Pro-Team GoCartVac User manual

GoCartVac™
Service Manual

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
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
www.pro-team.com 800.541.1456
ATTENTION
Before servicing any part
or proceeding with any
repair procedure on any
ProTeam vacuum,
ALWAYS disconnect
the vacuum from
the power source.

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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 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

Full Vacuum Parts
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1314
16
1
2
3
12
10
11
10
15
8
6
17
9
5
7
10
4
18
19
20
21
35
26
27
28
29
30
31
32
33
34
25
23
22
24
36
37
38
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 106583 Plastic Diffuser w/Connection Screw
Set (2 screws)
6 100335 Compression Ring w/Connection Screws
100378 Compression Ring Connection Screws
7 100014 Tetraseal
103731 Carbon Brush Set for 36V motor
8 103732 36V Motor w/Crimps, Replacement
103617 Complete 36V Motor Assembly w/Seal,
Compression Ring and Relay
(includes: #6,7,8,9)
9105496 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)
15 103623 Electrified Hose, 11/4" 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
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 106276 Battery, Lead Acid, 12V, 37AH
35 106283 Kit, Attachment Hardware for Charger
and Box Assembly
36 103476 Thermal Protector
37 106297 Wheel Set, Rear
38 106298 Wheel Set, Front
101678 50' Extension Cord (Not Shown)

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Remove Charger Panel
REMOVE CHARGER PANEL
Remove cover of cart by pulling straight up
carefully. ATTENTION: Pull up carefully as cord
is attached to vacuum.
1. Place cover into tray of cart. 2.
Remove side panel closest
to power switch by pushing
in and pulling up at the
same time.
3. Continue pulling up until
panel is removed.
Place aside.
4.
(Continued on page 5)

Remove Charger Panel
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REMOVE CHARGER PANEL (Continued from page 4)
Grab each end of the charging harness and work
back and forth as you pull apart.
5a. 5b.
Slide the charger’s black/red connector apart from
the other two.
6a. 6b.
Unplug charger from receptacle.
7. Using grip in panel pull up until panel is clear
from cart.
8.

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Replace Charger Panel
REPLACE CHARGER PANEL
2.
Connect plug of battery charger into
receptacle.
3. Slide red and black connector of charger
into other two red and black connectors
from batteries and vacuum.
4a.
4b.
Attach the charging harness terminal to the
three connectors of the charger, batteries
and vacuum.
5.
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.
(Continued on page 7)
Place corner molding
on one side of charger
panel.
1.

Replace Charger Panel
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REPLACE CHARGER PANEL (Continued from page 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.
6.
7.
If on tightly the four flanges are visible above
the cover.
8.
Put cover in place on top of cart. Push until
snaps into place.

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Remove Vacuum Panel
REMOVE VACUUM PANEL
Slide the remaining two red/black connectors apart
from each other.
2a. 2b.
Disconnect plug from vacuum.
3. Carefully remove vacuum panel
from cart.
4.
1. Remove Charger Panel (Page 4)

Replace Vacuum Panel
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REPLACE VACUUM PANEL
Place corner molding on one
side of vacuum panel.
1.
2a.
2b.
Connect the red/black connector of the
vacuum to the red/black connector from
the batteries.
3. Plug cable from cover of cart into vacuum. 4.
Slide panel into cart by
placing side without molding
into empty channel of
molding from side panel.
Confirm that the panel is rest-
ing on the bottom of the cart
and that the corner molding
and panel are even at the top.
5. Replace Charger Panel (Page 6)

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Remove Diffuser
REMOVE DIFFUSER
Remove vacuum from panel using Phillips
screwdriver to remove two screws and washers.
3. Remove cap by twisting
counter-clockwise.
4. Remove both
cloth and
paper filters.
5.
Using a 5/16 socket or flat head
screwdriver, remove two screws
holding plastic diffuser to motor.
7.
Turn vacuum upside down.
6. Remove diffuser. 8.
1. Remove Charger Panel (Page 4)
2. Remove Vacuum Panel (Page 8)

Replace Diffuser
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REPLACE DIFFUSER
Attach diffuser to motor with
two screws.
2.
Turn vacuum right side up
and place cloth and paper
filter into vacuum body.
3. Secure lid on vacuum by
turning clockwise.
4. Lay vacuum flat with mounting
holes up.
5.
Lay panel on top of vacuum aligning
mounting holes in vacuum with holes
in panel.
6. Attach vacuum to back panel with
washers and screws.
7.
Replace diffuser by placing the side with ridges
away from motor.
1.
If all changes are complete:
8. Replace Vacuum Panel
(Page 9)
9. Replace Charger Panel
(Page 6)

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Remove Receptacle
REMOVE RECEPTACLE
Locate and remove top horizontal connector on
battery control module (BCM) (white wire from
receptacle) with needlenose pliers.
1. Remove Charger Panel (Page 4)
2. Remove Vacuum Panel (Page 8)
3. Remove Diffuser (Page 10)
4.
Locate black wire with white connector from receptacle
on BCM and remove with needlenose pliers.
5. Remove two screws holding receptacle to vacuum
body with Philip’s screwdriver.
6.
Using fingers or flathead screwdriver, loosen
receptacle from vacuum.
7. Remove receptacle from vacuum.
8.

