Service Manual for X9.5 and Older Models

Service Manual for X9.5 and Older Models

I. Common Issues... 2 A. Direct Air Motor... 2 A.1. Direct Air Motor will not run.... 2 A.2. Direct Air Motor is making a squealing sound.... 2 B. Full Bag Indicator (FBI)... 3 B.1. Full bag light will not come ON.... 3 B.2. Bag is full but the FBI did not come ON.... 3 B.3. Bag is not full and the FBI light is on.... 3 C. General Issues:... 4 C.1 Why does the dust cover gap open when the lower motor is turned ON?... 4 C.2. The vacuum does NOT run but the lights in the handle switches are on.... 4 C.3. Identifying Models by PCB Layout or Belt Idler Assembly... 5 II. Maintenance Procedures... 6 A. Disassembly Instructions... 6 B. Removing the Brush Strips... 8 C. Replacing the Belt... 9 D. Replacing the LED Light Board... 10 E. Replacing the Spring Assist Assembly... 10 F. Replacing the Main PC Board...11 G. Replacing the Clean Air Motor... 12 H. Installing the Motor Cover... 13 I. Removing and Replacing the Direct Air Motor... 14 J. Replacing the Direct Air Motor Fan... 16 K. Replacing the Rear Wheels... 18 L. Replacing the Tilt Lock Pedal Spring... 18 III. General Troubleshooting... 19 A. Vacuum has no power.... 19 B. Direct Air Motor Will Not Run... 21 B.1. Direct Air Motor Will Not Run: No Headlights... 21 B.2. Direct Air Motor Will Not Run: Headlights are on... 22 C. Nozzle Suction Power is Weak... 24 C.1. There is no suction at the hose... 24 C.2. There is no suction at the nozzle... 24 D. Excessive Vibration... 25 E. Agitator/brushroll Does Not Rotate... 25 F. Agitator/brushroll Jam Test... 26 IV. Trouble Shooting -.4 and Older Models Only... 27 A. Full Bag Indicator (FBI) Comes On Too Soon or Not At All... 27 B. Agitator/brushroll Jam Light Comes On Too Soon or Not At All... 28 V. Trouble Shooting -.5 and.6 Models Only... 29 A. Direct Air Motor Starts But Shuts Off in 2 or 3 Seconds... 29 B. The Full Bag Indicator will flash On when the vacuum is shut Off.. 29 Table of Contents VI. Figures A. Correct Handle Installation... 4 B. PCB Layout and Belt Idler Assembly... 5 C. Location of Nozzle Cover Screws... 6 D. Agitator/Brushroll Assembly... 8 E. Belt Placement... 9 F. Clean Air Motor Wiring... 12 G. Ametek Clean Air Motor Wiring... 12 H. Clean Air Motor Placement... 12 I. Handle to Body Harness Connector... 19 J. Location of Winged Rocker Switch... 22 K. Location of Micro Switch... 22 L. Proper Position for Tools Activation Dial/Rotational Valve Handle... 23 M. Agitator/brushroll Jam Screw - FBI Screw Position... 27 N. Handle Assembly... 30 O. Body Assembly... 31 P. Nozzle Assembly... 32 Q. Handle Wiring... 33 R. Main Body Wire Harness.5 and.6 Models... 34 S. Main Body Wire Harness.4 and Older Models... 35 T. Description of Vacuum... 36

IMPORTANT SAFETY INSTRUCTIONS When using or servicing any electrical appliance, basic precautions should always be followed, including the following: WARNING: To reduce the risk of fire, electrical shock, or injury: 1. Do not leave vacuum unattended when plugged in. Unplug from outlet when not in use. 2. Turn off all controls before unplugging. 3. Do not attempt to service vacuum while plugged in. 4. Before handling PC board, discharge static electricity by using anti-static mat and ground strap. If anti-static mat is not available, touch a metal object that is grounded and only handle PC board by outside edges. WARNING: ELECTRIC SHOCK COULD OCCUR IF USED OUTDOORS OR ON WET SURFACES.

A. Direct Air Motor A.1. Direct Air Motor will not run. Check the following: I. Common Issues 1. The main switch must be ON and the floor/carpet switch must be in the carpet position. 2. The tools activation dial/rotational valve handle must be in the tools OFF position. 3. The vacuum must be out of the upright position (controlled by the wing rocker switch) unless the nozzle cover is off. 4. The clean air motor must have 12 to 18 volts going to the PC board via the blue/yellow tap wire. 5. The headlights should be on. This assures that the fuses on the PC board are working and there is power in the tap wire. (See Figure B. PCB Layout and Belt Idler Assembly) NOTE: All the above conditions must be met on.4 and older models..5 and newer models must also have the belt installed belt for the hall sensor to work, other wise the direct air motor will come on for 2 to 3 seconds then shut OFF. A.2. Direct Air Motor is making a squealing sound. Check for the following conditions: 1. The motor has been changed and the seals are out of place or the motor is not seated properly. 2. The bearings are damaged. 3. Hair or thread is wrapped around the motor shaft and the bearing under fan. 071807 2 I. Common Issues

B. Full Bag Indicator (FBI) B.1. Full bag light will not come ON. The full bag indicator is controlled by temperature. As the bag fills, the air flow is restricted causing the motor to work harder building up heat in the motor compartment. At a set point, this heat build up causes the FBI to illuminate. It may take up to 2 minutes for the FBI light to illuminate. If the airflow is not completely blocked off, the temperature may not reach the point needed to turn on the FBI light. Additionally, if the bag has been filled with fluffy type material such as carpet fiber, the air flow may not be restricted enough to cause the motor to build up heat. To test the FBI system: 1. The air flow must be completely blocked off. 2. Place the tool activation dial/rotational valve handle to the tools ON position. 3. Blocking off the hose the FBI light should illuminate with in 2 minutes. B.2. Bag is full but the FBI did not come ON. Check the bag for content. If the bag is full of carpet fiber or other fluffy material the air flow may not be restricted enough to cause the motor to heat up and the light to illuminate. B.3. Bag is not full and the FBI light is on. The FBI light will illuminate if the pores of the HEPA bag become clogged with a fine powder type substance, such as drywall dust. This is the most common reason for the light to illuminate. 071807 3 I. Common Issues

