Hoover PowerMAX Operating instructions

PowerMAX Canisters
PowerMAX canister models were introduced in 1993
as replacements for Spectrums, which they resemble
in appearance.
ALL PowerMAX canisters have power nozzles.
Nozzle motors are turned on (rug) and off (bare) at the
hose grip.
POWER
VARIABLE
CONTROL
Power nozzles packed with PowerMAX models are all
the style shown at the left with two brush brush roll,
headlight and belt check window,
All nozzles used with the PowerMAX have a belt check
window on the top.
On all models (on/off on unit or hose) the hose must be
plugged into the P.T.O. receptacle of the cleaner
before the canister will operate.
Variable speed motors are in some PowerMAX models.
Motor speed can be varied on the unit on some models
and on the hose on others. See drawings.
ALL POWERMAX models:
•Use Type "S", 7 quart, micro filtration T/A bags (std
"S" bags will work)
• Have reusable secondary filters in the bag cavity to
catch any fine dirt which may get past the T/A bag,
These filters can be washed in warm water.
• Have washable micro filters to clean exhaust air
even more before it is returned to the room. See
drawing.
• Have 25' cords on a cord reel
• Have covered tool storage on the cleaner
• Include a 4 piece tool set
• Have "check bag" indicators
• Have bag lid hinges designed to break away if the
lid is opened too far
4/93

Prominent parts of one PowerMAX model are shown
in the drawing below.
Refer to the Hoover Service Manual for repair proce-
dures and to the Microfiche Parts Catalog -- (dark
brown header) - for spare parts.
REMOTE
CONTROLS
SECONDARY
FILTER
CORD
REEL
TIA MICRO
BAG FILTER MOTOR
POWERON
LIGHT
POWER
ON/OFF
CHECK BAG
INDICATOR
WINDOW
LAMP
BRUSH ROLLER BELT
4/93

SERVICE INSTRUCTIONS
POWERMAX/SPECTRUM/FUTU RA
CLEANERS
Service Dept. 1/96

PowerMAX/Spectrum
AL
!BRAKE
ARM SWITCH
POWER LIGHT
MOTOR
MOTOR RETAINER
SWITCH
MOUNTING PLATE
HEOSTAT
SPEED CONTROL
,SPRING
BAG UD
EXHAUST
FURNITURE
GUARD
EXHAUST RLTER CASSETTE
BAG LID BAG
;AG COLLAR
SEAL RLTER
RETAINER
CORD REEL __
ASSEMBLY COLLAR
SUPPORT
SECONDARY RLTER
RECEPTACLE
ASSEMBLY
CORD
_. HANNEL
COVER
WHEEL
CARRIER
ASSEMBLY

I. General
The Futura, Spectrum and PowerMAX clean-
ers are straight air suction type canisters
designed to work efficiently at 120 Volts, 50
Hertz.
Features include:
Full bag indicators
Tool storage (hinged tool covers on Spectrum
and PowerMAX models)
150 ohose swivel at suction inlet
Seven quart throw away bag - Type S
Cord reels on deluxe models
Power Surge on deluxe Spectrum models
Powered nozzles on deluxe models
II. Basic operation
Futura
On Futura models, an on/off switch on the unit
provides power to the unit and powered
nozzle (where applicable). All models are
single speed.
Spectrum
On top of the line models, both the on/off
switch on the unit and hose must be activated
to power the unit. A rheostat located on either
the unit or the hose controls the motor speed.
Some models have a surge button on the
hand grip to increase the speed of the pow-
ered nozzle motor.
PowerMAX
On top of the line models, both the on/off
switch on the unit and hose must be activated
to power the unit. A rheostat located on either
the unit or the hose controls the motor speed.
Top of the line models incorporate an on/off
switch on the grip that controls the powered
nozzle.
Wiring diagrams are listed in the back of this
instruction.
III, Disassembly
A. Hose Assembly
Futura current carrying: This hose cannot be
disassembled and must be replaced as an
assembly.
• Futura straight air: To remove the hose grip,
use a flat punch to push in on the plastic
bosses on both sides of the grip while pulling
outward on the hose.
HOSE GRIP
To remove the hose connector, grasp and pull
outward while twisting•
HOSE CONNECTOR
Spectrum-PowerMAX hoses: The grip control
panel assm. (Rheostat and rocker switch)
latch, ring, inner tube and connector assm.
can be replaced by disassembling the right
and left hand grip halves.

