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
p. 2
2540 / 2545 • REPAIR
Table of contents

p. 3
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.
p. 4
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.
p. 5
2540 / 2545 • REPAIR

2. Electrical diagram
p. 6
2540 / 2545 • REPAIR
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
p. 7
2540 / 2545 • REPAIR

p. 8
2540 / 2545 • REPAIR
Y
D
B
J
T
G
H
C
I
Q
O
P
N
F
A
B
BB
M
KL
S
E
M’

p. 9
2540 / 2545 • REPAIR
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.
p. 10
2540 / 2545 • REPAIR
A
E
D
B’
C
B
A
WG
F
F

4.3. Fitting top cover
1. Push the motorband through the slot and fit the top cover (G) onto
the portable motor.
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
WG
F
F
B’

4.4. Replacing the up/down switch
1. Remove the top cover (see step 4.2.)
2. Release the fastons and press the switch (H) out of the frame.
3. Snap a new switch back into the frame 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.)
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 • REPAIR
H
grey
black
blue
I
red of rectifier (W)

4.6. Changing the battery
1. Remove the top cover (see step 4.2.)
2. Loosen spring (J) and spring (K) from the batteries by pressing
them together and pulling them 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
WJ
K
L

4.7. Changing the PCB
1. Remove the top cover (see step 4.2.)
2. Disconnect the wires from the PCB (M) and lift off the PCB from
its supports.
3. Fit a new PCB and reconnect the wires as shown in 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

5. Remove the spring (N) and circlip (O) from the bolt (P).
6. Remove the bolt from the frame. Roller (Q) can also 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

11. Unscrew the 3 bolts (X) that attach the motor to the frame and
remove the motor (U). (The gear wheel on the motor should also
be removed)
12. Remove the gear wheel from the motor 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

17. Before connecting the cables and the fastons see the photo below
or the electrical diagram, section 2
18. Test the operation of the portable motor.
19. Refit the top cover (see step 4.3.).
4.9. Changing the 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
brown

5. Loosen the 2 adjusting bolts (Z) on capstan.
6. Remove the motorband and fit a new motorband. Place the short
loop on the spool shaft with the stitched part upwards. Ensure that
the motorband is positioned under the safety arm (AA).
7. Push a bolt (Z) through the loop and tighten. Move the spool half a
turn upwards using the up/down switch.
8. Fit the second bolt above 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 secure it
with a circlip (R). (use a new circlip)
12. Test the operation of the portable motor.
13. Refit the top cover (see step 4.3.)
p. 18
2540 / 2545 • REPAIR
Z
Z
Y
T
R
S
AA

4.10. Changing the emergency down
1. Remove the top cover (see step 4.2.)
2. Disconnect all wiring from the emergency down switch (BB).
3. Unscrew the nut 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’