C. General Issues: C.1 Why does the dust cover gap open when the lower motor is turned ON? The direct air motor pulls more air into the dust compartment than the clean air motor can push out. This could be caused by the following: 1. The nozzle is not sitting on the floor; therefore the airflow is not restricted and will push the cover open. 2. The HEPA filter may be clogged, causing back pressure. 3. The bag inlet seal may be torn allowing air to bypass the HEPA bag, increasing the airflow so the clean air motor cannot relieve all the pressure. C.2. The vacuum does NOT run but the lights in the handle switches are on. The lights in the handle main power switch will come on any time the power cord is plugged into an outlet and the main power switch is turned ON. The light in the carpet/floor switch will be on any time there is power to the handle and both the main power switch and the carpet/floor switch are turned ON. 1. If the lights are on in the handle switch and vacuum won t run, check the thermal reset switch. 2. If the vacuum still won t run, make sure the handle is installed correctly. (See Figure A. Correct Handle Installation) 3. If the vacuum still won t run see section III. General Troubleshooting, A. Vacuum Has No Power Figure A. Correct Handle Installation Remove handle screw before installing handle Correctly Installed Handle Incorrectly Installed Handle 071807 4 I. Common Issues

C. General Issues - continued C.3. Identifying Models by PCB Layout or Belt Idler Assembly Figure B. PCB Layout and Belt Idler Assembly.5 and.6.4 and older PC Board Brush Roll AFI PC Board Fuse Belt Idler Assembly Belt Idler Assembly NOTE: The PC Boards in the.5 and.6 do not have adjustment pods because they have a hall sensor on the belt idler assembly. 071807 5 I. Common Issues

II. Maintenance Procedures A. Disassembly Instructions A. Step 1. Figure C. Location of Nozzle Cover Screws 1. Remove the handle and dust cover. 2. Place the vacuum face down on the bench. 3. Remove the base plate by removing the 2 (two) screws. 4. Remove the agitator/brushroll. 5. Remove the 5 (five) mounting screws on the underside of the nozzle base tray. (See Figure C. Location of Nozzle Cover Screws) A. Step 2. Removing the Back Path and Cover 1. Remove 1 (one) screw in the tools activation dial/rotational valve handle and 8 (eight) screws on the back path and hose. 2. Remove tools activation dial/rotational valve handle and back path cover. 3. Remove 1 (one) screw from the micro switch and then the remaining 13 (thirteen) screws in the back cover. 4. Remove the back cover allowing the micro switch to slide through the slot in cover. 5. Remove the tool clips. A. Step 3. NOTE: Skip to A. Step 4. if wiring harness is NOT being changed. 1. If wire inlet seal (foam seal where the wire goes through the dust compartment) is installed, remove it at this time. 2. Remove the wire harness connector from the dust compartment and the micro switch from the wiring harness. A. Step 4. Turn the vacuum over, depress handle release, and lay flat. Remove the nozzle cover. A. Step 5. WARNING - If the vacuum is not in the upright position before continuing with the next step, injury may occur or vacuum may be damaged. 1. Set the vacuum in the upright position and remove the 2 (two) screws from the spring assist bar. 2. Lay the vacuum flat. Remove the 3 (three) screws from the direct air motor inlet duct cover, and 1 (one) screw from each of the wire strain relief (2 each). 3. Remove the belt. 4. Remove 3 (three) screws from the idler cover and spring. 5. Disconnect the light lead connector from the light board (disconnect the ground wire if necessary). 6. Remove the 2 (two) screws from each of the pivot brackets. A. Step 6. 1. Lift the dust compartment up out of the nozzle base tray assembly. 2. Remove the pivot bushings and the direct air motor inlet seal from the dust compartment. A. Step 7. 1. Remove the 4 (four) screws holding the motor cover on the dust compartment. 2. Lift up on the motor cover and set it aside. -continue on next page 2 1 3 4 5 071807 5 II. Maintenance Procedures

A. Disassembly Instructions - Continued A. Step 8. 1..4 models and older - Remove the direct air motor by lifting up and rotating, and then disconnect the leads. 2..5 models and newer - Remove screw holding direct air motor in place and lift up. A. Step 9. Remove the clean air motor motor and disconnect the leads. A. Step 10. NOTE: Complete A. Step 10 and A. Step 11 only if wiring harness is being changed. 1. Remove the screw from the PC board. 2. Disconnect the wiring harness and remove the PC board. 3. Remove the screw in the metal plate and the metal plate from the dust compartment. A. Step 11. 1. Remove the 2 (two) screws that hold the thermal reset switch in place. 2. Remove the winged rocker switch from dust compartment and disconnect the leads. 3. Slide the wire harness through the hole in the back of the dust compartment 4. Raise the corner of the main body seal and remove the wiring harness. 071807 II. Maintenance Procedures

B. Removing the Brush Strips B. Step 1. 1. Remove the base plate by removing the 2 (two) screws. 2. Remove the agitator/brushroll. 3. If the belt un-loops itself from the motor shaft, the nozzle cover may need to be removed by removing the 5 (five) mounting screws on the underside of the nozzle base tray. (See Figure C. Location of Nozzle Cover Screws.) B. Step 2. Remove the rubber end cap covers. Figure D. Agitator/Brushroll Assembly B. Step 3. Remove the nuts on each end of the agitator/brushroll with a 7/16 socket driver. Figure D. Agitator/Brushroll Assembly B. Step 4. Slide off the end caps. Figure D. Agitator/Brushroll Assembly B. Step 5. Pry off the belt pulley with a standard screwdriver. Figure D. Agitator/Brushroll Assembly B. Step 6. Slide off the brush strips and replace. Figure D. Agitator/Brushroll Assembly B. Step 7. Line up the belt pulley and push on. B. Step 8. Reinstall the steel end caps and nuts and tighten with a socket. B. Step 9. Reinstall the rubber end cap covers. Figure D. Agitator/Brushroll Assembly 5 5 1 3 4 3 1 2 5 2 1 Agitator/brushroll End Cap Cover 2 1/4-28 Locking Hex Nut 3 Agitator/brushroll Steel End Cap 4 Agitator/brushroll Pully 5 Brush Strips 071807 II. Maintenance Procedures

