HandI Move 2540 Betriebsanleitung

Version 1.0 - 02/05/2006

PORTABLE MOTOR 2540 / 2545

REPAIR

1. Trouble shooting ...........................................................................................................................................3

1.1. Testing the portable motor .................................................................................................................3

1.1.1. Check the condition of the emergency switch .......................................................................3

1.1.2. Testing the operational functionality of the portable motor ..................................................3

1.2. Checking the batteries .......................................................................................................................3

1.3. Testing the motor ...............................................................................................................................4

1.4. Testing the PCB .................................................................................................................................4

1.5. Checking the fuse in the charging 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 motorband .................................................................................................................16

4.10. Changing the emergency down .......................................................................................................18

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2540 / 2545 • REPAIR

Table of contents

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2540 / 2545 • REPAIR

1. Trouble shooting

SYMPTOM :

•The hand control of the device does not work.

Change the hand control

» see step 4.1.

•The up/down switch of the device does not work.

Change the up/down switch

» see step 4.4.

•Buzzer continues operating after charging.

Check the fuse in the charging circuit

» see step 1.5.

Check the charger

» see step 1.6.

If both are operating correctly, change the PCB

» see step 4.7.

•Emergency down does not work.

Change the emergency down

» see step 4.10.

•The device does not work.

» start at step 1.1.

1.1. Testing the 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 with the up/down switch, then the hand

control is faulty

» see step 4.1.

•• If the device works only with the hand control, then the up/down

switch is faulty

» see step 4.4.

•Check the operation of the emergency down on the device.

•• If the device does not work or operates slowly

» go to step 1.2.

•• If the device works at normal speed

» go to step 4.7.

1.2. Checking the batteries

•Remove the top cover.

» see step 4.2.

•Remove the red and black wires from the batteries and measure the

voltage across the contacts of the three batteries in series.

•• If no voltage is present

» fit a new fuse between the batteries.

•• If a voltage is present

» proceed to the following step

•Apply a resistance of 2 x 2.2 Ohm 100 Watt to the batteries in series

for 5 seconds whilst measuring the voltage. After 5 seconds the volt-

age should not drop below 21 V. • Allow the battery to recover for

10 seconds and repeat the test.

•• If the voltage is lower than 21 V

» change the 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 rotates in both directions

» go to step 1.4.

•• If the motor does not rotate in both directions. Fit a new motor

» see step 4.8.

CAUTION!

AS 24 V D.C. IS APPLIED DIRECTLY TO THE MOTOR,

THE END-OF-RUN SWITCHES NO LONGER WORK.

THEREFORE ENSURE THAT THE MOTORBAND DOES

NOT ROLL UP INTO THE DEVICE FULLY OR BECOME

TWISTED.

•Reconnect the cable clips (fastons) to the motor.

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2540 / 2545 • REPAIR

white

brown

1.4. Testing the PCB

•Check that the fuse on the PCB is not burnt out. You can also mea-

sure the fuse with a multimeter to determine the resistance of the

fuse.

•• If the fuse is serviceable (a resistance is present): change the

PCB

» see step 4.7.

•• If the fuse is unserviceable (no resistance is present): replace the

fuse and check that the device functions. If the device does not

function, change the PCB.

» see step 4.7.

1.5. Checking the fuse in the charging

circuit

•Remove the top cover.

» see step 4.2.

•Check that the fuse in the charging circuit (on the motor) is not

burnt out. You can also measure the fuse with a multimeter to deter-

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

27.5 V DC

» Check the following point.

Connect the charger to the device and check the output voltage + the

LED indicator on the charger.

•If the LED illuminates orange and there is an output voltage of 29.5

V DC

» The charger is OK.

CAUTION:

WHEN THE BATTERIES ARE CHARGED THE LED

CHANGES BACK TO ILLUMINATED GREEN.

•If neither occurs

» Change the charger.

•Refit the top cover if it was removed.

» see step 4.3.

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2540 / 2545 • REPAIR

2. Electrical diagram

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2540 / 2545 • REPAIR

red (nr 14)

red (nr 9)

red (nr 10)

red (nr 25)

blue (nr 4) blue (nr 6)

blue (nr 5)grey (nr 1)

grey (nr 3)

grey (nr 2)

black (nr 22)

lack

(

nr 8

)

black (nr 7)

black (nr 13)

white (nr 16)

VV'

L1 L2 L3

M' M

hite(nr 18)

black (nr 11)

black (nr 12)

brown (nr 24)

brown (nr 17)

brown (nr 15)

red (nr 19)

red (nr 20)

red (nr 22)

red (nr 21)

MCircuit 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

HSwitch (up/down)

C1 Connector changer/power supply

C2 Connector hand control

UMotor SWF 404.148

WRectifier diodes (15A)

VFuse holder

V’ Fuse charging circuit (T 1,6A)

F2 Main fuse (ATO 7,5A)

L1 Battery 1

L2 Battery 2

L3 Battery 3

BB Emergency down switch

3. Overview of items described

ACap 2540 0060

BSelf locking hexagonal nut 2540 0053

BHexagonal bolt M6x120 2540 0055

CEnd cap washer 2540 0059

DYellow plate, handgrip 2540 2122

EHandgrip 2540 2131

FRound headed screw M6x12 2540 0036

F2 Fuse ATO 7.5 A 2540 0232

GTop cover PM + end section PM

HUp/down switch 2540 0204

I. Emergency switch 2540 0203

YLong spring, battery PM 2540 0132

KShort spring, battery PM 2540 0133

LBattery A208/2.5s PM 2540 0201

M PCB 3032 0000

M’ Glass fuse 6.3AT 5x20 mm 3032 0100

NDraw spring 1500 4340

OSliding circlip 2540 0071

PHexagonal bolt M6x100 2540 0070

QRoller 2 2540 0129

RSteel circlip 12 1500 3940

SRoller handgrip PM 2540 0126

TRoller 1 2540 0128

UDC motor SWF 404.148 2500 0260

VFuse holder PM 2540 0207

V’ Glass fuse 1AT 5x20 mm 3000 9260

WSwitch bridge rectifier 2540 0208

XCountersunk screw M6x12 2540 0035

YMotorband, portable motor 2540 0143

ZFitted screw (M5) 6x40 2540 0037

AA Safety arm 2540 0124

BB Pressure switch, emergency down 2540 0205

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2540 / 2545 • REPAIR

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2540 / 2545 • REPAIR

M’

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2540 / 2545 • REPAIR

AA V’

4. Changing parts

4.1. Changing the hand control

1. Unscrew the connector on the portable motor.

2. Connect a new hand control and test the functions.

Remember to screw the 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.

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2540 / 2545 • REPAIR

B’

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