HandI Move 2540 Operating instructions

Version 1.0 - 02/05/2006
©2006 Handi-Move / SUREHANDS®
All rights reserved
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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Table of contents

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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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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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2. Electrical diagram
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1
2
3
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)
b
lack
(
nr 8
)
black (nr 7)
black (nr 13)
white (nr 16)
S4
U
BB
C1
I
VV'
W
F2
L1 L2 L3
M' M
S3
S2
C2
H
w
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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Y
D
B
J
T
G
H
C
I
Q
O
P
N
F
A
B
BB
M
KL
S
E
M’

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R
V
U
W
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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A
E
D
B’
C
B
A
WG
F
F