C. Replacing the Belt C. Step 1. 1. Remove the base plate by removing the 2 (two) screws. 2. Remove the agitator/brushroll. 3. Remove the 5 (five) mounting screws on the underside of the nozzle base tray. (See Figure C. Location of Nozzle Cover Screws) C. Step 2. Discard the broken belt. C. Step 3. Note the layout of the idler assembly and the motor drive pulley. (See Figure E. Belt Placement) Loop the new belt over the motor drive pulley then continue directing the belt under the idler pulley. Insert the belt into the nozzle base tray. C. Step 4. Turn the vacuum over and pull the belt into the nozzle base tray. Loop belt around the agitator/brushroll making sure the ribs of the belt line up with the ribs on the agitator/brushroll. NOTE: Ensure the felt seals are installed in the nozzle base tray. C. Step 5. Insert the agitator/brushroll into the nozzle base tray making sure the rubber end cap covers fit precisely into the ribbed mounts on the nozzle base tray. Rotate the agitator/brushroll a few times to ensure the belt is mounted correctly. C. Step 6. Reinstall the base plate and the nozzle cover. NOTE: If the agitator/brushroll runs backwards, check the belt to ensure it is not twisted. Figure E. Belt Placement 071807 II. Maintenance Procedures

D. Replacing the LED Light Board D. Step 1. Remove the 5 (five) mounting screws on the underside of the nozzle base tray. (See Figure C. Location of Nozzle Cover Screws) D. Step 2. Remove the 3 (three) screws holding the light board onto the nozzle base tray - the middle screw may have the ground wire attached. D. Step 3. Disconnect the wire connector and replace the light board. D. Step 4. Install the 3 (three) screws into LED light board attaching it to the nozzle base tray. NOTE: If the ground wires are on the wiring harness or the LED light board, place the ground wires under middle screw. D. Step 5. Attach the wiring harness connector to the LED light board connector. D. Step 6. Reinstall the nozzle cover. E. Replacing the Spring Assist Assembly WARNING - If the vacuum is not in upright position injury may occur or vacuum may be damaged. - Always wear safety glasses during repair. E. Step 1. Remove the 5 (five) mounting screws on the underside of the nozzle base tray. (See Figure C. Location of Nozzle Cover Screws) E. Step 2. With the vacuum locked in the upright position, remove the 2 (two) screws from the bracket holding the spring. E. Step 3. Ensure that the spring has been disconnected. Lay the vacuum flat to remove the spring mount by pressing the ramped black tab of the spring mount with a flat screwdriver while pulling the spring out-ward. E. Step 4. Remove the bracket and mount from the old spring and attach to the new spring. E. Step 5. Push the spring mount into the motor cover until the mount snaps into place. E. Step 6. Lock the vacuum in the upright position. E. Step 7. Insert the two screws in to the spring bracket. E. Step 8. Reinstall the nozzle cover. 071807 9 II. Maintenance Procedures

F. Replacing the Main PC Board Note: Static electricity is a potential problem and could damage the PC board if a charge is transferred from yourself to the board during handling and installation. Keep the board in the anti-static packaging until ready to install. It is best to use anti-static protection such as a grounding wrist strap. Avoid performing this assembly on carpet or other areas which are prone to static charge buildup. Refer to Figure B. PCB Layout and Belt Idler Assembly, page 3. F. Step 1. 1. Remove the handle and the dust cover. 2. Place the vacuum face down on the bench. 3. Remove the base plate by removing the 2 (two) screws. 4. Remove the agitator/brushroll. 5. Remove the 5 (five) mounting screws on the underside of the nozzle base tray. (See Figure C. Location of Nozzle Cover Screws) F. Step 2. Turn the vacuum over, depress handle release, and lay flat. Remove the nozzle cover. F. Step 3. WARNING - If the vacuum is not in the upright position before continuing with the next step, injury may occur or vacuum may be damaged. 1. Set the vacuum in the upright position and remove the 2 (two) screws from the spring assist bar. 2. Lay the vacuum flat. Remove the 3 (three) screws from the direct air motor inlet duct cover, and 1 (one) screw from each of the wire strain relief (2 each) 3. Remove the belt. 4. Remove the 3 (three) screws from the idler cover and spring. 5. Disconnect the light lead connector from the light board (disconnect the ground wire if necessary). 6. Remove the 2 (two) screws from each of the pivot brackets. F. Step 4. 1. Lift the dust compartment up out of the nozzle base tray assembly. 2. Remove the pivot bushings and the direct air motor inlet seal from the dust compartment. F. Step 5. 1. Remove the 4 (four) screws holding the motor cover on the dust compartment. 2. Lift up on the motor cover and set it aside. F. Step 6. Remove the screw connecting the PC board to the dust compartment. F. Step 7. Disconnect the wire harness connector and slide the PC board from the dust compartment. F. Step 8. Slide the board into the side channels and push board into place, then connect the wire harness to the new board. F. Step 9. Re-insert the single screw to secure the board and reattach the wire harness connector. F. Step 10. Re-assemble the vacuum by continuing to section II. Maintenance Procedures, H. Installing the Motor Cover. 071807 10 II. Maintenance Procedures

