Drive Motors
Contents
1. Perform a visual inspection of the running surface It must show only slight running traces If the running surface shows deep grooves the motor collector is damaged Any further repair of the motor can only be performed by the INVACARE Service Department Installing carbon brushes Place carbon brush into its guide see drawing S NOTE Make sure that the carbon brush is not canted when introduced It must be able to move smoothly within the guide Introduce the solder cap of the carbon brush into the guide as shown in the drawing Screw in the stopper S NOTE Do not fasten too tightly it would destroy the stopper 13 3 Testing motor magnetic brake and free wheel switch Testing preparations replacing drive motors Remove battery boxes Remove splash protection Remove cable binders Remove the connection plug of the motor to be tested or replaced from the socket board NOTE Press down plug lock as otherwise the plugs would be dama ged Wear Limit min 11 mm Carbon Brus Solder Cap stopper Remove BUS plus Motor Cable Motor Cable 11 Testing drive motors Only basic tests can be performed on the drive motors Any further tests are only possible with special testing instruments The following components of the drive motors can be tested by means of a multimeter Motor coils for continuity Motor brakes for resistance Testing hints If the following tests2. show no results the drive motor should be sent in for testing Any further measurements can only be performed by the INVACARE Service Department Visual test of the plug contacts Test whether the contacts of the plug are not unduly bent up pushed back or oxidized Testing the electric circuit of the motor e Set multimeter to continuity check e Measure the continuity of the motor s electric circuit at the plug contacts shown in the drawing to the right NOTE Instructions on the use of the multimeters can be found in the User s Manual Testing the magnetic brake e Engage the motors e Set the multimeter to resistance measuring e Measure the resistance of the brake coils at the plug contacts shown in the drawing to the right It must amount to between 20 ohms and 200 ohms Testing the free wheel switch The free wheel switch switches the motors to pushing operation putting the magnetic brake out of function e Disengage motors e Set multimeter to resistance measuring e Measure the resistance of the brake coils at the plug contacts shown in the drawing to the right The resistance measured must amount to infinite Plug Contacts Motor Brake Contacts Motor Contacts Testing the Electric Circuit of the Motor Testing Magnetic Brake Resistance 20 ohms 200 ohms No continuity of the electric Parted cable in the motor Replace motor circuit of the motor Carbon brushes worn out Check replace carb
3. 13 0 Check and Repair Work on Drive Motors 13 1 General Drive motor assembled Drive unit assembled Chassis 1 2 Drive motor 3 2x Stopper for carbon brush 4 2x Coupling lever 5 Motor plug 6 Main module 7 2x Allen screw M6x30 with lock washer 8 Gear NOTE 9 Coupling mechanism e Depending on type the motors can be equipped with a coupling mechanism or with separate coupling levers Inspection Remedy e Motor vibrating emitting running noises gt Test motor replace if necessary e Motor won t start gt Test motor replace if necessary e Power brake not reacting gt Test brake replace motor if necessary e Gear emitting running noises or being gt Replace drive unit or gear blocked See chapter 11 6 13 2 Testing or replacing carbon brushes NOTE Removing carbon brushes e Worn out carbon brushes lead to a deterioration of the motor performance e Each motor is equipped with two carbon brushes They are located behind the lateral stoppers 4 of the motors Removing carbon brushes e Remove the stopper 4 NOTE Make sure that while you loosen the stopper same is being subjected to a slight spring pressure e Pull carbon brush from its guide 70 Testing carbon brushes e Testing length Measure the length of the carbon brush Orginal length 13 mm Wear limit 11 mm Once the carbon brush has reached the wear limit of 11 mm it must be replaced Testing the bearing surface
4. on brushes Resistance being 0 ohms short circuit in magnetic brake Replace motor Resistance clearly gt 200 Defective contact in the ohms but not infinite magnetic brake Replace motor 2 13 4 Disasembly Assembly of Drive Motor Disassembly of drive motor Motor fastening Locking screw M5 x 10 SW 8 mm NOTE e The first two steps apply only to motors with a coupling mechanism e Loosen locking screw SW 8 mm at the disengaging lever of the motor to be replaced e Remove the disengaging lever e Support drive motor with your hand loosen completely two fastening screws hexagon socket SW 5 mm with lock washers Fastening Screw and detach drive motor Hexagon Socket M6 x 30 SW 5 mm NOTE e Do not damage lose plastic bushing and starting damper Assembly drive motor Motor Output Shaft e Push plastic bushing on the motor output shaft ve Plastic Bushing e Place starting damper on the gear input shaft Gear Input Shaft Make sure that the driver of the starting damper interlocks with the gear input shaft e Fasten the motor to the gear by means of the two fastening screws hexagon socket SW 5mm and the two lock washers The following is to be observed The motor cables must point upwards to the frame of the chassis The slot of the motor output shaft must be in alignment with the driver of the starting damper NOTE e If key and slot are not aligned exactl
5. y turn the driving wheel gear output shaft until the slot locks into starting Damper Driver place and the motor is located exactly in front of the gear e Fasten screws hand tight Do not overturn 13 NOTE Position of Disengaging Lever e The following two steps apply only to motors with a coupling mechanism e Lock the motor by turning the shaft left by means of a suitable tool e g a pipe wrench driving position e Now mount the disengaging lever and fasten it by tightening the locking screw SW 8 mm The locking screw M 5 x 10 must contact exactly the flattened part of the shaft see drawing Disengaging Locking Screw Lever M5 x 10 SW 8 mm NOTE J Following the assembly make sure that no moving parts such as rods or screw connections are sliding against the motor casing Conduct a performance test e Lead the motor cable to the main module Connection Plan Motor Plug and plug the connection plug into the socket board linker Fahrmotor Batterie ACS Fahrpult rechter Fahrmotor left driving motor Battery ACS Remote right driving motor zu weiteren Modulen e Secure the cables by means of cable binders Position of the Cable Binders e Mount the splash protection A A CAUTION 3 a Following the assembly the correct operating of the Cable disengaging lever as well as the driving functions must be tested Binders gt Make a test drive lt 74
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