GoCartVac ®

Service Manual

ATTENTION

Before servicing any part or proceeding with any repair procedure on any

ProTeam vacuum,

ALWAYS disconnect the vacuum from the power source.

www.pro-team.com 866.888.2168

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

Stub Tube Replacement ........................................................................................... 48

Electrical Diagram .................................................................................................... 49

2

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 prior 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 www.pro-team.com 866.888.2168

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 105044 Motor Shroud/Diffuser w/Screw Set: 2 screws

6 100335 Compression Ring w/Connection Screws

100378 Compression Ring Connection Screws

7 100014 Tetraseal

8 103732 36V Motor w/Crimps, Replacement

103731 Carbon Brush Set for 36V motor

103617 Complete 36V Motor Assembly w/Seal,

Compression Ring and Control Module

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

9 105496 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) (2 pack)

15 103623 Electrified Hose, 1 1 /

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 Complete

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 105828 Battery, Lead Acid, 12V, 37AH

35 106283 Kit, Attachment Hardware for Charger and

Box Assembly

36 107294 Thermal Protector

37 106928 Exhaust Muffler

38 105790 2 Wire Electrified Hose Cord (15")

39 106297 Rear Wheel Set w/Axle

40 106298 Front Wheel Set

101678 50' Extension Cord (Not Shown) www.pro-team.com 866.888.2168

12

9

11

7

6

37

5

15

16

38

1

2

3

Full Vacuum Parts

14 13

18

17

36

20

8

10

4

19

31

25

22

32

24

23

29

30

28

27

35

33

26

34 21

39

40

3

Remove Charger Panel

REMOVE CHARGER PANEL

1.

Remove cover of cart by pulling straight up carefully. ATTENTION: Pull up carefully as cord is attached to vacuum.

2.

Place cover into tray of cart.

3.

Remove side panel closest to power switch by pushing in and pulling up at the same time.

4.

Continue pulling up until panel is removed.

Place aside.

4

(Continued on page 5) www.pro-team.com 866.888.2168

REMOVE CHARGER PANEL

(Continued from page 4)

Remove Charger Panel

5a.

Grab each end of the charging harness and work back and forth as you pull apart.

5b.

6a.

Slide the charger’s black/red connector apart from the other two.

6b.

7.

Unplug charger from receptacle.

www.pro-team.com 866.888.2168

8.

Using grip in panel pull up until panel is clear from cart.

5

Replace Charger Panel

REPLACE CHARGER PANEL

1.

Place corner molding on one side of charger panel.

2.

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.

3.

Connect plug of battery charger into receptacle inside cart housing.

4a.

Slide red and black connector of charger into other two red and black connectors from batteries and vacuum.

4b.

6

5.

Attach the charging harness terminal to the three connectors of the charger, batteries and vacuum.

(Continued on page 7) www.pro-team.com 866.888.2168

REPLACE CHARGER PANEL

(Continued from page 6)

Replace Charger Panel

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.

7.

Put cover in place on top of cart. Align hole in cover over top of vacuum.

www.pro-team.com 866.888.2168

7

Remove Vacuum Panel

REMOVE VACUUM PANEL

1. Remove Charger Panel (Page 4)

2a.

Slide the remaining two red/black connectors apart from each other.

2b.

3.

Disconnect plug from vacuum.

Carefully remove vacuum panel from cart.

8 www.pro-team.com 866.888.2168

Replace Vacuum Panel

REPLACE VACUUM PANEL

1.

Place corner molding on one side of vacuum panel.

2a.

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.

2b.

3.

Connect the red/black connector of the vacuum to the red/black connector from the batteries.

5. Replace Charger Panel (Page 6)

4.

Plug cable from cover of cart into vacuum.

www.pro-team.com 866.888.2168

9

Remove Diffuser

REMOVE DIFFUSER

1. Remove Charger Panel (Page 4)

2. Remove Vacuum Panel (Page 8)

3.

Remove vacuum from panel using Phillips screwdriver to remove two screws and washers.

4.

Remove cap by twisting counter-clockwise.

5.

Remove both cloth and paper filters.

6.

Turn vacuum upside down.

7.

Using a 5/16 socket or flat head screwdriver, remove two screws holding plastic diffuser to motor.

8.

Remove diffuser.

10 www.pro-team.com 866.888.2168

Replace Diffuser

REPLACE DIFFUSER

1.

Replace diffuser by placing the side with ridges away from motor.

2.

Attach diffuser to motor with two screws.