G. Replacing the Clean Air Motor G. Step 1. Figure F. Clean Air Motor Wiring G. Step 2. 1. Remove the handle and the dust cover. 2. Place the vacuum face down on the bench. 3. Remove the base plate by removing the 2 (two) screws. 4. Remove the agitator/brushroll. 5. Remove the 5 (five) mounting screws on the underside of the nozzle base tray. (See Figure C. Location of Nozzle Cover Screws) Turn the vacuum over, depress handle release, and lay flat. Remove the nozzle cover. Blue Wire Black/White Wire White Wire G. Step 3. Figure G. Ametek Clean Air Motor Wiring WARNING - If the vacuum is not in the upright position before continuing with the next step, injury may occur or vacuum may be damaged. 1. Set the vacuum in the upright position and remove the 2 (two) screws from the spring assist bar. 2. Lay the vacuum flat. Remove the 3 (three) screws from the direct air motor inlet duct cover, and 1 (one) screw from each of the wire strain relief (2 each). 3. Remove the belt. 4. Remove 3 (three) screws from the idler cover and spring. Yellow Wire White Wire 5. Disconnect the light lead connector from the light board (disconnect the ground wire if necessary). 6. Remove the 2 (two) screws from each of the nozzle base tray pivot brackets. Black Wire G. Step 4. Figure H. Clean Air Motor Placement G. Step 5. 1. Lift the dust compartment up out of the nozzle base tray assembly. 2. Remove the pivot bushings and the direct air motor inlet seal from the dust compartment. 1. Remove the 4 (four) screws holding the motor cover on the dust compartment. 2. Lift up on the motor cover and set it aside. Side of clean air motor should line up here in dust compartment G. Step 6. G. Step 7. G. Step 8. G. Step 9. To remove the clean air motor, grasp and lift it (located in the upper motor compartment) from the mount. Note the orientation of the motor mount on the bracket end of the motor. The motor must be installed in the same manner with the flat edge of the rubber mount against the flat walled structure on the dust compartment. Attach the wires to the new motor as shown in Figure F. Clean Air Motor Wiring or Figure G. Ametek Clean Air Motor Wiring. In the old style motor (Figure F. Clean Air Motor Wiring), notice that the blue wire should again be attached to the base of the white wire connection with a zip tie. Insert the motor into the motor compartment. (See Figure H. Clean Air Motor Placement) G. Step 10. Re-assemble the vacuum by continuing to section II. Maintenance Procedures, H. Installing the Motor Cover. 071807 11 II. Maintenance Procedures

H. Installing the Motor Cover Note the proper location of the two cables passing from the clean air motor compartment to the direct air motor compartment. They should be stored in the channel of the rib wall before the motor cover is reinstalled. If not, the rib wall could pinch and damage the cables. The cables may also prevent the motor cover from seating properly into place. Make sure all gaskets are also seated properly. H. Step 1. Set the motor cover into place and secure with 4 (four) screws. H. Step 2. Attach the 2 (two) inner pivot brackets. Note that each bracket locks into place to be properly seated. H. Step 3. Attach the inlet seal to the inlet of the direct air motor. H. Step 4. Attach the two outer pivot brackets. H. Step 5. Slide the outer pivot brackets into the channels of the base compartment. H. Step 6. Secure each outer pivot bracket with 2 (two) screws on each bracket. H. Step 7. Attach the inlet duct cover with 3 (three) screws. H. Step 8. H. Step 9. Note the layout of the idler assembly and the motor drive pulley. (See Figure E. Belt Placement) Loop the new belt over the motor drive pulley then continue directing the belt under the idler pulley. Insert the belt into the nozzle base tray. Turn the vacuum over and pull the belt into the nozzle base tray. Loop the belt around the agitator/brushroll making sure the ribs of the belt line up with the ribs on the agitator/brushroll. NOTE: Ensure the felt seals are installed in the nozzle base tray. H. Step 10. Insert the agitator/brushroll into the nozzle base tray making sure the rubber end cap covers fit precisely into the ribbed mounts on the nozzle base tray. Rotate the agitator/brushroll a few times to ensure the belt is mounted correctly. H. Step 11. Reinstall the spring assist: 1. Push the spring mount into the motor cover until the mount snaps into place. 2. Lock the vacuum in the upright position. 3. Insert the two screws in to the spring bracket. H. Step 12. Reinstall the base plate and the nozzle cover. H. Step 13. Reinstall the dust cover. 071807 12 II. Maintenance Procedures

I. Removing and Replacing the Direct Air Motor I. Step 1. 1. Remove the handle and the dust cover. 2. Place the vacuum face down on the bench. 3. Remove the base plate by removing the 2 (two) screws. 4. Remove the agitator/brushroll. 5. Remove the 5 (five) mounting screws on the underside of the nozzle base tray. (See Figure C. Location of Nozzle Cover Screws) I. Step 2. Removing the Back Path and Cover 1. Remove 1 (one) screw in the tools activation dial/rotational valve handle and 8 (eight) screws on the back path and hose. I. Step 3. I. Step 4. I. Step 5. I. Step 6. I. Step 7. I. Step 8. 2. Remove the tools activation dial/rotational valve handle and the back path cover. 3. Remove 1 (one) screw from the micro switch and then the remaining 13 (thirteen) screws in the back cover. 4. Remove the back cover allowing the micro switch to slide through the slot in cover. 5. Remove the tool clips. NOTE: If wiring harness does not need to be changed, Skip to I. Step 6. 1. If wire inlet seal (foam seal where the wire goes through the dust compartment) is installed, remove it at this time. 2. Remove the wire harness connector from the dust compartment and the micro switch from the wiring harness. Turn the vacuum over, depress the handle release, and lay the vacuum flat. Remove the nozzle cover. WARNING - If the vacuum is not in the upright position before continuing with the next step, injury may occur or vacuum may be damaged. 1. Set the vacuum in the upright position and remove the 2 (two) screws from the spring assist bar. 2. Lay the vacuum flat. Remove the 3 (three) screws from the direct air motor inlet duct cover, and 1 (one) screw from each of the wire strain relief (2 each) 3. Remove the belt. 4. Remove 3 (three) screws from the idler cover and spring. 5. Disconnect the light lead connector from the light board (disconnect the ground wire if necessary). 6. Remove the 2 (two) screws from each of the pivot brackets. 1. Lift the dust compartment up out of the nozzle base tray assembly. 2. Remove the pivot bushings and the direct air motor inlet seal from the dust compartment. 1. Remove the 4 (four) screws holding the motor cover on the dust compartment. 2. Lift up on the motor cover and set it aside. 1..4 models and older - Remove the direct air motor by lifting up and rotating, and then disconnect the leads. 2..5 models and newer - Remove the screw holding the direct air motor in place and lift up. - continue on next page 071807 13 II. Maintenance Procedures

