Aircare DuctMaster III FG0090 Instructions for use

DuctMaster III
(Optional: Available in 220/240 Volt, 50/60 Hz Power)
OPERATING INSTRUCTIONS & PARTS MANUAL
Part Number: FG0090
MM0151
Updated 07/12/2011
Page 1 of 26
Air-Care is a Division of D.P.L. Enterprises, Inc.
3868 E. Post Road, Las Vegas, NV 89120 [phone], Fax [phone]
Website: www.air-care.com, E-mail: [email protected]

Page 2 of 26
Table of Contents
Item Page #
Unpacking Instructions 3
Safety Precautions 4
Operating Instructions 5
How to Connect the Air-Care DuctMaster 6
Duct Cleaning Procedures Using the Air-Care DuctMaster 7
Dryer Duct Cleaning Procedures Using the Air-Care DuctMaster 8
Maintenance 10
Brush Motor Replacement Instructions 11
Included Parts and Accessories 13
DuctMaster Control Panel 16
Optional/Replacement Parts & Accessories 17
Specifications 18
Changing Pancake-Style Brush Bristles 19
Troubleshooting Guide 22
Glossary 24
Warranty 25

Page 3 of 26
Unpacking Instructions
Remove the outer box and inspect for damage. Report all damage immediately to your carrier. If
special set-up instructions are required, they will be taped to the outside of the equipment or in the
“Operating” section of this manual.
Inspect all of the packing material for small parts before discarding packaging material. Report all
damage to Air-Care immediately. Any attempt at repairing suspected damages may void warranty.
Check that all parts are present (See Page 13-15)
Air-Care DuctMaster
Air-Care DuctMaster III
Dryer Exhaust Flap Clip
3” x 4” x 3” “Y” Adapter
Hose, 3” x 12.5’ W/Cuffs
Dual Stage 20 Gal. Bag Filter (5/pkg.)
3
rd Stage 13” x 15” x 1” Electra Gold
4
th Stage HEPA, 14” x 18” x 3”
Inlet Plug, 3” Red (Dust Cap for Vacuum)
Adapter, 3” to 1 ½” or 3” to 2” Hose Cuff
Brush, 24” Lint
Kit, 1 ½” Tool
oMesh Carrying Bag
oExtension (2 pcs)
oCrevice Tool
oFloor Tool (14”)
oBulk Pickup Tool
oUpholstery Tool
oElbow
oHose, 1.5” X 15’
oEnlarger, 1.5”-2”
Hose, 1 ½” X 35’ Brush and Motor Assembly. Includes 12” Pancake-Style Brush
Drill Powered Dryer Duct Cable (20 ft) with 4” Brush
Remote Control

Page 4 of 26
Safety Precautions
Always use safe and common sense precautions when working with Air-Care equipment. Do not
block walkways with equipment, and remove delicate and breakable articles from the immediate work
area. The following are precautions that should be reviewed by all persons who will be involved in
the cleaning activity.
Other than the 3 filters and the brush there are no user serviceable components in Air-Care
TurboJets and Air-Care DuctMaster. Only trained technicians should attempt to make internal
repairs on this equipment.
Always unplug both power cords before removing the covers or working on the wiring.
Inspect AC power plugs to be sure the ground pins are in place.
Never connect power to Air-Care equipment unless all covers and safety shields are in place.
Mechanical and electrical parts could activate and cause injury.
Never allow anyone but a properly trained technician to use the equipment or cleaning products.
All Air-Care equipment is designed for US standard 115 volt, 60 Hz AC. The Air-Care DuctMaster
is optionally available in 220/240 Volt, 50/60 Hz Power. Always check the specifications on the
equipment before connecting electrical power to Air-Care Equipment.
If you have questions about the safe use of any Air-Care product, call 702-454-5515.
Equipment specifications and part numbers are subject to change without notice.

