HandI Move 2540, Repair Manual

Page 1: ...Version 1 0 02 05 2006 2006 Handi Move SUREHANDS All rights reserved PORTABLE MOTOR 2540 2545 REPAIR ...

Page 2: ...arging circuit 4 1 6 Checking the charger and the charging cycle 5 2 Electrical diagram 6 3 Overview of items described 7 4 Changing parts 10 4 1 Changing the hand control 10 4 2 Removing top cover 10 4 3 Fitting top cover 11 4 4 Replacing the up down switch 11 4 5 Changing the emergency switch 12 4 6 Changing the battery 12 4 7 Changing the PCB 13 4 8 Changing the motor 13 4 9 Changing the motorb...

Page 3: ...e portable motor 1 1 1 Check the condition of the emergency switch First check that the emergency switch is in position 1 If it is not set the emergency switch to position 1 1 1 2 Testing the operational functionality of the portable motor Check operation of the hand control and the up down switch on the device If neither operate on the device_ go to the following step If the device works only wit...

Page 4: ...batteries see step 4 6 test the operation of the device and go to step 1 5 step 1 6 If the batteries recover well and more than 21 V is indicated reconnect the red and black wires to the batteries go to step 1 3 motor test 1 3 Testing the motor Remove the cable clips fastons from the motor Then apply 24 V DC directly to the contacts of the motor Repeat this test with reversed polarity If the motor...

Page 5: ...er mine the resistance of the fuse If the fuse is serviceable a resistance is present go to step 1 6 If the fuse is unserviceable no resistance is present change the fuse go to step 1 6 1 6 Checking the charger and the charging cycle Connect the charger to the mains and check the output voltage the LED indicator on the charger If the LED is illuminated green and the output voltage is higher than 2...

Page 6: ...ack nr 12 brown nr 24 brown nr 17 brown nr 15 red nr 19 red nr 20 red nr 22 red nr 21 M Circuit board M Fuse PCB T 6 3A I Emergency switch On Off S2 Micro Switch upward movement S3 Micro Switch downward movement S4 Micro Switch H Switch up down C1 Connector changer power supply C2 Connector hand control U Motor SWF 404 148 W Rectifier diodes 15A V Fuse holder V Fuse charging circuit T 1 6A F2 Main...

Page 7: ...PM 2540 0133 L Battery A208 2 5s PM 2540 0201 M PCB 3032 0000 M Glass fuse 6 3AT 5x20 mm 3032 0100 N Draw spring 1500 4340 O Sliding circlip 2540 0071 P Hexagonal bolt M6x100 2540 0070 Q Roller 2 2540 0129 R Steel circlip 12 1500 3940 S Roller handgrip PM 2540 0126 T Roller 1 2540 0128 U DC motor SWF 404 148 2500 0260 V Fuse holder PM 2540 0207 V Glass fuse 1AT 5x20 mm 3000 9260 W Switch bridge re...

Page 8: ...p 8 2540 2545 REPAIR Y D B J T G H C I Q O P N F A B BB M K L S E M ...

Page 9: ...p 9 2540 2545 REPAIR R V U W AA V ...

Page 10: ...connector tight 4 2 Removing top cover 1 Remove the end caps A of the handgrip using a screwdriver 2 Loosen the locknuts B and remove 3 Remove the washer C 4 Take the plate D off the 2 bolts B 5 Unscrew the handgrip E from portable motor 6 Loosen the screws F and remove them 7 Remove the top cover G from the portable motor p 10 2540 2545 REPAIR A E D B C B A W G F F ...

Page 11: ...or 2 Ensure the cover is correctly seated 3 Tighten the top cover with the screws F 4 Push the handgrip E onto the shaft 5 Position the plate D on the other side 6 Push the washer C over the bolt B 7 Screw on the locknuts B 8 Refit the end caps A on the handgrip p 11 2540 2545 REPAIR A E D C B A W G F F B ...

Page 12: ... refitting the top cover 5 Refit the top cover see step 4 3 4 5 Changing the emergency switch 1 Remove the top cover see step 4 2 2 Release the fastons and press the switch I out of the frame 3 Snap a new switch back into the frame see photo clip below and refasten the fastons 4 Test the functioning of the switch before refitting the top cover 5 Refit the top cover see step 4 3 p 12 2540 2545 REPA...

Page 13: ...out of the frame 3 Release the fastons on the batteries L 4 Remove the batteries from the frame 5 Position a new battery in the frame and reconnect the cables NOTE NOTE THE MARKINGS ON THE FASTONS SEE PHOTO OF ELECTRICAL DRAWING 6 Refit the springs 7 Test the operation of the portable motor 8 Refit the top cover see step 4 3 p 13 2540 2545 REPAIR W J K L ...

Page 14: ...n the photo or on the drawing see section 2 4 Test the operation of the portable motor 5 Refit the top cover see step 4 3 4 8 Changing the motor 1 Remove the top cover see step 4 2 2 Remove the long spring J by pressing it together and pulling it out of the frame 3 Remove the fastons from the battery L 4 Remove the battery from the device p 14 2540 2545 REPAIR M J L black of battery ...

Page 15: ... be removed 7 Remove circlip R 8 Remove shaft S from the frame Roller T can be removed 9 Disconnect the cables from the up down motor U 10 Remove the fastons from the components on the motor and remove the components fuse V rectifier W these must be unscrewed p 15 2540 2545 REPAIR Q P O N W V U Y T R S ...

Page 16: ...r and fit it on the new motor check the presence of the bronze ring 13 Unscrew the screw from the motor where the rectifier is to be fit ted 14 Fit the rectifier and the fuse holder on the motor 15 Install the motor back in the frame 16 Carry out steps 2 to 8 in reverse order to proceed with the assembly NOTE USE NEW CIRCLIPS WHEN ASSEMBLING p 16 2540 2545 REPAIR U X X X ...

Page 17: ...motorband 1 Remove the top cover see step 4 2 2 Unwind the motorband Y fully but ensure that the adjusting bolts Z are aligned with the holes provided using the Up Down button 3 Remove circlip R 4 Remove the shaft S from the frame Roller T can then be removed p 17 2540 2545 REPAIR Y T R S Z red of battery red of charger socket red of rectifier red of charger socket red of emergency switch white br...

Page 18: ...e the motorband and tighten Tip to fit the second bolt above the motorband push the motorband through a bit further but tighten it fully Then roll up the motorband fully using the up down switch 9 Grease the shaft S and the end of the roller T where it touches the motor frame 10 Then push the shaft into the frame and through the roller T 11 Push the shaft through the other side of the frame and se...

Page 19: ...of the emergency down button BB 4 Remove the emergency down button BB and fit a new button 5 Secure the button with a nut snap in a new switch BB and recon nect the wiring as shown in the photo or the electrical diagram see Section 2 p 19 2540 2545 REPAIR brown to motor D1 white to motor C1 white to PCB C3 black D2 red C2 brown to motor C3 BB BB ...