I. Removing and Replacing the Direct Air Motor - Continued I. Step 9. The direct air motor is located in the lower motor compartment (nearest the nozzle). To remove the direct air motor place a hand on each side of motor and lift up and rotate the motor toward the dust compartment. I. Step 10. Disconnect the white and black motor leads. I. Step 11. To install the motor: 1. Ensure the rubber seal is installed on the dust compartment. 2. Ensure the motor seal by the shaft is in good condition. 3. Place the black wire under the motor and connect it. Connect the white wire, (hold the black wire as you place the motor into the motor compartment to keep from pinching the wire). 4. Place the motor into the motor compartment, (do not push all the way down) shaft side first then fan side, keeping the motor level as it goes in. 5. Check the back of the vacuum to ensure the scroll housing is not catching on the rubber seal. 6. Rotate the motor as you push it down into the dust compartment. Once in place the metal motor support should rest in between the bracket. 7. Raise up the shaft end of the motor, install the wire guide, and push the motor down into place. Note the proper location of the two cables passing from the clean air motor compartment to the direct air motor compartment. They should be stored in the channel of the rib wall before the motor cover is reinstalled. If not, the rib wall could pinch and damage the cables. The cables may also prevent the motor cover from seating properly into place. Make sure all gaskets are also seated properly. 071807 14 II. Maintenance Procedures

J. Replacing the Direct Air Motor Fan J. Step 1. 1. Remove the handle and the dust cover. 2. Place the vacuum face down on the bench. 3. Remove the base plate by removing the 2 (two) screws. 4. Remove the agitator/brushroll. 5. Remove the 5 (five) mounting screws on the underside of the nozzle base tray. (See Figure C. Location of Nozzle Cover Screws) J. Step 2. Removing the Back Path and Cover 1. Remove 1 (one) screw in the tools activation dial/rotational valve handle and 8 (eight) screws on the back path and hose. J. Step 3. J. Step 4. J. Step 5. J. Step 6. J. Step 7. J. Step 8. 2. Remove the tools activation dial/rotational valve handle and the back path cover. 3. Remove 1 (one) screw from the micro switch and then the remaining 13 (thirteen) screws in the back cover. 4. Remove the back cover allowing the micro switch to slide through the slot in cover. 5. Remove the tool clips. NOTE: If wiring harness does not need to be changed, Skip to I. Step 6. 1. If wire inlet seal (foam seal where the wire goes through the dust compartment) is installed, remove it at this time. 2. Remove the wire harness connector from the dust compartment and the micro switch from the wiring harness. Turn the vacuum over, depress handle release, and lay flat. Remove the nozzle cover. WARNING - If the vacuum is not in the upright position before continuing with the next step, injury may occur or vacuum may be damaged. 1. Set the vacuum in the upright position and remove the 2 (two) screws from the spring assist bar. 2. Lay the vacuum flat. Remove the 3 (three) screws from the direct air motor inlet duct cover, and 1 (one) screw from each of the wire strain relief (2 each) 3. Remove the belt. 4. Remove 3 (three) screws from the idler cover and spring. 5. Disconnect the light lead connector from the light board (disconnect the ground wire if necessary). 6. Remove the 2 (two) screws from each of the pivot brackets. 1. Lift the dust compartment up out of the nozzle base tray assembly. 2. Remove the pivot bushings and the direct air motor inlet seal from the dust compartment. 1. Remove the 4 (four) screws holding the motor cover on the dust compartment. 2. Lift up on the motor cover and set it aside. Separate the scroll housing halves by removing the three e-clips and one screw. J. Step 9. Remove the nut from the motor fan by loosening it counter-clockwise then unscrewing the nut clockwise. 071807 15 II. Maintenance Procedures

J. Replacing the Direct Air Motor Fan- Continued J. Step 10. 1. Replace the fan. 2. Note the placement of the washer(s) on the fan. The placement of these washers is critical to allow the fan to tighten properly on the motor shaft. 3. Tighten the nut counter-clockwise. J. Step 11. Reinstall the scroll housing with one screw and three e-clips. J. Step 12. To install the motor: 1. Insure the rubber seal is installed on the dust compartment. 2. Insure the motor seal by the shaft is in good condition. 3. Place the black wire under the motor and connect it. Connect the white wire, (hold the black wire as you place the motor into the motor compartment to keep from pinching the wire). 4. Place the motor into the motor compartment, (do not push all the way down) shaft side first then fan side, keeping the motor level as it goes in. 5. Check the back of the vacuum to ensure the scroll housing is not catching on the rubber seal. 6. Rotate the motor as you push it down into the dust compartment. Once in place, the metal motor support should rest in between the bracket. 7. Raise up the shaft end of the motor, install the wire guide, and push the motor down into place. Note the proper location of the two cables passing from the clean air motor compartment to the direct air motor compartment. They should be stored in the channel of the rib wall before the motor cover is reinstalled. If not, the rib wall could pinch and damage the cables. The cables may also prevent the motor cover from seating properly into place. Make sure all gaskets are also seated properly. 071807 16 II. Maintenance Procedures

K. Replacing the Rear Wheels NOTE: When replacing the wheels or hubcaps for.4 and older models, the entire wheel/axle set needs to be replaced. K. Step 1. Remove the rear wheel hubcaps by depressing the 3 lock tabs on the inside of the wheel. K. Step 2. Remove the e-clip on the outside of the wheel hub. Slide the rear wheel from the shaft, and replace with new wheel. L. Replacing the Tilt Lock Pedal Spring L. Step 1. 1. Remove the handle and the dust cover. 2. Place the vacuum face down on the bench. 3. Remove the base plate by removing the 2 (two) screws. 4. Remove the agitator/brushroll. 5. Remove the 5 (five) mounting screws on the underside of the nozzle base tray. (See Figure C. Location of Nozzle Cover Screws) L. Step 2. 1. Remove the rear wheel hubcaps by depressing the 3 lock tabs on the inside of the wheel. 2. Remove the e-clip on the outside of the wheel hub. Slide the rear wheel from the shaft. L. Step 3. 1. Remove the e-clip holding the tilt lock pivot shaft to the nozzle base tray (this e-clip is located in front of the rear wheel axle). 2. Remove the tilt lock shaft by sliding it back through the hole. L. Step 4. Remove the tilt lock pedal by lifting it out from the top from the inside of the nozzle base tray. L. Step 5. Remove the tilt lock spring by lifting it out from the interior of the nozzle base tray. L. Step 6. Replace the tilt lock spring by fitting it into its proper mounting structure. Note that the 1/4 long tab on this spring points downward and sits flush with the backside of the nozzle base tray. L. Step 7. 1. Insert the tilt lock pedal and slide the tilt lock pivot through the hole in the nozzle base tray and through the hole in the tilt lock pedal. 2. Re-attach the e-clip to the pivot. L. Step 8. 1. Reinstall the rear wheel and secure with e-clip. 2. Reinstall the hubcap. L. Step 9. Reinstall the nozzle housing (5 screws). 071807 17 II. Maintenance Procedures

