Model 1548., Why can't I install carry handle.

Turn the machine over (with the handle released). Remove the 4 screws (2 on each end of the cover over the brush). Remove the cover. There are 2 screws, deep in the machine (behind drive train wheels) remove the screws. With the machine in the same position, note 2 plastic clips located on either side of the top cover. Release the clips using a slotted screw drive.

The pedal assembly must be replaced,( part # 558401S), as it has a gear pressed to it which has come loose. The handle, switch plate, and upper motor cover must be removed first. To remove the plastic switch plate, remove it's screws and insert a flat screwdriver into the rectangular slot in it to pop it off. Four screws hold the upper motor shell in place. Next the switch button must be removed. The Techdrive assembly can be removed by removing the three screws on the bottom. Drop the drive down, and unhook it's belt from the gear on the end of the armature shaft. The pedal assembly can be removed by removing the remaining screw from the bottom of the drive unit. The N/D pedal has two parts - the pedal itself, and the shift cam. Observe carefully how these units fit together. After installing the new pedal and replacing the screw and washer to secure it, re-install the drive unit. The shift must be in the Drive position to install it, and remember to replace the belt. Be sure to line up the arm on the drive unit so that it engages the slot at the base of the handle pivot and re-install the other items.

The pedal assembly must be replaced,( part # 558401S), as it has a gear pressed to it which has come loose. The handle, switch plate, and upper motor cover must be removed first. To remove the plastic switch plate, remove it's screws and insert a flat screwdriver into the rectangular slot in it to pop it of. Four screws hold the motor cover in place. Next the switch button must be removed. The Techdrive assembly can be removed by removing the three screws on the bottom. Drop the drive down, and unhook it's belt from the gear on the end of the armature shaft. The pedal assembly can be removed by removing the remaining screw from the bottom of the drive unit. The N/D pedal has two parts - the pedal itself, and the shift cam. Observe carefully how these units fit together. After installing the new pedal and replacing the screw and washer to secure it, re-install the drive unit. The shift must be in the Drive position to install it, and replace the belt. Be sure to line up the arm on the drive unit so that it engages the slot at the base of the handle pivot and re-install the other items

The pedal assembly must be replaced,( part # 558401S), as it has a gear pressed to it which has come loose. The handle, switch plate, and upper motor cover must be removed first. To remove the plastic switch plate, remove it's screws and insert a flat screwdriver into the rectangular slot in it to pop it off. Four screws hold the upper motor shell in place. Next the switch button must be removed. The Techdrive assembly can be removed by removing the three screws on the bottom. Drop the drive down, and unhook it's belt from the gear on the end of the armature shaft. The pedal assembly can be removed by removing the remaining screw from the bottom of the drive unit. The N/D pedal has two parts - the pedal itself, and the shift cam. Observe carefully how these units fit together. After installing the new pedal and replacing the screw and washer to secure it, re-install the drive unit. The shift must be in the Drive position to install it, and remember to replace the belt. Be sure to line up the arm on the drive unit so that it engages the slot at the base of the handle pivot and re-install the other items.

this is how you do it Lower handle and place vacuum on floor so you can see bottom of power head. Examine the power head to remember what it should look like when finished. Unscrew the four screws (Phillips screwdriver). Lift off cover. Lift out brush. Remove belt from brush and motor shaft. Place new belt around motor shaft, then around brush just prior to reinserting brush. Make sure the belt is placed correctly. Reinsert brush in slots. Rotate manually toward motor a few time to center the belt. Replace cover and screws. Tighten securely. Check cover to make sure it's properly secured.

