Maytag M500 User manual

Ultra Light Weight Vacuum
Service Manual
M500
Revision: 1.0
Issued: 11/11/2014

Page 2
Table of Contents
I. Basic Assembly and Operation
A. Parts Identication ..................................................................................................................................4
B. Grounding Instructions ............................................................................................................................5
C. General Performance ...............................................................................................................................5
D. Installing the Handle ...............................................................................................................................6
E. Operation
On/Off Switch .........................................................................................................................................7
Circuit Breaker ........................................................................................................................................8
II. Maintenance
A. How to Change the Vacuum Bag ............................................................................................................9
B. Replacing the Belt .................................................................................................................................10
C. Agitator Maintenance ...................................................................................................................... 11-12
D. Replacing the Agitator ..........................................................................................................................13
E. Replacing the Squeegee .........................................................................................................................14
F. Replacing the Wheels .............................................................................................................................15
G. Replacing the Foot Pedal .....................................................................................................................16
H. Removing Nozzle Cover .......................................................................................................................17
I. Removing the Hard Shell Bag ...............................................................................................................18
J. Removing the Handle Duct ....................................................................................................................19
K. Removing Clogs ...................................................................................................................................20
L. Replacing the Switch .............................................................................................................................21
M. Replacing the Power Cord ............................................................................................................. 22-23
N. Replacing the Motor Cord .............................................................................................................. 24-26
O. Replacing the Circuit Breaker ...............................................................................................................27
P. Replacing the PC Board ........................................................................................................................28
Q. Replacing the Motor Fan ................................................................................................................. 29-30
R. Replacing the Motor ..............................................................................................................................31
III. Troubleshooting
A. Performance .................................................................................................................................... 32-33
B. Motor .....................................................................................................................................................33
C. Electrical ............................................................................................................................................... 34
IV. Diagrams
A. Wiring ....................................................................................................................................................35
V. Contact Information ............................................................................................................................36

Page 3
WARNING! To reduce the risk of re, electric shock, or injury:
1. Do not leave vacuum unattended when plugged in. Unplug from outlet when not in use
and before servicing.
2. Do not attempt to service the unit while vacuum is plugged in.
3. WARNING: ELECTRIC SHOCK COULD OCCUR IF USED OUTDOORS OR ON WET
SURFACES.
4. Do not allow to be used as a toy. Close attention is necessary when used by or near
children.
5. Use only as described in this manual. Use only manufacturer’s recommended
attachments.
6. Do not use with damaged cord or plug. If vacuum is not working as it should, has been
dropped, damaged, left outdoors, or dropped into water, return it to a service center.
7. Do not pull or carry by cord, use cord as a handle, close a door on cord, or pull cord
around sharp edges or corners. Do not run vacuum over cord. Keep cord away from
heated surfaces.
8. Do not unplug by pulling on cord. To unplug, grasp the plug, not the cord.
9. Do not handle plug or vacuum with wet hands.
10. Turn off all controls before unplugging.
11. Do not put any object into openings. Do not use with any opening blocked; keep free
of dust, lint, hair and anything that may reduce air ow.
12. Keep hair, loose clothing, ngers and all parts of body away from openings and
moving parts.
13. Do not pick up anything that is burning or smoking, such as cigarettes, matches or
hot ashes.
14. Do not use without vacuum bag and/or lters in place.
15. Use extra care when cleaning on stairs.
16. Do not use to pick up ammable or combustible liquids such as gasoline or use in
areas where they may be present.
17. For grounded models, connect to a properly grounded outlet only. See Grounding
Instructions.

Page 4
A. Parts Identication
I. Basic Assembly and Operation
1 Ergonomic Handle
2 On / O Power Switch
3 Bag Compartment
4 Vacuum Nozzle
5 Headlight
6 Furniture Guard
7 Quick Release Cord Hook
8 Handle Release Pedal
9 Circuit Breaker Reset Button
4
3
1
2
5
6
7
8
9

Page 5
This vacuum must be grounded. If it should malfunction or
break down, grounding provides a path of least resistance
for electric current to reduce the risk of electric shock.
This vacuum is equipped with a cord having an equipment-
grounding conductor and grounding plug. The plug must be
plugged into an appropriate outlet that is properly installed and
grounded in accordance with all local codes and ordinances.
This vacuum is for use on a nominal 120 volt circuit and has a
grounding attachment plug that looks like the plug illustrated
in Figure B. Grounding. Make sure that the vacuum is
connected to an outlet having the same conguration as the
plug. No adapter should be used with this vacuum.
WARNING - Improper connection of the equipment-grounding conductor can result in a risk of electric
shock. Check with a qualied electrician or service person if you are in doubt as to whether the outlet is
properly grounded. Do not modify the plug provided with the vacuum. If it will not t the outlet, have a
proper outlet installed by a qualied electrician.
Figure B. Grounding
3
Grounded
Outlet
Grounded
Outlet Box
Grounding
B. Grounding Instructions
• Keep machine and all accessories clean and in good operating condition.
• Change vacuum bags and lters as recommended to maintain optimum cleaning efciency.
• Always use genuine bags, belts and parts, as use of other products may result in poor cleaning or
ltration performance. Tacony ltration products are designed for maximum performance.
• Store machine carefully in dry area.
I. Basic Assembly and Operation
C. General Performance