Page 5 of 26
Operating Instructions
Set-Up and Testing
The Air-Care DuctMaster combines the high powered vacuum with a hose and brush assembly to
both agitate and collect debris at the same time. Once completely set up, with the vacuum motors
running, the brush end can then be inserted into each duct and the brush motor started for thorough
cleaning.
The Air-Care DuctMaster has significantly MORE static pressure than Air-Care TurboJet Negative Air
Machines and will be able to pull heavy, moist or sandy construction debris out of dryer vents,
commercial ducts, chimneys, and restoration areas. It is NOT meant to be a wet vacuum for liquids.
To test an Air-Care DuctMaster, plug one of the power cords into a suitable 120-volt outlet. Line #1
will supply power to VAC1 and VAC2 and the Brush Motor, while Line #2 will provide power to VAC3
and VAC4. If all 4 VAC Motors are to be used at one time, Line 1 and Line 2 must be plugged into 2
independent power outlets rated at 15 Amps each or more. If you are not sure if 2 outlets are
independent, press the center “test” button; the green power light will only light up if the 2 power
cords are in independent power outlets. In some areas there may be independent lines, but the green
light may not light up – This is true in Canada.
The optional 220/240 Volt Air-Care DuctMaster also requires 2 independent electrical outlets; each
must be 7.5 to 10 amps. This version does not come with a “test” button and green power light.
WARNING: DO NOT TURN ON MORE THAN 2 VAC MOTORS BEFORE PERFORMING THE
‘TEST’, WHICH WILL INDICATE A GREEN LIGHT IF PLUGGED INTO TWO INDEPENDENT
OUTLETS. IF THE EQUIPMENT IS NOT PLUGGED INTO INDEPENDENT OUTLETS BEFORE
TURNING ON MORE THAN 2 VAC MOTORS, A POWER SURGE MAY OCCUR AND TRIP A
CIRCUIT BREAKER IN THE BUILDING.
Because of a unique full flow check valve system, any combination of motors can be used. Any one
motor can be used by itself or any 2 or 3 can be used with the same airflow and static pressure (water
lift). The Remote and the Power Brush operate from Power Cord #1, so even if you are only using
Vac Motor #3 or #4 that use Power Cord #2, both power cords must be plugged in for the brush to
operate.
One motor will provide more airflow than most single motor shop or HEPA vacuums, and two motors
will usually be more than adequate for most vacuuming needs. In those cases where extra power is
required, simply plug in the 2nd power cord and turn on the 3rd or 4th motor as required.

Page 6 of 26
How to Connect the
Air-Care DuctMaster
The Air-Care DuctMaster is an extremely powerful and versatile tool. The 3” vacuum hose is ideal for
collecting construction debris without clogging and can be directly inserted into a 4” air or dryer duct.
It can also be used with the “Y” adapter paired up with an agitation tool, such as the Air Whisk or 20’
drill driven cable to be inserted at the same location. When connecting to a dryer duct, it is important
to clip the outside flap open for proper cleaning.
For collecting debris in a variety of situations, a set of 1 ½” diameter tools is supplied. See pages 3
and 13 for a list of these tools.
The Air-Care DuctMaster’s high volume and high static “water lift” make it even more effective at
removing debris from smaller diameter air ducts than many other standard duct vacuums.
Air-Care has self-study and classroom and field training on how to clean all types of air systems, call
800-322-9919 for details.