3.

Turn vacuum right side up and place cloth and paper filter into vacuum body.

4.

Secure lid on vacuum by turning clockwise.

5.

Lay vacuum flat with mounting holes up.

If all changes are complete:

8. Replace Vacuum Panel

(Page 9)

9. Replace Charger Panel

(Page 6)

6.

Lay panel on top of vacuum aligning mounting holes in vacuum with holes in panel.

www.pro-team.com 866.888.2168

7.

Attach vacuum to back panel with washers and screws.

11

Remove Vacuum Receptacle

REMOVE VACUUM RECEPTACLE

1. Remove Charger Panel (Page 4)

2. Remove Vacuum Panel (Page 8)

3. Remove Diffuser (Page 10)

4.

Inside vacuum locate and remove top horizontal connector on battery control module (BCM) (white wire from receptacle) with needlenose pliers.

5.

Locate black wire with white connector from receptacle on BCM and remove with needlenose pliers.

6.

Remove two screws holding receptacle to vacuum body with Philip’s screwdriver.

7.

Using fingers or flathead screwdriver, loosen receptacle from vacuum.

12

8.

Remove receptacle from vacuum.

www.pro-team.com 866.888.2168

Replace Receptacle

REPLACE RECEPTACLE

1.

Thread wires of new or existing receptacle through hole in vacuum body.

2.

Push receptacle until flush against body of vacuum.

3.

Attach receptacle to vacuum body with two screws using a Phillips screwdriver.

4.

Connect the black receptacle wire to the vertical

BCM location marked “Switch” with needlenose pliers or fingers.

If all changes are complete:

6. Replace Diffuser (Page 11)

7. Replace Vacuum Panel (Page 9)

8. Replace Charger Panel (Page 6)

5.

Connect the white receptacle wire onto the top horizontal BCM connection labeled “Switch.” www.pro-team.com 866.888.2168

13

Remove Power Cable

REMOVE POWER CABLE

1. Remove Charger Panel (Page 4) 2. Remove Vacuum Panel (Page 8) 3. Remove Diffuser (Page 10)

4.

Locate white wire from receptacle and remove from BCM.

5.

Locate white wire from power cable and remove from BCM.

6.

Locate black wire of power cable on BCM. Remove w/needlenose pliers or fingers.

7a.

With crescent wrench holding nut unscrew the strain relief.

7b.

8a.

Holding outer nut, unscrew the inner nut from the threads on the cable.

Remove cable from vacuum.

14

8b.

www.pro-team.com 866.888.2168

Replace Power Cable

REPLACE POWER CABLE

1.

Thread wires of new or existing cable through hole in vacuum body.

2.

Thread wires through inner nut and tighten nut.

3.

Screw strain relief up to washer and outer nut.

Tighten all with crescent wrench.

4.

Attach the white wire from power cord to the middle connector (marked with +36V).

5.

Attach the white wire from switch receptacle to the top connector (marked with SWITCH).

6.

Connect black wire of power cable to “-36” on

PC board.

If all needed changes are complete:

7. Replace Diffuser (Page 11) 8. Replace Vacuum Panel (Page 9) 9. Replace Charger Panel (Page 6) www.pro-team.com 866.888.2168

15

Remove/Replace Thermal Switch

REMOVE THERMAL SWITCH

1. Remove Charger Panel (Page 4)

2. Remove Vacuum Panel (Page 8)

3. Remove Diffuser (Page 10)

4.

Locate and remove thermal switch connector from BCM.

REPLACE THERMAL SWITCH

5.

Disconnect the other end of the thermal swich from motor wire.

1.

Connect male connector of new or existing thermal switch to motor wire.

If all needed changes are complete:

3. Replace Diffuser (Page 11)

4. Replace Vacuum Panel (Page 9)

5. Replace Charger Panel (Page 6)

2.

Connect female connector of thermal switch to

“MOTOR” on BCM.

16 www.pro-team.com 866.888.2168

REMOVE BCM

1. Remove Charger Panel (Page 4)

2. Remove Vacuum Panel (Page 8)

3. Remove Diffuser (Page 10)

Remove Battery Control Module (BCM)

4.

Remove all wires connected to BCM.

5.

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

Remove BCM.

www.pro-team.com 866.888.2168

17

Replace Battery Control Module (BCM)

REPLACE BCM

1.

Screw new or existing BCM to motor compression ring with either a flathead screwdriver or 5/16 socket.

2.

Connect black wire of power cable to “-36” on

PC board.