III. General Troubleshooting A. Vacuum has no power. A. Step 1. 1. If there are lights in the handle switches there is power to the handle, continue to Step 2. 2. If there are no lights in the handle switches, there is no power to the vacuum or the power cord is faulty. a. Check the power source. b. Replace the power cord if damaged or faulty. c. Retest the vacuum. NOTE: Vacuum may not run even though the lights in the handle are on. If the handle is plugged in and turned ON, the handle switch light will turn on even when the handle isn t installed in the vacuum. A. Step 2. Handle switches are lit but neither motor will run. 1. Ensure the handle is installed correctly. (See Figure A. Correct Handle Installation) 2. Push the reset on the back of the vacuum and retest (See Figure T. Description of Vacuum) 3. If the vacuum still does not run continue to Step 3. A. Step 3. 1. Unplug the vacuum. 2. Remove the handle. Check the connector ends for any burnt pins. 3. If the connector ends are in good condition continue to Step 4. 4. If faulty connectors are found, replace the wiring harness. 5. Reassemble the vacuum and retest. A. Step 4. 1. Plug the power cord in and turn the switches on. 2. Plug a test meter or light into the handle connector at the bottom of the handle, (one lead into the square connector on the upper right (See Figure I. Handle to Body Harness Connector #4) and the other into the square connector on the lower left (See Figure I. Handle to Body Harness Connector #3). 3. If the handle has power, continue to Step 5. 4. If the handle does NOT have power: a) Unplug vacuum and disassemble handle. b) Check all connections in handle. c) If all the connections in the handle are good, change the wiring harness or install a new handle. d) If all the connections in the handle are NOT good, replace any faulty connections. e) Reassemble and retest vacuum. Figure I. Handle to Body Harness Connector #1 - Only square on connector. This is main power connector (Black Wire) connects to blue/yellow body harness. #4 - Connector for direct air motor via roto valve micro switch to winged rocker switch to PCB. #6 & #3 - Grounds. #5 & #2 - Not used 6 3 5 2 4 1 071807 18 III. General Troubleshooting

A. Vacuum has no power. - Continued A. Step 5. 1. Disassemble the vacuum and disconnect the PC board. 2. Using a test light or meter, test connector 10 (thermal lead) and either 5 or 6 (ground) on the main connector on the wire harness. (See IV. Figures, P. Main Body Harness.5 and.6 Models or IV. Figures, S. Main Body Wire Harness.4 and Older Models) 3. If the vacuum does NOT have power continue to Step 6. 4. If there is power to the PC board (thermal switch is good): a) Check the fuse on the PC board. (See Figure B. PCB Layout and Belt Idler Assembly) b) If the fuse is faulty, replace the fuse. c) If the fuse is good, replace the PC board. d) Retest the vacuum. e) If the vacuum still does not run skip to Step 7. A. Step 6. 1. Remove the clean air motor. 2. Disconnect the blue/yellow lead that connects to the thermal switch. 3. Place a meter or test light to the blue/yellow lead and the ground lead on the PC board connector. 4. With the vacuum plugged in and power switch ON, check for current flow. 5. If the vacuum has power at this point continue to Step 7. 6. If the vacuum does NOT have power call Tacony Technical Support at 1-800-643-7459 A. Step 7. 1. Connect the clean air motor to 110/120 volts (Use jumper wires and straight wire the motor). 2. If the motor does NOT run, reassemble the vacuum with a new motor and retest. 3. If the motor does run: a) Check the fuse on the PC board. (See Figure B. PCB Layout and Belt Idler Assembly) b) If the fuse is faulty, replace the fuse. c) If the fuse is good, replace the PC board. d) Retest the vacuum. NOTE: If vacuum still will not run call Tacony Technical Service at 1-800-643-7459. 071807 19 III. General Troubleshooting

B. Direct Air Motor Will Not Run 1. If nozzle cover is installed, the vacuum must be out of the upright position before the direct air motor will run. 2. If the nozzle cover is not installed, the direct air motor should run in the upright position. 3..5 and newer models: If the belt is not installed, or the hall sensor is defective, the vacuum may run 2 to 3 seconds and then cut off. 4. The handle should be attached to the vacuum and plugged into wall outlet. (See Figure A. Correct Handle Installation) Check for headlights: 1. Direct air motor will not run. Clean air motor runs. 2. Turn the main power switch ON, (green light in switch on) and the floor/carpet switch to the carpet position with green light on. Note: these lights will be on any time the handle is plugged into the outlet and switches are turned ON. No headlights: See Section B. 1. No Headlights. Headlights are on: See Section B. 2. Working Headlights B.1. Direct Air Motor Will Not Run: No Headlights B.1. Step 1. 1. Remove the dust cover then lay the vacuum face down. B.1. Step 2. 2. Remove the nozzle cover (5 screws). 3. Place vacuum in the upright position and remove the 2 (two) screws from the assist spring. 4. Lay the vacuum flat and remove the direct air motor inlet cover - 3 (three) screws in the inlet cover. 5. Remove the 2 (two) screws on each side of the dust compartment in brackets. 6. Remove the motor cover (4 (four) screws). Check the clean air motor tap wire voltage: 1. Place one lead from a multi-meter on the white motor wire connection, and one lead on the blue or yellow tap wire connection. (See Figure F. Clean Air Motor Wiring or Figure G. Ametek Clean Air Motor Wiring) 2. Turn the vacuum ON with the main power switch. With clean air motor running, read the voltage on the meter. 3. If reading is 12 to 18 AC volts the clean air motor is good. 4. If voltage is less than 12 volts replace the clean air motor. 5. If voltage is 18 or more, check fuse on the PCB: a) If fuse is faulty replace fuse and retest vacuum. b) If fuse is good replace the PCB and retest the vacuum. If vacuum still does not work properly continue through Section B.2. Direct Air Motor Will Not Run: Headlights are on: 071807 20 III. General Troubleshooting