Current
Hose Assembly INSULATING
SLEEVE
GRIP CONTROL PANEL
ASSEMBLY (Includes
Rocker Switches & Rheostat)
\._RIP- L,H,
RELEASE
LATCH
PLUG
LATCH
HOSE GRIP
(MALE END)
RE'TAINING
RING
,. LATCH
RING
GRIP - R.H. 4NER TUBE
ASSEMBLY
1. Remove retaining ring on end of hose grip.
a. Retaining ring is a bayonet type assembly -
rotate ring counterclockwise and pry off end
of grip.
2. Remove four screws in handle grip.
Note the position of wiring for ease of reas-
sembly.
B. Hose/Hose grip (male end)
The hose grip cannot be disassembled. If the
hose or grip are damaged the hose must be
replaced as an assembly.
The pigtail cord in the grip can be repaired
using a service repair kit.
DESCRIPTION
40300051 Service cord repair kit
2 wire
40300052 Service cord repair kit
3wire
Cleaner assembly
Note: Before making any repair or adjustment,
bag lid and paper bag should be removed.
A. Bag lid
1. Lift bag lid latch and open bag lid.
2. Push lid open past the first detent, lid will
release.
Note: To reattach lid, align hinges with
appropriate slots and push them into main
body.
3. Remove hinges (snap fit - release tab - lift
out).

4. Remove bag lid latch.
a. Release latch spring on indentation in bag
lid and slide latch out (snap fit).
5. Remove full bag indicator.
e. Snap fit - release holding tab on support
rib.
6. Remove bag collar seal.
B. Bag collar support
1. Snaps out -pivot support upward toward
handle.
C. Secondary filter/filter retainer
1. Pull off filter retainer, friction fit, lift out filter.
D. Tool lid (where applicable)
1. Friction fit -lift lid upward and tilt backwards
until lid pops free.
2. Remove cleaning tools.
E. Exhaust (micro) filter (Spectrum/
PowerMAX units)
1. Pull up - slide out.
\
2. Open grid on cassette and remove filter.
F. Motor cover
1. Remove the three mounting screws and lift
off cover (Screws are located in tool cavities.)
2. After the motor cover is removed, note
proper wire locations, then release sufficient
wires to allow easy removal of the cover.
G. Switch
1. Remove motor cover (step 1, item F).
2. Disconnect switch leads (one from crimped
insulator).
3. Remove switch pedal. Note: Remove pedal
carefully to prevent losing the spring.
a. Insert at blade screwdriver between pedal
and housing, on either side near hinge.

b. Pry enough to release hinge while pulling
up carefully on the pedal.
4. Remove switch mounting nut.* Switch then
drops down.
Note: When reinstalling switch be sure to
include switch mounting plate.
* The switch style was changed on PowerMAX
and Futura models in mid-1994. The current
switch is a snap-in design as shown below. To
accommodate the latest switch, the switch
pedal was modified by removing the extended
post that contacts the switch button. Both
switch pedals are available in service and
identified on the microfiche parts list as switch
pedal with post and switch pedal without post.
When changing an old style switch you must
also update the switch pedal or remove the
post on the existing pedal.
SWITCH
OLD NEW
_E_DED POST"
NEW
EXTENDED POST
REMOVED
H. Cord reel pedal/brake arm
BRAKE BRAKEARM
SWITCH
II
•MOUNTING
L.- WIRE CONNECTOR
1. Insert at blade screwdriver between pedal
and housing near the hinge pin nearest the
word cord. (This hinge pin is shorter)
2, Pry enough to release hinge and lift off.
3. Remove brake arm.
a. Lift flap on brake arm upward - release
brake arm body from slot in motor cover -snap
fit.
b, Lift out from top or bottom of motor cover.
I. Power light
1. Remove by pushing upward from beneath
cover.
2. Disconnect leads replace light assembly.