Duct Cleaning with the
Air-Care DuctMaster
The Air-Care DuctMaster has a unique dual function. The rotating brush of the hose assembly
agitates the dust and debris in the air duct, while the vacuum motors function as the debris collector.
This method of cleaning only requires that the supply and return grills be removed and the air system
turned off.
After connecting the Air-Care DuctMaster power cords to 2 separate power outlets (different circuits),
connect the 1 ½” X 35’ brush and motor hose assembly or the optional 2” X 35’ brush and motor hose
assembly to the 3” to 2” hose adapter that you placed in the inlet of the Air-Care DuctMaster.
Use the vacuum motor switches on the panel to select the motors you want to use to vacuum the
ducts: 1 to 4 motors can be used. The motors can be turned on and off with these switches. This
arrangement allows the technician to run the motors even if the remote is lost or broken.
The Remote uses an Infrared Light beam
similar to a Television Remote. The
operator must be in sight of the front of the
DuctMaster where the Remote Receivers
are located for it to operate. The operator
can be across the room or up on a ladder
and the remote will function as long as
there are no obstructions between the
operator and the sensor on the DuctMaster
Panel. The remote will NOT work between
rooms.
Once the technician inserts the brush into
the duct, use the wireless remote control to
turn on the brush motors (top button). Cleaning Floor Ducts
When the technician cannot push the vacuum hose in any farther, press
the FWD/REV button (bottom button) on the wireless remote to “reverse”
the brush rotation to allow it to go deeper into the ducts. Repeat this
process for every supply and return duct.
Where you have long ducts, such as main trunk lines without access
doors, you will have to make “cut-ins”, so that you can access the entire
length of the duct. The larger “main duct” can also be cleaned with the
Air-Care DuctMaster.
After cleaning each duct, each opening should then be decontaminated
with our EPA registered sanitizer, Soot Set sealer and Liquid Odor Kill
deodorizer.
Cleaning Ceiling Vents
Page 7 of 26

Dryer Duct Cleaning with the
Air-Care DuctMaster
YOU WILL NEED: Air-Care DuctMaster and the drill powered dryer duct cable with 4” dryer duct
brush (Included with DuctMaster).
Dryer exhaust ducts vary in construction, materials and configuration from city to city. The general
procedure for using the drill powered dryer duct cable described here may need to be modified to
safely and effectively clean these ducts in your area. An alternate tool to the drill powered cable is
the Forward and Reverse Air Whisk, which requires an air compressor.
CAUTION: Cleaning the exhaust duct on a clothes dryer will improve performance and reduce future
lint build up, but the dryer itself must also be cleaned and lint removed from its fan, heating area and
other interior components to reduce the risk of fire.
1. With the dryer running, clip the outside flap “OPEN” and check the airflow at the exhaust with a
flow meter. Write down the reading for comparison after cleaning.
Caution: If you cannot locate where the air exhausts outside then you cannot guarantee your
work and probably should not try to clean it. Refer the customer to their contractor.
2. Turn off the dryer, remove power, then move it away from the wall and disconnect the exhaust
tubing. If it is a gas dryer, be careful to not damage or break the gas line.
3. Attach the 3” diameter DuctMaster vacuum hose to
the end of the exhaust duct (inside or outside,
depending on configuration).
4. Use 20’ drill powered dryer duct cable with 4” dryer
duct brush.
5. Insert the drive end of the cable into the chuck of
your Electric Drill. A low speed (300-500RPM), 3/8”:
chuck is best suited.
6. Place the drill in the Air-Care drill holder and secure
with the included straps. Plug the drill into the foot
pedal switch and plug the pedal cord into the wall.
The pedal leaves both hands free.
7. Turn on the vacuum motors in the Air-Care
DuctMaster then insert the 4” brush into the dryer
vent. Start the drill using the foot pedal only AFTER
the brush has been inserted into the duct.
8. If you experience resistance to the brush, the cable may “Twist Up” on you. If so, STOP the
drill. Try reversing the rotation and go slowly until you get past the restriction.
9. A slow steady insertion is ideal, but you may need to pull the cable out a few inches and push
it rapidly back to get around some obstructions and elbows.
10.If the cable cannot be pushed all the way to the end of the duct, it may be necessary to also
insert the cable and brush from the other end of the duct.
11.If there is visible lint clog or bird nest, the Nest Claw tool may be needed to break it up. Attach
the nest claw tool to the cable with a setscrew, which is the same way the 4” dryer duct brush
attaches. CAUTION: The Nest Claw can be very aggressive and may damage flexible ducts.
12.If you only have access to one end of the exhaust duct, use the “Y” adapter to allow the
vacuum and the cable to be inserted from the same end of the exhaust duct.
Page 8 of 26