B.2. Direct Air Motor Will Not Run: Headlights are on B.2. Step 1. 1. Check the position of tools activation dial/rotational valve handle. Tool dial must be in OFF position. Rotate the tool dial fully counter clockwise and then back to full clockwise or OFF position. B.2. Step 2. B.2. Step 3. 2. If the vacuum runs reassemble and retest. 3. If the vacuum does NOT run, continue to B.2. Step 2. 1. Check the winged rocker switch to ensure it is not broken or sticking and that the wing is extended and facing down. 2. Replace the switch if necessary and retest. 3. If the vacuum runs reassemble and retest. 4. If the vacuum does NOT run, continue to B.2. Step 3. 1. Looking at the back of the vacuum at the 3 o clock position of the tools activation dial/rotational valve handle, a spring is visible which is part of the micro switch for the direct air motor. With a small screw driver press the spring to the right to ensure the micro switch is activated. 2. The tools dial and upper portion of the back path may be removed to gain access to the micro switch. Figure J. Location of Winged Rocker Switch Main Body Nozzle (shown without cover) Winged Rocker Switch TANDEM A I R SYSTEM B.2. Step 4. 3. Turn the vacuum on and press the micro switch. Figure K. Location of Micro Switch 4. If the direct air motor starts, reassemble and retest. 5. If the direct air motor does not start continue to B.2. Step 4. 1. Bypass or jump the micro switch. (See Figure K. Location of Micro Switch) 2. If the vacuum starts, replace the micro switch and then reassemble the vacuum and retest. 3. If the vacuum does NOT start, continue to B.2. Step 5. TOOLS ON TOOLS OFF A B To jump micro switch, remove wires from connectors A and B and join them together. Figure is shown without Air Hose Path Cover which normally covers this switch. B. Step 5. 1. Remove the dust cover and then lay vacuum face down. 2. Remove the nozzle cover (5 screws). 3. Place the vacuum in the upright position and remove the 2 (two) screws from the assist spring. 4. Lay the vacuum flat and remove the direct air motor inlet cover - 3 (three) screws in the inlet cover. 5. Remove the 2 (two) screws on each side of the dust compartment in brackets. 6. Remove the motor cover (4 (four) screws). B.2. Step 6. 1. Check the wiring on the winged rocker switch for broken wires. 2. If all the wiring is good, continue to B.2. Step 9. 3. If any wiring is faulty, replace wiring or switch and retest. 071807 21 III. General Troubleshooting

B. Direct Air Motor Will Not Run - continued B.2. Step 7. If all switches appear to be good: B.2. Step 8. B.2. Step 9. 1. Check the brown wire on the wing rocker switch as follows. Place one lead of the multi-meter on the brown wire from the micro switch. Place the other lead on the white/green wire at the PCB connector (#6) you should read 120 volts with main power switch ON and floor/carpet switch in carpet position and Tool activation dial/rotational valve handle in the tools OFF position. 2. If the voltage is low, go to the rotational valve micro switch and disconnect the brown wire from the handle connector and the black micro switch wire turn the main power switch ON and place the carpet/floor switch to carpet. Place one lead from the multi-meter to the brown wire from the handle and the ground wire to the number 5 or 6 PCB connector, voltage should read around 120 volts. 3. If the voltage is within normal limits, the micro switch is faulty. 4. If voltage is low then the problem is in the handle connector or the handle wiring. 1. Unplug the direct air motor and hook it up directly to 110 volts. 2. If the motor runs continue to B.2. Step 9. 3. If the direct air motor does NOT run replace it and reassemble the vacuum and retest. 1. Check the wiring to the direct air motor and the PC board. 2. If all the wiring is good (not pinched and all connectors good) replace the PC board and retest. 3. If any wiring or connectors are faulty, replace them and retest. 4. Continue to B.2. Step 10. B.2. Step 10. 1. If the motor runs reassemble the vacuum. 2. If the motor does NOT run replace the wiring harness; reassemble and retest. NOTE: If vacuum still will not run call Tacony Technical Service at 1-800-643-7459. Figure L. Proper Position for Tools Activation Dial/Rotational Valve Handle Line up notch with screw at 11 O clock position before attaching Tools ON / OFF Dial 071807 22 III. General Troubleshooting

C. Nozzle Suction Power is Weak 1. Bag may be full or contain fine particles such as drywall dust or talc. 2. Filters may be dirty and need replaced. C.1. There is no suction at the hose C.1. Step 1. The tool activation dial/rotational valve handle should be in the tools ON position. C.1. Step 2. C.1. Step 3. Remove the hose and check for a clog in the hose. (If clogged remove the clog). NOTE: If hose is clogged there will be suction at the hose inlet on the back path of the vacuum. If there is no suction at the hose inlet at the back path: 1. Remove the tool activation dial/rotational valve handle. 2. Remove the 7 (seven) screws holding on the air hose path and hose inlet connector. 3. If clogged remove clog and re-assemble. C.2. There is no suction at the nozzle C.2. Step 1. The tool activation dial/rotational valve handle should be in the tools OFF position. C.2. Step 2. C.2. Step 3. C.2. Step 4. C.2. Step 5. C.2. Step 6. Check the nozzle tray and agitator/brush roll for clog, clean agitator/brush roll as required. Remove the dust cover and turn the vacuum ON, in carpet mode. The bag should inflate assuring the air path is open and the direct air motor is working. If suction is still weak: 1. Remove the agitator/brush roll, nozzle cover, and direct air motor inlet cover. 2. Check for clogs in the inlet duct and direct air motor inlet, if clogged remove the clog and test again. Models.5+ and newer, if suction is still weak: Turn vacuum over and remove the clean out door and check and remove any clogs. NOTE: You may turn the vacuum on and check the suction at the clean out door. This is done with the dust cover installed, and with the upper motor only, if you have suction the air path is open and the clog is in the direct air motor. Models.5 and older, if suctions is still weak: Remove the back cover to check the air path. If the air path is clear, the clog is in the direct air motor. If clog is in the direct air motor remove the direct air motor (See II. Maintenance Procedures, I. Removing and Replacing the Direct Air Motor) and the remove the outer scroll housing and check for any clog. C.2. Step 7. Re-assemble the vacuum and retest. 071807 23 III. General Troubleshooting