J. Rheostat (Models with rheostat in motor
cover)
1. Remove button on top of motor cover.
2. Release appropriate leads.
3. Release mounting tabs on each end of
rheostat - lift out.
K. Cord reel
The cord reel is replaced as an assembly
only.
1. Remove motor cover (step 1, item F).
2. Disconnect leads.
MOUNTING
SCREW
CORD
FERRELL
3. Push outward on side of main body and lift
cord reel straight up and out.
4. Lay reel aside and remove cord ferrell.
a. Remove mounting screw. (Early models)
b. Grasp back edge of ferrell and pull up and
out.
NOte: The ferrell is carried as part of the cord
reel. When reinstalling ferrell, insert top first
into opening, then push down and into place.
5. Install new cord reel assembly. When
reinstalling cord reel, be sure lead wires are
routed through retainer at bottom of reel. This
is to prevent interference with exhaust filter
frame.
L. Cord (cord reel models)
1. Repeat steps 1,2,3 and 4, section J.
2. Remove preturns on cord reel.
a. Depress brake pad and turn cord reel to
remove preturns. Bracket will turn counter-
clockwise.
3. Unwind the cord from the cord reel.
4. Remove the cord and terminal block.
a. Flex cord reel and slide locating tabs out
of cord reel housing.
b. Unlock the two end tabs and continue to
side the terminal block outward.

5. Removecordand replace.
6. Set cord reelat properpreturns (3).
a. Holdcord reelwith cord reel support
facing upand turncord reel support clock-
wise.
CORD REEL
SUPPORT_
MOTOR
BRUSH CARRIER
BALANCING
RING
FAN COVER
SPRING WASHER
THRUST
WASH:
BRUSH HOLDER
MOTOR
RING
MOTOR
MOUNT
ARMATURE FIELD
COiL
STAR
RING
BRUSH
FAN
M. Motor
1. Remove motor cover (step 1, item F).
2. Remove motor retainer (4 screws).
3. Disconnect the appropriate leads and
remove the motor.
4. Rotate the armature to check for noise or
bearing failure.
5. Remove brush carriers from the motor and
check carbon brushes. Be sure they slide
freely in the holder.
If brushes are worn, replace. Also, check
condition of commutator. If worn, replace
armature.
6. Remove fan cover.
a. Insert a screwdriver in indentations be-
tween fan cover and diffuser and tap with
mallet.

Note: Upon reassembly of the fan cover it
best to line up the fan cover and diffuser and
set motor upright on bench and "tap" around
the perimeter of the diffuser until the fan cover
seats. This will eliminate tapping directly on
the fan cover which could dent and cause the
fan to rub.
7. Remove the fan nut by turning clockwise.
Armature shaft has a screwdriver slot.
8. Remove fan and check for wear at the
hub.
9. Remove two screws which secure upper
motor housing and remove field and arma-
ture.
Note: On some models it will be necessary to
remove the threaded balancing ring on the
top of the motor. This ring was used to bal-
ance the motors in production. It is not neces-
sary to replace this ring upon reassembly of
the motor. Both service and production motors
are now produced without this ring.
Upon reassembly be sure motor mount is
positioned properly.
N. Speed Control (where applicable)
Note: The speed control is an integral part of
the motor cover assembly. This assembly
includes the cover, speed control and required
lead wires.
1. Remove motor cover (step 1, item F).
2. Disconnect the appropriate leads and
remove the motor retainer assembly (4
crews).
3. Replace motor retainer assembly com-
plete.
Note: When reattaching motor retainer be
careful not to pinch furniture guard/seal.
O. Thermal Protector (PowerMAX units)
The Thermal protector is held in position with
a clip located on the rear wall near the motor
exhaust.
Remove clip and disconnect leads at insulated
terminals to remove.
P. Receptacle assembly
1. Remove motor cover (step 1, item F).
2. Disconnect leads.
3. Remove cord channel cover.
a. Remove the one screw, grasp cover at
receptacle end and pull free. Release tabs
from main body, lift up and out.