13.Once the duct has been cleaned, the dryer should also be cleaned.
14.Remove the back cover of the dryer and clean out the lint on the internal components. Usually
4-8 screws are used to mount the back cover. Access to the interior of the dryer will vary with
model, be careful to not damage it.
15.Once the duct and dryer are clean, connect the dryer to the wall opening with aluminum hose.
(The Consumer Product Safety Commission does NOT recommend plastic connector hoses,
nor does any major dryer manufacturer).
16.Turn the dryer on and again check the airflow outside. Typically over 1000 fpm (feet per
minute) (1000 fpm = 5 mps [meters per second]) is good, and less than 1000 fpm is not.
Continue cleaning until you have reached airflow over 1000 fpm. If 1,000 fpm cannot be
obtained, the duct may be damaged and require a contractor to correct the problem
17.Clean up any lint around the outside of the dryer, clean the exterior of the dryer and if you have
a sticker or magnet, date it for a follow-up cleaning in 12 months.
Using Air-Care DuctMaster to Clean Dryer Duct
Page 9 of 26

Page 10 of 26
Maintenance
The Air-Care DuctMaster requires a minimum amount of maintenance, normally limited to cleaning or
replacing filters as they become filled with dirt and debris. It is always beneficial to keep the exterior
and interior of the machine clean. A qualified technician should perform all electrical or mechanical
repairs. The brush head motor should be wiped off and metal particles captured by the magnets in
the motor should be removed with compressed air or a brush. The Batteries in the Remote should be
changed annually.
Filter Removal & Replacement
1. Turn off all the VAC motors, and unplug the Air-Care DuctMaster.
2. Open the front door and remove the bag from its 3” tube at the rear of the door.
3. Carefully remove the bag filter through the door and dispose of it properly in accordance with
any local state or federal regulations applicable.
4. If there is noticeable debris build up on the electra silver pre-filter above the HEPA filter, push it
to the rear and lift it off and clean it. It can be rinsed with water or sprayed with Dynamite
cleaner and rinsed, but it must be DRY before reinstalling it onto the HEPA canister filter.
5. To remove the HEPA, release the top latch and both side latches and lift the vacuum tank off
the base.
6. Lift the HEPA out and inspect it for damage or clogging. Inspect the gasket under the HEPA.
7. Install a new HEPA filter, by placing it into the base with the airflow arrow pointing down.
8. Install a new dual stage bag filter following the instructions on the bag. It collects heavy debris
in the bottom section of the bag and lighter debris in the top section.

Brush Motor Replacement Kit for
DuctMaster and TruckMaster
Updated Coaxial Spring Mount
This new version of the Brush Motor and Mount retains all the advantages of the original and includes
some improvements to reliability, durability, and Debris Collection.
This motor and Hose mount will replace all previous motors and mounts.
KEEP THE NEW MOTOR FULLY ASSEMBLED!
First remove the OLD motor and mount from your hose:
1. Remove the screws holding the metal collar on the end of the hose and save the screws and
nuts to mount the new motor and mount.
2. Cut the 3 wires for the motor leaving enough cord to crimp (or solder) the wires to the new
motor wires. All 3 wires will need to be the same length for this new Motor Connection.
3. You will no longer need any of the parts in the original motor assembly unless you are
returning it to Air-Care with an RMA for warranty evaluation.
Installing the NEW Motor Assembly.
1. Be sure you have all the parts for the installation.
a. Your original Screws, 10-32 x 5/8” long machine screws,
b. 10-32 Hex Nuts with built in Lock Washers.
2. Remove the outer insulation from the black power cord in the hose to expose the 3
insulated motor wires about 2 inches long.
3. Strip the insulation off of all 3 wires about ½” back from the ends.
4. Slide the black Shrink Tubing over the cable. It will be slid over the new connections after
the wires are connected.
5. Slide the 3 pieces of shrink tubing over each of the motor wires. The connections can be
made by Crimping the new connectors or soldering them. If you are planning to solder the
connections, be sure the blue shrink tubing is far enough away from the heated ends to
prevent it from shrinking prematurely.
6. The wires may be different colors from the Motor than the ones from the hose cable. The
order is not important, the brush will operate with any combination of wires, but it may turn
in the opposite direction in some cases, but will still reverse as before.
7. Each of the 3 wires from the hose can now be inserted into the Crimp connectors on the
new motor. Try to twist the wires tight enough so that all of the strands go into the silver
Page 11 of 26