3.

Connect female connector of thermal switch to “MOTOR” on BCM.

4.

Reconnect black wire of receptacle to “SWITCH” on BCM.

5.

Attach the black wire from the motor to the bottom horizontal connector (marked with MTR+).

6.

Attach the white wire from new power cord to the middle connector (marked with +36V).

7.

Attach the white wire from receptacle to the top connector (marked with SWITCH).

If all needed changes are complete:

8. Replace Diffuser (Page 11) 9. Replace Vacuum Panel (Page 9) 10. Replace Charger Panel (Page 6)

18 www.pro-team.com 866.888.2168

Remove Motor/BCM Assembly from Vacuum

REMOVE MOTOR/BCM ASSEMBLY FROM VACUUM

1. Remove Charger Panel (Page 4)

2. Remove Vacuum Panel (Page 8)

3. Remove Diffuser (Page 10)

4. Remove Receptacle (Page 12)

5. Remove Power Cable (Page 14)

6.

Use flathead screwdriver to remove 3 washer cover caps.

7.

Use Phillips screwdriver to remove screw and

Z-washer. Remove all three.

8a.

Push well nut into vacuum using screwdriver.

8b.

9.

Remove motor from vacuum body.

www.pro-team.com 866.888.2168

10.

Remove dome filter.

19

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.

1.

Press dome filter onto bottom of motor.

2.

Place motor into vacuum body.

3.

Align motor as shown in picture (BCM close to power cable hole).

4.

Press well nuts into holes in vacuum body.

Rotating as pushing in may ease assembly.

5.

Ensure well nut is flush against vacuum body.

6.

Inside vacuum view of well nut.

20

(Continued on page 21) www.pro-team.com 866.888.2168

Replace Motor/BCM Assembly into Vacuum

REPLACE MOTOR/BCM ASSEMBLY INTO VACUUM

(Continued from page 20)

7.

Replace Z-washers and screws.

8.

Tighten screw on Z-washer until well nut has tightened against vacuum wall.

9.

Press washer cover/cap over washer.

10.

Replace power cable. Follow Steps 1 through

6 on Page 15.

If all changes are complete:

12. Replace Diffuser (Page 11)

13. Replace Vacuum Panel (Page 9)

14. Replace Charger Panel (Page 6)

11.

Replace receptacle. Follow Steps 1 through 5 on Page 13.

www.pro-team.com 866.888.2168

21

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)

5a.

Remove screw and wire retaining clamp on motor with 5/16” socket.

5b.

6a.

Use end of flathead screwdriver, gently wedge between center of motor brush and clip. Turn screwdriver counter-clockwise to push out the wire clip under the motor brush insulation.

Do not press downward on the clip or use excessive force as this may break the clip.

6b.

22

(Continued on page 23) www.pro-team.com 866.888.2168

REMOVE MOTOR BRUSHES

(Continued from page 22)

Remove Motor Brushes

7a.

Remove two screws and bracket over the motor brushes.

7b.

TIP:

New carbon brushes give off small sparks briefly once motor is engaged while brushes finish aligning.

This is normal.

8.

Remove motor brush. Remove 2nd motor brush in same way. Tip brush upward and slide connector out.

www.pro-team.com 866.888.2168

23

Replace Motor Brushes

REPLACE MOTOR BRUSHES

1a.

Obtain new motor brushes and slide into place with wire clip/tab going under the top insulation.

1b.

2.

Replace brush brackets with screws.

3.

With end of flathead screwdriver, push wire clip back into place.

If all changes are complete:

5. Replace Motor/BCM Assembly (Page 20)

6. Replace Diffuser (Page 11)

7. Replace Vacuum Panel (Page 9)

8. Replace Charger Panel (Page 6)

4.

Replace screw and wire retaining clamp on each side of motor.

24 www.pro-team.com 866.888.2168

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/Replace Motor Assembly

REPLACE MOTOR ASSEMBLY

5.

Remove thermal switch connector from BCM.

6.

Remove thermal switch from motor wire.

1.

Connect one of the thermal switch wires to new motor wire. It does not matter which wire.

2.

Connect thermal switch’s other wire to

“MOTOR–” on BCM.

If all changes are complete:

4. Replace Motor/BCM Assembly (Page 20)

5. Replace Diffuser (Page 11)

6. Replace Vacuum Panel (Page 9)

7. Replace Charger Panel (Page 6)

3.