Page 6
The vacuum cleaner and the handle are packed separately. To assemble handle:
1. Remove the two handle bolts located at the top of the upper handle duct (Fig. A.)
2. Remove the handle tube bracket. (Fig. B)
3. Line up the handle tube with the posts in the upper handle duct (Fig. C,)
4. Secure the handle tube bracket over the handle tube with the two handle bolts (Fig. D)
Fig. A Fig. B
Fig. C Fig. D
I. Basic Assembly and Operation
D. Installing the Handle

Page 7
1 On/Off Switch
To turn the vacuum on high speed, push the handle switch to the (II) position.
To Turn the vacuum on low speed, push the handle switch to the (I) position.
To turn the vacuum off, push the handle switch to the (O) position. (Fig. A)
2 How to Lower the Handle
To release the handle, step on the pedal on the back of the nozzle (Fig. B) and pull back on
the handle.
Fig. A
I. Basic Assembly and Operation
E. Operation
Fig. B

Page 8
3. Circuit Breaker Protector
Your vacuum cleaner comes equipped with a Manual Reset Circuit Breaker Protector. This circuit
breaker is designed to protect your vacuum cleaner from damage due to an obstruction in the agitator
or motor fan. Should this situation occur, the circuit breaker protector will safely shut off your vacuum
cleaner to avoid any potential damage.
To reset the circuit breaker:
CAUTION: Unplug the vacuum cleaner before servicing.
1. Check for problem (obstruction or clog in agitator or motor fan.)
2. Correct problem.
3. Locate “tripped” breaker. It is the small black rocker switch located on the back side of the nozzle
housing. (Fig. A)
4. Push the reset button.
5. Plug vacuum cleaner in and begin using again.
Fig. A
I. Basic Assembly and Operation
F. Operation (Continued)

Page 9
1. Always operate the vacuum cleaner with a vacuum bag installed.
2. Unplug the vacuum cleaner.
3. Unzip the hard shell outer bag.
4. Pull the tab outward as shown to open the bag holder. (Fig. A)
5. Pull up on the tab as shown to simultaneously close and remove the bag. (Fig. B)
6. Slide a clean bag into the bag holder. (Fig. C)
7. Then press the top of the bag collar into place until the bag holder tab snaps into place. (Fig. D)
8. Zip the hard shell bag closed.
II. Maintenance
A. Replacing the Vacuum Bag
Fig. A Fig. B
Fig. C Fig. D

Page 10
CAUTION: Unplug the vacuum cleaner before servicing.
1. Release the nozzle and ip the vacuum over so the bottom plate is showing.
2. Turn the two basetray cover screws to the left and remove the baseplate. (Fig. A)
3. Remove the agitator.
4. Remove the nozzle cover as shown on page 17, II. Maintenance, H. Removing Nozzle Cover
6. Discard the old belt and place the new belt around the motor shaft.(Fig. B)
7. Loop the belt around the agitator and replace the agitator as shown. (Fig. C)
NOTE: Make sure the agitator end caps are both turned the same way. The at side should be
facing the baseplate (as shown in Fig. C) unless the brushes are well worn. If the brushes are
worn down, place the at side of the endcaps down into the nozzle housing to increase cleaning
performance and extend the life of the brushroll. (Fig. D)
8. Reinstall the baseplate into the nozzle housing.
9. Replace the nozzle cover.
II. Maintenance
B. Replacing the Belt
Fig. A Fig. B
Fig. C Fig. D

Page 11
CAUTION: Unplug the vacuum cleaner before servicing
The following procedures are recommended to ensure maximum performance and extend the life of the
agitator.
Remove all hair and ber from the brushroll.
This should be done once a month for residential use and once a week or more for commercial use.
1. Remove the baseplate by turning the screws to the left as shown in Fig. A..
2. Cut all the hair and ber down the length of the brushroll using a sharp object such as a utility knife or
scissors (Fig. B) Turn the brushroll and repeat.
3. Reinstall the baseplate.
3. Plug the machine in and turn it on to pull the hair and ber into the bag. (Continued on next page)
Fig. A Fig. B
II. Maintenance
C. Agitator Maintenance

Page 12
CAUTION: Unplug the vacuum cleaner before servicing
Clean around the bearings.
This procedure should be performed every 6 months for household use and once a month or more for
commercial use.
1. Remove the baseplate by turning the screws to the left as shown in Fig. A.
2. Remove the agitator. Press thumbs against the black end caps as shown in Fig. B to remove them and
expose the bearings.
3. Clean out and debris that has collected around the bearings with a small tool (Fig. C.)
4. Reinstall end caps. Make sure the brush spins freely when held by the ends. If not, replace. Reinstall
brushroll into the vacuum and attach the baseplate.
II. Maintenance
C. Agitator Maintenance (continued)
Fig. A Fig. B
Fig. C