D. Excessive Vibration 1. Check the direct air fan for damage. Replace if necessary. (See II. Maintenance Procedures, J. Replacing the Direct Air Motor Fan) 2. The agitator/brushroll may be out of balance. 3. To test the agitator/brushroll for balance: Models.4 and older: 1. Remove the agitator/brushroll and run the direct air motor. 2. If vibration stops with the agitator/brushroll removed, replace the agitator/brushroll and retest. Models.5 and newer: 1. Remove the nozzle cover and install the hall sensor test plug. (If test plug is not installed, the direct air motor will only run 2 to 3 seconds and then shut off.) 2. Remove the agitator/brushroll and run the direct air motor. 3. If vibration stops with the agitator/brushroll removed, replace the agitator/brushroll and retest. E. Agitator/brushroll Does Not Rotate 1. Check the condition of the belt. Replace if necessary. 2. Check the agitator/brushroll for excessive hair build-up. Clean agitator/brushroll if necessary. Also see III. General Troubleshooting, B. Direct Air Motor Will Not Run 071807 24 III. General Troubleshooting

F. Agitator/brushroll Jam Test F. Step 1. 1. Turn the vacuum on. Turn the carpet/floor switch to carpet. Run the vacuum over a sock or towel to jam the agitator/ brushroll. NOTE: Be sure to use thick enough sock or towel material so it doesn t wrap around the agitator/brushroll. 2. The agitator/brushroll should stop completely, the direct air motor should turn off immediately, and the red indicator light should turn on. (The clean air motor should continue to run). 3. If all conditions are met continue to F. Step 2. 4. If jam test fails remove the sock, and start the test again. 5. If test fails a second time, troubleshoot the source as either the PC Board or the Hall Sensor Assembly, and make the appropriate repairs. Then test again. F. Step 2. Turn the Carpet/Floor switch to Floor. F. Step 3. Turn Carpet/Floor switch to Carpet. Does the agitator/brushroll come on? NO: Repeat F. Step 3. YES: Replace PC Board, and test again. F. Step 4. Turn On/Off switch to Off. F. Step 5. Remove sock/towel. F. Step 6. Turn On/Off switch to On again. If the red indicator light does not come back on the jam function is working properly. If the red indicator light stays lit, replace the PC board and repeat the test. 071807 25 III. General Troubleshooting

IV. Trouble Shooting -.4 and Older Models Only A. Full Bag Indicator (FBI) Comes On Too Soon or Not At All If the light comes on too soon, the bag may be full or contain fine particles such as drywall dust or talc. If the light does not come on at all, the bag may be full of fluffy material. If replacing the bag does not solve these problems, the sensor may need to be adjusted as follows: Testing the Full Bag Indicator: 1. Run the vacuum for five minutes to warm it up. Make sure the bag is new and the filters are clean. 2. With the wand kept in the stowed position, turn the tools activation dial/rotational valve handle to the Tools ON position. 3. The full bag indicator should illuminate within 18-23 seconds after turning the dial to the Tools ON position. 4. If the indicator comes on sooner or slower than 18-23 seconds (or not at all), the sensitivity may need to be adjusted. Adjusting the Full Bag Indicator: 1. Unplug the power cord, remove the dust cover, and lay the vacuum flat. 2. Locate the two plugs on the right side of the motor cover. (See Figure M. Agitator/brushroll Jam Screw - FBI Screw Position) 3. Remove the left plug from the motor cover. A gray colored adjustment screw should be visible through the hole. 4. The slot of the screw should be in the Ten o clock position. If not, adjust it to the Ten o clock using a small flat-headed screwdriver that fits through the hole. NOTE: Be careful not to apply pressure while making the adjustment. 5. Reassemble the vacuum and retest it to ensure it is operating properly. 6. If the problem still exists, or if the screw is already adjusted to Ten o clock, make gradual adjustments (approximately one hour increments or less). Turn the adjustment screw counter-clockwise to make it less sensitive (LED turns yellow slower), and clockwise to make it more sensitive (LED turns yellow faster). It is important to make small adjustments and test the vacuum after each adjustment. 7. Retest the vacuum after each adjustment using the above procedures until the FBI comes on within 18-23 seconds. Figure M. Agitator/brushroll Jam Screw - FBI Screw Position Motor Cover Plugs Covering Screws Airflow Screw Brushroll Jam Screw Correct Position (Ten O Clock) Correct Position (Eleven O Clock) 071807 26 IV. Trouble Shooting -.4 and Older Models Only

B. Agitator/brushroll Jam Light Comes On Too Soon or Not At All If the sensor is coming on too soon, the customer may be vacuuming one extra plush carpet. Set the height adjustment to higher level and retest. If the sensor still comes on too soon, it may be out of calibration and need adjusting. - See Adjusting the Agitator/brushroll Jam Indicator below. If sensor is coming on too late or not at all the sensor may be out of calibration and need adjustment. - See Adjusting the Agitator/brushroll Jam Indicator below. Adjusting the Agitator/brushroll Jam Indicator: 1. Unplug the power cord, remove the dust cover, and lower the upper body to the reclined position. 2. Locate the two plugs on the right side of the motor cover. (See Figure M. Agitator/brushroll Jam Screw - Full Bag Screw Position) 3. Remove the right plug from the motor cover. A gray colored airflow adjustment screw should be visible through the hole. 4. The slot of the screw should be in the Eleven o clock position. If not, adjust it to the Eleven o clock position using a small flat-headed screwdriver that fits through the hole. NOTE: Be careful not to apply pressure while making the adjustment. 5. Reassemble the vacuum and retest it to ensure it is operating properly. Follow testing procedure in Section III.Troubleshooting: G. Agitator/brushroll Jam Test 6. If the problem still exists, or if the screw is already adjusted to Eleven o clock, make gradual adjustments (approximately one hour increments or less). Turn the adjustment screw counter-clockwise to make it less sensitive (harder to jam) and clockwise to make it more sensitive (easier to jam). It is important to make small adjustments and test the vacuum after each adjustment. Figure M. Agitator/brushroll Jam Screw - FBI Screw Position Motor Cover Plugs Covering Screws Airflow Screw Brushroll Jam Screw Correct Position (Ten O Clock) Correct Position (Eleven O Clock) 071807 27 IV. Trouble Shooting -.4 and Older Models Only