Page 12 of 26
8. Slide the Blue shrink tubing over the metal connector; Heat the tubing to shrink it in place.
A hair dryer, heat gun or even a cigarette lighter can be used. Be careful to not burn
yourself, the plastic hose or heat the other shrink tubing at this time.
9. Connect the other 2 wires following the same procedure.
10.When all 3 wires are connected and insulated, slide the black shrink tubing over them and
as far towards the motor as possible. Heat this shrink tubing to shrink it on to the wires.
11.Next, slip the Nylon Loop Strap over the wires. This will guide the wires. The Loop Strap
will be held in place with one of the 10-32 x 5/8” screws used to hold the black nozzle on
the hose.
12.Insert the screws into the mounting holes in the Nozzle and thread the screws into the
original holes in the hose if possible. If this is difficult, you may need to drill new holes in
the hose using the 2 holes in the Black Nozzle as a guide. Use a 3/16” diameter drill.
13.When the screws are in place, place the loop strap hole over one of the screws and install
one of the nuts then tighten the screw with a screwdriver. It may be necessary to use a
screw driver to thread the screws through the loop strap.
14.If your hose has a metal stiffener, install its loop over the other screw, install the nut and
tighten it. If there is no stiffener, just install the nut and tighten the screws.
15.Your repair and upgrade is now complete and ready to test. If you have any questions,
please call Air-Care Tech Support, 800-322-9919.

Page 13 of 26
Included Parts and Accessories for
Air-Care DuctMaster
See Pictures on Following 2 Pages
Ref # Description Part #
1 Dryer Exhaust Flap Clip COM0196
2 3” x 4” x 3” “Y” Adapter SADM0055
4 Hose, 3" x 12.5’ w/ Cuffs SADM0046
5 Dual Stage 20 Gal. Bag Filter (5/pkg.) SADM0021
6 3rd Stage 13 x 15 x 1 Electra Silver SADM0024
7 4th Stage HEPA, 14 x 18 x 3 F0048
8 Inlet Plug, 3” (Dust Cap for Vacuum) COM0223
9 Adapter, 3” to 1 ½” or 3” to 2” Vacuum Hose ACC0012
10 Brush, 24” Lint COM0202
11 Kit, 1.5” Tool (11a through 11i) SADM0057
A. Mesh Carrying Bag FG0101
B. Floor Tool, 14” wide ACC0161
C. Bulk Pickup Tool ACC0160
D. Upholstery Brush ACC0162
E. Elbow ACC0163
F. Crevice Tool ACC0159
G. Extension (2 pcs) ACC0158
H. 15 Foot Hose ACC0152
I. Enlarger – 1.5” to 2” COMP0303
12 Hand Held IR Remote Controller SADM0028
13 Hose (Red), 1 ½” X 35’ DuctMaster Brush and Motor Assembly. Includes:
12” DuctMaster Brush, .021” Bristles FG0074
14 Cable, 20’ Drill Powered Dryer Duct with 4" Dryer Brush FG0090
Not
Shown Air-Care DuctMaster Training DVD SAO0040
Not
Shown Air-Care DuctMaster Dryer Duct Cleaning DVD SAO0039

Included Parts and Accessories
for Air-Care DuctMaster
(Ref#) Listed on Previous Page
(
Ref #2
)
3” x 4” x 3” Y Ada
p
te
r
(Ref #1) Vent Flap Clip
(Ref #6) 3r
d
Stage Silver,
Electrostatic Air Filter
(
Ref #4
)
Hose
,
3” x 12.5’ with Cuffs
(
Ref # 10
)
Brush
,
24” Lint
(Ref #5) Dual Stage 20 Gal.
Bag Filter (5/pkg.)
(
Ref #7
)
4
th
Sta
g
e HEPA
,
14 x 18 x 3
(Ref #8) 3” Inlet Plug
Page 14 of 26
(Ref #9) Adapter, 3” to 1 ½”
or 3” to 2” Hose Cuff