4. Replacereceptacleassembly.
a. Insertflat blade screwdriverbetween
receptacle andmain bodyand pry upward to
release tabon rearof receptaclefrom main
body.
b. Once tab free, push receptacle downward
until free.
Note: When reinstalling new receptacle
assembly be sure lead wires are firmly in-
serted into slots molded in wiring channel on
main body. This prevents pinching leads and
eases installation of channel cover.
Q. Rear wheels
The rear wheels snap to the main body by
tabs molded into the hub. To remove, tabs
must be pushed inward while pulling out on
the wheel.
R. Power nozzles -Spectrum
See Service Instructions Quadraflex Power-
matic Nozzle
Futura/Spectrum
See Service Instructions Powermatic Nozzle
Late Models.

WIRING DIAGRAMS
Futura
_PrI|TE BLACK
WHITE •_RMINAL
ATTACHMENT
CORD _LUE
MODELS $3509, S3511, S3513, S3515
$3523, $3527, $3533, $3553
ON/OFF
SWITCH__ WHITE
["-_'rt iLACK-.,_
WH.__.J W.UAT.e
TERMINAL
BLUE
AI"rACHMENT
CORD ORANGE MODEL
WHITE MODEL_
(S353S, 83545)
ilNSULATED TERMINAL
FWHrrE
FIELD
COILS
WHITE
RED _
i
WHITE / _eLO';
COLE
WHITE
CORDREEL WHITE
MODELS $3525, S3535,
S3545, S3559
__ INSULATED TERMINAL
.._ BLACK ___HITE
,LOE I!
tL,RE_E.A=E
I
NHfrE
l
!
!
MODELS $3551, $3555, $3557, S3563,
$3S6S, S3567, S3S71, $3573 Z_INBULATED T_RMINAL

WHITE-_
TERMINA
PURP_._
iREEl
BLACK"j
O O__!.!.!.!.!.!.!._-FF ° WHITE
BLACK --_
SWITCH ARMATURE
P INSULATED -_
TERMINAL
ORANGE _
WHITE_
WIRING DIAGRAMS
Spectrum
INSULATED TERMINAL
/WHITE
r RECEPTACLE -
r_,-_ TERMINAL _
REID
-COIL
WHITE
_ INSULATED TERMINAL
MODEL $3575
MODELS $3585, $3595
WH_-_
CORD
P°R:
eLACK--_"
CONN.=On\ I
--o---'-o WHiTe "_
ON/OI_
SWITCH WHITE
YELLOW.
SPEED C,_ONTRO_
-"-- INSULATED
TERMINAL
BLACK -d
ARMATURE ---'_
ORANGE "_.
ORANGE*
INSULATED TERMINAL
rWNn-_
RECEPTAC
I,,,
RNEO- _-'t _/
INSULATI[D
TERM_N. I
_- TERMINI _L
INDICATOR
BLACK _-CONNECTOR
INSULATED TERMINAL
REEL
PURPLE.
SPEEI
MODEL S3605
ORANGE. CONNECTOR
BLACK
INSULATED TERMINAL

WIRING DIAGRAMS
PowerMAX
INSULATED TERMINAL
WHITE
INSULATED
TERMINAL
_RMJNAL"7
PURPLE/RE_
WIDE F't.J_m_-F
BLADE'-' !\ v
:;::ix
WHITE WHITE
ON)OFF BLACK
SWITCH
3L_CK
TERMINAL
WHITE
MODELS 3603, S3603-040
CONNECTOj_!
ON/OFF
WH]T
INSULATED.
TERMINAE-
TERMINAL-/
PURPLE/RE_
WIDE j-t_ELj,'--
._DE- I\--
WHITE"J \
TERMINAL .J
SWITCH WHITE
INSULATED.-._
TERMINAL (
WHITE
_.- INSULATED TERMINAL
MODELS S3611, $3615