Replace Receptacle
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REPLACE RECEPTACLE
Thread wires of new or existing
receptacle through hole in
vacuum body.
1. Push receptacle until flush against body of vacuum. 2.
Attach receptacle to vacuum body with two screws
using a Phillips screwdriver.
3. Connect the black receptacle wire to the vertical
BCM location marked “Switch” with needlenose
pliers.
4.
Connect the white receptacle wire onto the top hori-
zontal BCM connection labeled “Switch.”
5.
If all changes are complete:
6. Replace Diffuser (Page 11)
7. Replace Vacuum Panel (Page 9)
8. Replace Charger Panel (Page 6)

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Remove Power Cable
REMOVE POWER CABLE
Locate white wire from receptacle
and remove from BCM.
4. Locate white wire from power
cable and remove from BCM.
5. Locate black wire of power cable on
BCM. Remove w/needlenose pliers.
6.
With crescent wrench holding nut
unscrew the strain relief.
7a.
Holding outer nut, unscrew the inner
nut from the threads on the cable.
Remove cable from vacuum.
8a. 8b.
7b.
1. Remove Charger Panel (Page 4) 2. Remove Vacuum Panel (Page 8) 3. Remove Diffuser (Page 10)

Replace Power Cable
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REPLACE POWER CABLE
Thread wires of new or existing cable through hole
in vacuum body.
1. Thread wires through inner nut and tighten nut. 2.
Screw strain relief up to washer and outer nut.
Tighten all with crescent wrench.
3. Attach the white wire from power cord to the
middle connector (marked with +36V).
4.
Attach the white wire from switch receptacle to
the top connector (marked with SWITCH).
5. Connect black wire of power cable to “-36” on
PC board.
6.
If all needed changes are complete:
7. Replace Diffuser (Page 11) 8. Replace Vacuum Panel (Page 9) 9. Replace Charger Panel (Page 6)

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Remove/Replace Thermal Switch
REMOVE THERMAL SWITCH
Disconnect the other end of the thermal swich
from motor wire.
5.
REPLACE THERMAL SWITCH
Connect male connector of new or existing
thermal switch to motor wire.
1. Connect female connector of thermal switch to
“MOTOR” on BCM.
2.
1. Remove Charger Panel (Page 4)
2. Remove Vacuum Panel (Page 8)
3. Remove Diffuser (Page 10)
If all needed changes are complete:
3. Replace Diffuser (Page 11)
4. Replace Vacuum Panel (Page 9)
5. Replace Charger Panel (Page 6)
Locate and remove thermal switch connector
from BCM.
4.

Remove Battery Control Module (BCM)
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REMOVE BCM
Remove all wires connected to BCM.
4. Remove screw holding BCM to compression ring
with either a flathead screwdriver or 5/16 socket.
Remove BCM.
5.
1. Remove Charger Panel (Page 4)
2. Remove Vacuum Panel (Page 8)
3. Remove Diffuser (Page 10)

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Replace Battery Control Module (BCM)
REPLACE BCM
Screw new or existing BCM to motor
compression ring with either a flat-
head screwdriver or 5/16 socket.
1. Connect black wire of
power cable to “-36” on
PC board.
2. Connect female connector of
thermal switch to “MOTOR”
on BCM.
3.
Reconnect black wire of receptacle to “SWITCH”
on BCM.
4. Attach the black wire from the motor to the
bottom horizontal connector (marked with MTR+).
5.
Attach the white wire from new power cord to the
middle connector (marked with +36V).
6. Attach the white wire from receptacle to the top
connector (marked with SWITCH).
7.
If all needed changes are complete:
8. Replace Diffuser (Page 11) 9. Replace Vacuum Panel (Page 9) 10. Replace Charger Panel (Page 6)

Remove Motor/BCM Assembly from Vacuum
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REMOVE MOTOR/BCM ASSEMBLY FROM VACUUM
Use flathead screwdriver to remove 3 washer
cover caps.
6. Use Phillips screwdriver to remove screw and
Z-washer. Remove all three.
7.
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)
Push well nut into vacuum using screwdriver.
8a. 8b.
Remove motor from
vacuum body.
9.
Remove dome filter.
10.