Included Parts and Accessories for
Air-Care DuctMaster (Continued)
(
Ref #11
)
Kit
,
1.5” Tool
(
11a throu
g
h 11i
)
(Ref #13) Hose (Red), 1 ½” x 35’ DuctMaster Brush
and Motor Assembly. Includes Brush Below.
(Ref #26) Brush, 12” DuctMaster, 021” BLK Bristles
(Ref #14) Cable, 20’ Drill Powered Dryer Duct
W/4” Brush
(Ref #25) 4” Dryer Duct Brush
(
Ref #12
)
Handheld IR Remote
Page 15 of 26

Air-Care DuctMaster Control Panel
1
,
2
,
3
,
& 4 Vac Motor Switches
Green “Test” Indicator Light- Indicates That
Both Power Cords are in Independent
Power Outlets
“Test” Switch for Green Indicator Light
(Not included on 220/240Volt, 50/60 Hz)
Power Brush Override Switch FWD/REV Brush Switch
Power Cords
(Not included on 220/240Volt, 50/60 Hz)
(Ref#16) 12” Non-Marking Wheels
(Ref#18) Front Swivel Caster Wheel
Motors are Mounted in “L” Unit For
Easy Access
Exhaust Grill
Hose, 1 ½” X 35’ DuctMaster Brush
and Motor Assembly. Includes: 12”
Pancake-Style Brush, .021” Level
Bristles
Page 16 of 26

Optional/Replacement Parts and Accessories
(Re rf #21) Air Care Fogge
Model 2600
Page 17 of 26
(Ref #24) Hose, 2" X 35' DuctMaster Brush and
Motor Assembly: Includes: 18” Pancake Brush
(Ref #27) Brush, 18” DuctMaster, .032” BLK
Bristles
(Ref #19) Coupler, 3" Hose to 3"
Hose, Black (Hose not included)
Ref # Description Part #
Air-Care DuctMaster, Complete Assembly FG0090
Air-Care DuctMaster, 220/240 Volt, 50/60 Hz, Complete Assembly FG0099
16 Wheels, 12” Non-Marking ACC0006
Not
Shown Vacuum Motors (4), 120 Volt, 7 AMP High Volume
Vacuum Motors (4) 220/240 Volt 50/60 Hz, 3.5 AMP High Volume SADM0017 SADM0018
18 Wheel, Front Swivel Caster COM0096
19 Coupler, 3" Hose to 3" Hose ACC0009
21 Air-Care Fogger 1.2M Hose FG0008
24 Hose (Blue), 2” X 35’ DuctMaster Brush and Motor Assembly. Includes 18”
DuctMaster Brush, .032” Bristles FG0075
25 4” Dryer Duct Brush FG0072
26 Brush, 12” Pancake-Style, .021” Level Bristles SAO0307
27 Brush, 18” DuctMaster, .032” Level Bristles, BLK SADM0013
Not
Shown Bristles, 12” Pancake-Style, .021” Level Bristles set (3 bundles for 1
change), BLK SAO0310
Not
Shown Bristles, 18” DuctMaster, .032” Level, BLK BA0003
Not
Shown Connector Housing for Brush Motor COM0163
Not
Shown Connector Pins, Female for Brush Motor (3 Required) EC0046
Not
Shown Kit, Power and Control Modules (Call for individual part information as built
into the Air-Care DuctMaster version) SADM0056