Connect remaining motor wire to “MTR+” on

BCM. Go to Page 21 – Step 1-11.

www.pro-team.com 866.888.2168

25

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)

5.

Remove horizontal motor connector from BCM.

6.

Remove thermal switch connector from BCM.

7.

Remove PC Board.

8.

Remove remaining 3 screws which attach compression ring to motor.

If all changes are complete:

10. Replace Motor/BCM Assembly (Page 20)

11. Replace Diffuser (Page 11)

12. Replace Vacuum Panel (Page 9)

13. Replace Charger Panel (Page 6)

9.

Remove ring over top of motor.

26 www.pro-team.com 866.888.2168

REASSEMBLE COMPRESSION RING

Reassemble Compression Ring

1.

Place new or existing compression ring over top of motor such that cut outs in ring are aligned with motor brushes.

2.

Replace three of the screws which attach the ring to the motor. Leave out a screw which is not under a wire clamp

(where the BCM was attached).

3.

Re-attach PC board in remaining hole on compression ring.

4.

Reconnect thermal switch’s other wire to “MOTOR” on BCM.

If all changes are complete:

6. Replace Motor/BCM Assembly (Page 20)

7. Replace Diffuser (Page 11)

8. Replace Vacuum Panel (Page 9)

9. Replace Charger Panel (Page 6)

5.

Reconnect remaining motor wire to “MTR+” on BCM.

www.pro-team.com 866.888.2168

27

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)

REASSEMBLE TETRASEAL

5.

Remove compression ring per Steps 5 through 9 on Page 27.

6.

Remove tetraseal by pulling up and over the top of motor.

1.

Place new or existing tetraseal over top of motor.

2.

Press down on seal until flush with motor flange.

If all changes are complete:

4. Replace Motor/BCM Assembly (Page 20)

5. Replace Diffuser (Page 11)

6. Replace Vacuum Panel (Page 9)

7. Replace Charger Panel (Page 6)

3.

Replace compression ring, BCM and re-wire per Steps 1 through 5 on Page 27.

28 www.pro-team.com 866.888.2168

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)

Remove/Reassemble Motor

5.

Disconnect thermal switch from motor wire.

REASSEMBLE MOTOR

6.

Remove compression ring and tetraseal per Steps 5 and 6 on Page 28.

1.

Replace compression ring, tetraseal and BCM on new motor per Steps 1 through 3 on Page 28.

If all changes are complete:

3. Replace Motor/BCM Assembly (Page 20)

4. Replace Diffuser (Page 11)

5. Replace Vacuum Panel (Page 9)

6. Replace Charger Panel (Page 6)

2.

Reconnect thermal switch to motor wire.

www.pro-team.com 866.888.2168

29

Batteries/Harness Safety Notice/Precautions

TO REPLACE:

Batteries

Fusible Link

Battery Red Jumper Wire

Battery Power Harness

Safety glasses required

Remove all metal jewelry; rings, watches, chains, etc.

Use insulated wrench when working with batteries

SAFETY NOTICE:

WARNING: Risk of electric shock CAUTION: Read Safety Notice prior to assembly

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 present.

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. Remove all metallic items such as watches, bracelets and personal jewelry when working on or around battery terminals. As a further precaution, only insulated tools should be used to prevent accidental short circuits.

5. Carefully inspect batteries prior 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.

PERSONAL SAFETY PRECAUTIONS:

1. While performing this assembly, ensure someone is within range of your voice or close enough to come to your aid.

2. When working with lead acid batteries, ensure plenty of fresh water and soap is available nearby in case battery acid contacts skin, clothing or eyes.

3. Wear complete eye protection and clothing protection. Avoid touching eyes while working near batteries.

4. Never smoke or allow a spark or flame in the vicinity of batteries.

5. Be extra cautious to avoid the risk of dropping a metal tool onto a battery.

6. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with batteries.

30 www.pro-team.com 866.888.2168

Battery Termination Schematic

+ – +

Fusible Link

(105842)

Red Jumper

(105844)

– +

–

M

1

M

2

Power Harness

(105834)

Refer to this schematic for removing and replacing of battery wires.

www.pro-team.com 866.888.2168

31

Disassemble/Reassemble GoCart

DISASSEMBLE GOCART

1. Remove Charger Panel (Page 4) 2. Remove Vacuum Panel (Page 8)

3.

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

32 www.pro-team.com 866.888.2168

Remove/Replace Fusible Link

REMOVE FUSIBLE LINK – Please Read Safety Precautions on Page 2

1. Disassemble GoCart (Page 32)

2.

