Repair Cord in handle of Eureka 4040A

[Eureka4040A]

I own a 1979 vintage Eureka ESP wide track vacuum, model 4040A.
The cord wore out where it comes out of the handle and I need help repairing it.
The only help I've been able to find is here by HooverCelebrity.
www.vacuumland.org/cgi-bin/TD/TD-VIEWTHREAD.cgi?13369

His post gives a good idea of this challenge.

"The only gripe I have about this cleaner would be servicing the cord and switch. It's nearly impossible to do. The handle grip has to come off, the wires all go up the handle... you have to carefully take the switch out.. and if you want to remove the cord, you may as well forget it. Once that cord-strain gets pushed into the handle, you may as well cut it off and drill it out if you want to remove it. I have no idea how those cords would have been serviced on a regular basis back when those cleaners were more prevalent. Thankfully my cleaner had a perfect cord, but I tried taking the cord out of a different "parts machine" 2091 I had laying around, which was in pretty rough shape... and I cursed and gnashed my teeth trying to get that cord out, but I finally got it."


I haven't been able to find a schematic for the 4040A. The closest I've come is the
2000 series, which handle looks the same as the 4040A.
http://www.usavacuum.com/category-s/197.htm

My questions are:

1. How to remove the rubber handle grip from the top of the metal handle.
I've tried heating it up with a hair dryer and it still won't budge.

2. The 3-position ESP / off Rocker Switch just slides into the handle. It is not
held in place by screws. Can I pull it out? And if I do can I repair the
cord from there, and will it still work when I push it back in?

3. It looks like the 30 foot long main cord plugs into the back of the Rocker Switch.
Does it plug in or is it soldered?

4. Do you have a step-by-step plan for replacing this cord?

Thank you

 

[hoovercelebrity]

Hi Mel,

Any chance you could post a photo of the cleaner? I assume it's similar to the one that I own, but I'm not real good with Eureka model numbers.

I used a pot of boiling water to get the handle grip off. I boiled the water, and then held the end of the handle in the pot for about 30 seconds - then had on a pair of rubber dishwashing gloves, and used a dish rag, and was able to get it off. It did take some working with, and didn't just "pop off". You may have to go back and forth a few times. I think if you end up ruining the grip, they are still used on modern Sanitaire machines (which are Commercial Eurekas). You would likely be able to order a new one and just replace it. Double check on that before destroying the original one, though.

Directly behind the switch, on the back of the handle, is there a sticker with a warning about using the cleaner on wet surfaces? If so, peel that sticker off, and beneath, there are slots that should allow you to maneuver a tiny screwdriver or awl in order to compress the clips on the switch enough to be able to pop the switch out. I would imagine that Eureka had a tool that fit in those slots that allowed for easy switch removal.

The switch has leads coming off of it that go up the handle, along with the wires from the cord. All of the wires are tied together with wire nuts. The cord does not plug directly into the switch.

I did find a parts schematic for 4000-series Eureka cleaners:
http://www.hescoinc.com/schematics/eureka/e_4000.pdf

Hesco is great for ordering parts, I've ordered many parts from them over the years. I beleive they do still stock the cord for this model. I recently ordered a few extra to keep on hand in case I need them down the road.

Best of luck!

~Fred

 

[hoovercelebrity]

I was going thru some photos on my phone and found this picture showing all of the lead wires coming up the handle, from the switch and cord...

 

[louvac]

Just an FYI

Guys, 


 


Have you ever wondered why there is a short "T" cut-out behind the handle? Well, there is a service tool that was available to authorized repair shops. This allowed for the easily removal of the switch, which once removed, gained you access to some of the internal wiring. 


 


What I am not sure is if this front access would allow you to compress the cord strain relief from the inside thus allowing you to push it back out from the handle along with the cord's connections. Perhaps another Eureka fan (pardon the pun) could shed some light on this?


 


 


 

 

[Eureka4040A]

Success.

Thanks Fred,

I used your boiling water suggestion. I kept the handle grip in the hot water for 60 seconds
and the grip expanded enough to come off. There was a plastic cup in the end
of the handle protecting the wire/wire nuts.

I repaired the cord, and then held the handle grip in hot water again to get it
to expand so that it would go back on the handle.

Thanks for your knowledge and help.

Mel

 

[hoovercelebrity]

Yay! Glad you were able to get it figured out; those are tricky!

-Fred