Specifications
Specification Description
Size 21” W x 36” D x 40” H
Weight 94 lbs
Power requirements:
115 Volt AC, 60Hz, 14 AMPS x 2
(Optional: 220/240 Volt, 50/60 Hz, 8 AMPS x 2)
Power Brush draws 2 AMPS for 115 Volt and 1 AMP for
220/240 Volt
Power Cords (qty 2) Attached
Filtration 4 stages HEPA
1st and 2nd Stage 20 Gallon Dual Stage Bag
3rd Stage 13” x 15” x 1” Electra Silver
4th Stage 14” x 18” x 3” HEPA Filter
Hose Attachments
Hose, 1 ½” X 35’ DuctMaster Brush and Motor Assembly.
Includes: 12” Pancake-Style Brush, .021” BLK Bristles
Power Brush RPM is 2,000 max. with 1500 Watt Brushless DC
Motor
3” x 12.5’ Hose with Cuffs
Operating Environment 25 to 125 Deg F (-4 to 50Deg C)
Construction Rotation Molded Poly Body
Operating Controls,
DuctMaster
4 Individual VAC Motor Switches
“Independent Circuit” Indicator Light
(Not included with 220/240 Volt, 20/50 Hz version)
ON/OFF Brush Switch
Fwd/Rev Brush Switch
IR Remote Control
Air Flow 120-500 CFM
Static Pressure 75 Inches W.G.
Motors 7 AMP Integrated Motor for each Blower (4)
(4 AMP @ 240 Volts on 220/240 Volt, 50/60 Hz version)
Blowers Single Stage, Tapered Blade, Low Noise, High Efficiency Vacuum
Wheels (4)
Wheels 12” Fixed Rear and 4” Front Swivel Non-Marking Wheels
All Prices and Specifications are subject to change without notice
Page 18 of 26

Pancake-Style Brush P/N SAO0307
12” Bristle Replacement Instructions
Updated: 9/10/12
The configuration of the 12” brush (0.021 Dia
Bristles) for the TruckMaster and DuctMaster 1.5”
vacuum hose and Motor has been changed to a
Shorter, “Pancake-Style” hub that allows it to
negotiate sharp turns in smaller air ducts than the
previous type hub. This 12” Brush directly replaces
the original 12” Brush asm.
Page 19 of 26
The 2” Vacuum Hose and motor still use the 18”
brush with 0.032” dia Bristles in the traditional,
longer hub.
This 12” Brush will work on the 2” hose.
While the 18” Brush will fit on the 1.5” hose, there
are some situations where the 18” brush may not
start properly (Due to the brush being held HIGHER by the 2” hose, so the thicker bristles are easier
for the motor to turn it).
Description P/N Quantity
Hub, Pancake-Style, Top SAO0287 1
Hub, Pancake-Style Cover (Bottom) SAO0288 1
Screws, 6-32 x 3/8” L Flat Head Phillips SS NBS0045 3
Set Screw, 8-32 x ½” NBS0152 1
Bristle bundle, 12” Long, 0.021” dia, Level SAO0306 .03 Hank (.3 to .4 oz)
Bristle Replacement set (3 Bundles) SAO0310 3
Bristles, Master Hank CB0001 1 Hank
Shrink Tubing, ¼” SHOP0011 1.4 Inch (0.12 Ft)
Rubber Band (#19) COM0328 1
Allen Key (Wrench) 5/64” L Shape Not Included
Instructions to Change Bristles COM0327 1
The new Pancake-Style Brush hub bristles are replaceable, but the process is different and the
replacement bristles are pre-assembled into 3 bundles that are retained with ¼” shrink tubing that is
bent to match the shape of the grooves in the Pancake-Style Hub.
Each of these bundles should weigh between 0.3 ounces and 0.4 ounces and contain between 115
and 124 individual bristles that are 0.021” diameter by 12 inches long. The Bristles will be slipped
into a piece of ¼” heat-shrink Tubing (Before it is heated) P/N SHOP0011.

Installing Bristles into the Pancake-Style Brush (SAO0307)
1. Be sure all parts are available to assemble the 12” Pancake-Style brush. See List at top.
2. Layout the Pancake-Style Brush Hub “TOP” piece with the 3 deep grooves facing up.
3. Install the pre-formed bundle of bristles (SAO0306) into one of
the grooves as shown. It must be centered with the Shrink
Tubing NOT extending out of the groove.
4. Install the Second and third bundles of bristles and push them
deep into the groove. None of the bristles can be allowed to be
out of the groove when the assembly is complete.
5. Place the Bottom of the Pancake-Style Hub over the bristles in
the Grooves of the top of the Hub, and turn it over so the 3
screws can be installed.
Page 20 of 26