Remove fusible link from batteries using insulated wrenches. See

Safety Notice and Personal Safety Precautions on Page 30.

REPLACE FUSIBLE LINK

1.

On positive terminal of battery B1, and using the red terminal end of the fusible link: a) Place 7/16 bolt through ring of harness and battery terminal.

b) Place 7/16 nut on end of bolt.

c) Tighten assembly with either two

7/16 insulated end wrenches or a torque wrench d) Torque to 25-30 in-lbs.

e) Place protector over the battery terminal.

3. Resassemble GoCart (Page 32)

2.

On negative terminal of battery B2, and using the black terminal end of the fusible link: Follow a) thru e) of

Step 1 in this section.

www.pro-team.com 866.888.2168

33

Remove/Replace Red Jumper Wire

REMOVE RED JUMPER WIRE

1. Disassemble GoCart (Page 32)

2.

Remove red jumper wire from batteries using insulated wrenches.

See Safety Notice and Personal Safety Precautions on Page 30.

REPLACE RED JUMPER WIRE

1

On negative terminal of battery B1, and using the black terminal end of the red jumper harness: Follow a) thru e) on Step 1 of Replace

Fusible Link on Page 33.

2

On positive terminal of battery B3, and using the red terminal end of the red jumper harness: Follow a) thru e) on Step 1 of Replace Fusible

Link on Page 33. If only replacing red jumper, Follow a) thru e) on

Step 1 of Replace Fusible Link on

Page 33.

34 www.pro-team.com 866.888.2168

REMOVE POWER HARNESS

1. Disassemble GoCart (Page 32)

Remove/Replace Power Harness

2.

Remove power harness wire from batteries using insulated wrenches. See Safety Notice and Personal Safety Precautions on Page 30.

REPLACE POWER HARNESS

1.

On negative terminal of battery B2, and using the black terminal end of the power harness follow a) thru e) on Step 1 of Replace

Fusible Link on Page 33.

3. Reassemble GoCart (Page 32)

2.

On positive terminal of battery B2 and using the red terminal end of the power harness follow a) thru e) on Step 1 of

Replace Fusible Link on Page 33.

www.pro-team.com 866.888.2168

35

Replace Batteries/Harness

REPLACE BATTERIES

1. Disassemble GoCart (Page 32)

1.

Remove all wire harnesses from the batteries using insulated wrenches.

See Safety Notice and Personal

Safety Precautions on Page 30.

3. Reassemble GoCart (Page 32)

2.

Place new batteries in cart as shown.

To replace all harnesses follow directions on Page 35.

36 www.pro-team.com 866.888.2168

Remove/Replace Charger

REMOVE CHARGER

1. Remove Charger Panel

(Page 4)

REPLACE CHARGER

2a.

Remove the screws, nuts and washers from existing charger.

2b.

1.

Place new Charger in cutout location on panel.

2.

Position so that the fan vents are toward the handle of the panel. Push screws through holes in panel and charger.

3a.

Place the washer and then the nut/star washer over the screws. Tighten screw to

10 in-lbs.

3b.

www.pro-team.com 866.888.2168

37

Remove Cover of Electrical Enclosure

REMOVE COVER OF ELECTRICAL ENCLOSURE

1. Remove Charger Panel (Page 4)

2.

Remove the 4 screws holding the cover of the electrical enclosure.

3.

Pull open the cover to expose wires and components.

4a.

Remove the black, red and green wires from the receptacle terminals.

4b.

38 www.pro-team.com 866.888.2168

Replace Cover of Electrical Enclosure

REPLACE COVER ONTO ELECTRICAL ENCLOSURE

1 Push crimped end of green, black and red wire from switch onto terminals of receptacle.

2 Using the four screws secure cover to enclosure.

www.pro-team.com 866.888.2168

39

Remove/Replace Charger Receptacle

REMOVE CHARGER RECEPTACLE

1. Remove Charger Panel (Page 4)

2. Remove Cover of Electrical Enclosure (Page 38)

3.

Squeeze together the sides of the receptacle.

REPLACE CHARGER RECEPTACLE

4.

Push through hole while continuing to squeeze sides.

1.

Push new receptacle through the cover of the enclosure.

2. Replace Cover onto Electrical Enclosure (Page 39)

3. Replace Charger Panel (Page 6)

40 www.pro-team.com 866.888.2168

Remove Electrical Box and Connections

REMOVE ELECTRICAL BOX & CONNECTIONS

1. Remove Charger Panel (Page 4)

2. Remove Cover of Electrical Enclosure (Page 38)

3a.

