANEL (Continued from page 6)

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.

If on tightly the four flanges are visible above

the cover.

Put cover in place on top of cart. Push until

snaps into place.

8www.pro-team.com 800.541.1456

Remove Vacuum Panel

REMOVE VACUUM PANEL

Slide the remaining two red/black connectors apart

from each other.

2a. 2b.

Disconnect plug from vacuum.

3. Carefully remove vacuum panel

from cart.

1. Remove Charger Panel (Page 4)

Replace Vacuum Panel

www.pro-team.com 800.541.1456 9

REPLACE VACUUM PANEL

Place corner molding on one

side of vacuum panel.

2a.

2b.

Connect the red/black connector of the

vacuum to the red/black connector from

the batteries.

3. Plug cable from cover of cart into vacuum.

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.

5. Replace Charger Panel (Page 6)

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