Page 13
CAUTION: Unplug the vacuum cleaner before servicing
1. Remove the baseplate by turning the screws to the left as shown in Fig. A.
2. Remove the agitator by pulling it outward.
3. Loop belt around the new agitator pulley. Make sure the belt is around the motor shaft and is not
twisted. If the belt falls off of the motor shaft it may be necessary to remove the nozzle cover to
reinstall the belt. See page 17, II. Maintenance, H. Removing Nozzle Cover
4. Roll agitator into place. Position end caps as shown in Fig. B.
II. Maintenance
D. Replacing the Agitator
Fig. A Fig. B

Page 14
The squeegee prevents debris from blowing behind the vacuum on hard surfaces. The squeegee makes
direct contact with the oor and may wear out. To replace the squeegee, follow the steps below.
CAUTION: Unplug the vacuum cleaner before servicing.
1. The squeegee is located on the baseplate cover (Fig. A)
2. Remove the baseplate by turning the two screws to the left.
3. Flip the baseplate over. There are 5 small openings on the underside (Fig. B)
4. Insert a small screwdriver through the openings to push the squeegee out of the baseplate cover
(Fig. C.) After popping out one side it should be possible to slide the squeegee out. If not continue to
push the squeegee out at each opening until it is free.
5. Flip the baseplate cover back over. Press the new squeegee into the groove in the baseplate. It may be
necessary to use a small screwdriver to press it into place. (Fig. D)
II. Maintenance
E. Replacing the Squeegee
Fig. A Fig. B
Fig. C Fig. D

Page 15
CAUTION: Unplug the vacuum cleaner before servicing.
1. Use a large at screw driver to pop out the old wheel assembly as shown in Fig A and B.
2. Press the wheel into place until both sides of the axle lock into the base tray. It may be necessary to
use a screwdriver to press the axles into place. (Fig. C)
II. Maintenance
F. Replacing the Wheels
Fig. A Fig. B
Fig. C

Page 16
CAUTION: Unplug the vacuum cleaner before servicing
1. Flip the machine over and lay at.
2. Remove the two hold down clamps shown in Fig. B.
3. Remove the old foot pedal and axle assembly.
4. Install new foot pedal assembly. Position the spring so that the long section is inserted in the hole as
shown in (Fig.C.)
5. Install the foot pedal and axle as shown in gure C and D. .
Fig. A Fig. B
II. Maintenance
G. Replacing the Foot Pedal
Fig. C Fig. D

Page 17
II. Maintenance
CAUTION: Unplug the vacuum cleaner before servicing.
1. Release the nozzle and ip the vacuum over so the bottom plate is showing.
2. Remove the two screws holding the nozzle cover on.(Fig. A)
3. Flip the machine back over and lift the nozzle cover off. (Fig. B)
H. Removing the Nozzle Cover
Fig. A Fig. B

Page 18
CAUTION: Unplug the vacuum cleaner before servicing
1. Unfasten the Velcro strap located on the lower section of the handle duct (Fig. A.)
2. Open hard shell bag and remove the dust bag (Fig. B.)
3. Take out the four screws to remove the bag holder (Fig. C.) Be careful not to lose the seal located
behind the bag holder.
4. The hard shell bag is now free from the machine.
II. Maintenance
I. Removing the Hard Shell Bag
Fig. A Fig. B
Fig. C

Page 19
CAUTION: Unplug the vacuum cleaner before servicing.
1. Remove the hard shell bag as shown on the previous page.
2. Remove the two screws in the neck coupling (Fig. A.)
3. Remove both halves of the neck coupling (Fig. B.)
4. Pull the handle duct up to remove it from the upper motor housing (Fig. C.)
II. Maintenance
J. Removing the Handle Duct
Fig. A Fig. B
Fig. C

Page 20
CAUTION: Unplug the vacuum cleaner before servicing.
If a foreign object is caught in the vacuum a clog may form. If the vacuum is clogged a decrease in
cleaning performance may occur. To remove a clog, follow the steps below:
1. Remove the hard shell bag and separate the lower handle duct as shown on pages 18 and 19.
2. Check the handle duct for clogs (Fig. A.) Any clogs can be removed by running a stiff piece of wire or
another object through the handle duct.
3. If the handle duct is clear, check the motor chamber for clogs (Fig. B.)
4. If the motor is clear, remove the nozzle cover as shown on page 17, II. Maintenance, H. Removing
Nozzle Cover. Then remove the three screws for the fan duct cover and check the fan duct for clogs.
(Fig. C)
5. Reassemble the vacuum
II. Maintenance
K. Removing Clogs
Fig. A Fig. B
Fig. C