HOSE WIRING DIAGRAM
Spectrum
S3605
INSULATEO
TERHINAL_--_
WHITE-_
--SWTTCH
CONNECT_
S3595
S3585

HOSE WIRING DIAGRAM
PowerMAX
S3603, S3603-040
~RED
YELLO_V
S3609
$3611, S3615

IV. Troubleshooting check list - Futura
This model is designed to operate at 120 Volts, 60 Hertz only. Operating characteristics and
electrical checks may vary if input voltage differs appreciably from the 120 VAC specified.
The following is provided as a guide to aid in determining the origin of a problem for which this
model could require service. If problems do occur, especially related to poor performance or
intermittent operation of the motor, conventional causes should be examined prior to changing
electronic and other related components.
Problem
A. Motor won't
run
B. Motor runs,
cleaner
won't pick-
up
C. Bags
bursting
D. Cord won't
rewind (cord
reel models)
Possible Cause Possible Solution
,
2.
3.
4.
5.
6.
7.
Not plugged in firmly.
No voltage in wall plug due to
blown or tripped breaker.
Open in power cord.
Cord reel contacts worn (cord reel
models).
On/off switch failed.
Open circuit in motor.
Open circuit or wire not con-
nected.
1. Check to see that attachment cord prongs are
in good shape and not bent.
2. Check fuse or reset breaker.
3. Replace cord.
4. Replace cord reel assembly.
5. Replace switch.
6. Check motor wiring, armature, field, and brush
carrier assembly.
7. Replace wires or remake connections
as necessary. Check for stuck motor brushes.
1. Obstruction in hose.
2. Bag full.
3. Secondary filter clogged.
4. Poor seal between bag lid and
main body.
5. Fan loose on motor shaft.
1. Remove obstruction.
2. Install new bag and advise customer.
3. Clean filter.
4. Check furniture guard warping, or
obstructions which would prevent a good fit.
5. Replace fan, if necessary, and tighten fan nut
securely.
1. Bag pores clogged, fine dirt,
powder, etc. 1. Change bag, advise customer to change bag frequently when picking up fine
dirt.
1. Cord reel lost preturns.
2. Cord reel brake arm out of
position.
1. Readjust at three preturns.
2. Checkand reposition.

V. Troubleshooting check list - Spectrum/PowerMAX
This section is intended as a guide to help further diagnose a possible problem related to the
electrical system in Spectrum/PowerMAX models that have a power light, rheostat, and speed
control.
Problem Possible Cause
A, Motor 1, Hose not connected.
won't run 2. Speed control failed.
B. Motor runs
in high
speed -
shuts off in
low speed
C. Power
nozzle runs,
cleaner motor
doesn't
(Modal S3585
only)
D. Units runs, 1.
power nozzle
doesn't
(models
$3595, S3605
only)
E. Power nozzle 1.
won't run.
(PowerMAX)
Possible Solution
1. Connect hose and check operation.
3. Power takeoff bad or leads not
connected properly.
4. On/off switch on hose bad.
5. Thermal protector failed (PMAX)
2, Replace motor retainer assembly, The speed
control is incorporated in this assembly. The
yellow lead on the replacement speed control
incorporates a resistor, Remove the entire
yellow lead back to the insulated terminal
when removing the old motor retainer
assembly.
3, Remake connections and/or replace
power takeoff.
4. Replace switch.
5. Replace,
1. Failed speed control resistor
(yellow lead).
2. Bad rheostat.
1. Replace motor retainer assembly.
Note: Motor cover, speed control, and
resistor replaced as an assembly.
2. Replace rheostat.
1. On/off switch on hose bad. 1. Replace switch.
Switch on hose bad. 1. Replace switch.
Switch on hose bad. 1. Replace switch.

Troubleshooting Guide
Spectrum & Powermax Canister Cleaners