Remove 4 screws, nuts and washers holding electrical enclosure to panel with Phillips screwdriver and 3/8” end wrench.

3b.

4.

Remove black wire with Phillips screwdriver from power receptacle.

5.

Remove red wire with Phillips screwdriver from power receptacle.

www.pro-team.com 866.888.2168

41

REASSEMBLE ELECTRICAL BOX AND CONNECTIONS

1.

Using Phillips screwdriver put bare end of red wire from switch into silver terminal of receptacle.

2.

Using Phillips screwdriver put bare end of black wire from switch into gold terminal of receptacle.

3.

Place enclosure over switch and receptacle.

4.

Place four screws through panel into threaded screw locations in corners.

(Page 39)(Page 6)

42

Place washer and nut/star-washer over end of screw and tighten using screwdriver. Torque to 10 in-lbs.

www.pro-team.com 866.888.2168

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)

4.

Squeeze together sides of switch.

REPLACE POWER SWITCH

5.

While continuing to squeeze, pull switch from hole in panel.

1a.

Push new switch assembly through cut-out in the panel such that the line

(on-state) is closest to the top of the panel.

1b.

If all changes are complete:

2. Reassemble Electrical Box and Connections (Page 42)

3. Replace Cover onto Electrical Enclosure (Page 39)

4. Replace Charger Panel (Page 6) www.pro-team.com 866.888.2168

43

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 ground wire from receptacle.

REPLACE POWER RECEPTACLE

Remove 2 screws holding receptacle to panel and remove receptacle.

1.

Place flanged receptacle in the side panel cut-out, with ground pin down.

Attach with screws.

Tighten to 5 in-lbs.

2.

Using Phillips screwdriver put bare end of green ground wire back into ground terminal of receptacle.

If all changes are complete:

3. Reassemble Electrical Box and Connections (Page 42)

4. Replace Cover onto Electrical Enclosure (Page 39)

5. Replace Charger Panel (Page 6)

44 www.pro-team.com 866.888.2168

REMOVE SWIVEL ELBOW CUFF

Remove/Replace Swivel Elbow Cuff

1.

2.

Place one hand on hose (close to cord strain relief) and one on the elbow cuff.

3a.

Bend down until the cuff is loose from the hose.

REPLACE SWIVEL ELBOW CUFF

3b.

1.

Push the smaller end of new elbow cuff into hose until the textured part of the elbow is against the hose.

www.pro-team.com 866.888.2168

45

Remove Switch in Hose Handle

REMOVE SWITCH

1.

2.

Remove the 8 screws which hold the handle together.

3.

Remove top cover.

4.

Lift up and remove angled tube.

COPPER CONTACTS.

Use pencil eraser to clean away any build up.

5.

Lift out and remove switch and BCM.

46 www.pro-team.com 866.888.2168

REASSEMBLE SWITCH

Reassemble Switch in Hose Handle

1.

Place new switch/BCM in handle.

Place switch with the ON position

( I ) facing the stub tube.

3.

Place BCM such that wires are closest to the switch and not against handle wall.

4.

Ensure stub tube is inserted into angle tube.

Place angled tube into handle.

5.

Confirm copper rings on angled tube are against the metal clips on BCM.

www.pro-team.com 866.888.2168

6.

Replace handle cover.

7.

Tighten 8 screws holding 2 sides of handle together.

47

Stub Tube Replacement

Tools needed: Phillips Head Screw Driver (not included in kit).

1.

Remove eight Phillips screws from hose handle then remove top half of housing.

2.

Remove stub tube from top half of hose handle.

3.

Remove stub tube from plastic adapter by pressing button and sliding apart. Insert NEW stub tube.

Make sure to lock button in place.

2

7

4

5

8

6

1

3

4.

Insert the connected stub tube and plastic adapter into handle.

Align ridge on stub tube with groove in handle.

5.

Make sure copper strips on hose are making contact with the copper relays on the control board.

6.

Replace top half of hose handle and tighten screws. Follow numbered screws above to make tightening easy.

7.

Insert hose handle into upper section of wand. Connect hose handle power plug with the powerhead’s power plug.

48 www.pro-team.com 866.888.2168

Electrical Diagram www.pro-team.com 800.541.1456

49

P.O. Box 7385, Boise, Idaho 83707 • 866.888.2168

www.pro-team.com

#106591 Revised 6/12