This repair requires extensive disassembly. First remove the handle, bag assembly, and switch "scuff" plate. To remove the switch plate, remove the screw at the bottom, and the upper screw that secures the cord. Insert a screwdriver into the rectangular slot in the plastic and pop it off. The cord must also be removed. One screw holds the cord cover to the lower motor shell. Remove the screw and push with a flat screwdriver on the back of the cover to unlatch it. Next remove the upper motor shell ( 4 screws ). The next piece to come off is the switch button. Pry upward on it's attaching lugs to free it, pull it upward far enough to disconnect it from the switch rod. The power drive assembly is next to go. Three screws on the bottom of the motor unit hold it in. DO NOT remove the center screw beneath the shift lever. The drive pedal must be in DRIVE for removal. The transmission drops down to get it out ( you may have to wiggle and pull on it to free it). Next the headlight frame assembly must be removed. You will see 2 screws at the rear, and 2 long screws in front which also secure the fan housing. After removing the screws, the headlight frame can be removed. Be careful to note the proper location of all wires! The right carbon brush assembly must be removed to allow the switch to slide back for removal. It is held in place by 1 screw and a tab on it's holder. Two screws hold the switch itself in place. One is on a tab on top of the switch, and the other is on the right bottom of the lower motor shell. The lower screw also serves as a motor mount screw. The switch can now be removed by inserting a small screwdriver along it's front edge and prying it backwards. It is wise to clear dust and lint from the motor contacts prior to re-assembly. Be sure the terminals on the field coil have not gotten bent before putting the new switch in place. Snap the new switch in place and replace the screws. It is easiest to replace the wires in this order:
1- Holding the headlight assembly off to the right, install the lower headlight wire.
2- Next connect the wire from the left carbon brush to the upper switch terminal.
3- Connect the upper headlight wire.
4- Gently replace the right carbon brush assembly, secure it with it's screw ( do not overtighten ) , and connect it's wire to the lower switch terminal.
After the switch is in, install the headlight frame screws, transmission and belt, and switch button in reverse order. Be sure the shift arm on the left side of the drive unit engages the slot or pin on the handle pivot assembly. The cover and trim pieces can now be re-installed.

The pedal assembly must be replaced,( part # 558401S), as it has a gear pressed to it which has come loose. The handle, switch plate, and upper motor cover must be removed first. To remove the plastic switch plate, remove it's screws and insert a flat screwdriver into the rectangular slot in it to pop it of. Four screws hold the motor cover in place. Next the switch button must be removed. The Techdrive assembly can be removed by removing the three screws on the bottom. Drop the drive down, and unhook it's belt from the gear on the end of the armature shaft. The pedal assembly can be removed by removing the remaining screw from the bottom of the drive unit. The N/D pedal has two parts - the pedal itself, and the shift cam. Observe carefully how these units fit together. After installing the new pedal and replacing the screw and washer to secure it, re-install the drive unit. The shift must be in the Drive position to install it, and replace the belt. Be sure to line up the arm on the drive unit so that it engages the slot at the base of the handle pivot and re-install the other items

The pedal assembly must be replaced, as it has a gear pressed to it which has come loose. The handle, switch plate, and upper motor cover must be removed first. To remove the plastic switch plate, remove it's screws and insert a flat screwdriver into the rectangular slot in it to pop it of. Four screws hold the motor cover in place. Next the switch button must be removed. The Techdrive assembly can be removed by removing the three screws on the bottom. Drop the drive down, and unhook it's belt from the gear on the end of the armature shaft. The pedal assembly can be removed by removing the remaining screw from the bottom of the drive unit. The N/D pedal has two parts - the pedal itself, and the shift cam. Observe carefully how these units fit together. After installing the new pedal and replacing the screw to secure it, re-install the drive unit. The shift must be in the Drive position to install it, and replace the belt. Be sure to line up the arm on the drive unit so that it engages the slot at the base of the handle pivot and re-install the other items.

before you do all this, check the cord where it mounts to the handle up top by the pivoting strain relief. Frequently the cord goes bad right where it snaps in the strain relief.
first you will need to remove the handle, bag, and the cord. there is a release button for the handle, the mini emptor on the bottom of the bag twists off away from the body. there should be 2 screws on the scuff plate, one to hold the cord strain relief and another down by the transmission for the scuff plate. use a small flathead screw driver in the slot of the scuff plate and pry up. it will pop off. you should also take out the screw in the cord cover where it plugs, pop the cover off and remove the cord. now you can remove the top cover. there will be 2 screws in the front of the unit, and 2 screws under the scuff plate. they are either phillips or T15,T20 torx. remove those 4 screws and you can lift the top cover off and access the motor and the switch. check for bad motor carbon brushes and a worn commotator where the brushes ride. let me know if you need anything else.

Set the bottom part of the handle down(not the part that the screws go in)the contact board will fit into slots on the left side of thehandle half, the switch will go where the cutout is for it on the top, the plug is notched to fit at the lower front part of the handle. Then put the the tube into the hose and set it into the handle. There is a ribe near where the tube sticks out of the handle, it fits into a slot just before it sticks out. There also is a stop for the hose to up against so the contact rings can't slip off. Then put the other half on and screw it down.