Helion HLNA0769, Manual

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24
Gears
Periodically remove the gear cover to clearly inspect the gears and ensure there
is no debris in the gear compartment.
Proper gear mesh setting is crucial for proper operation and life of gears in your
product. It is important to have the pinion gear (attached to motor) as close to
the spur gear (attached to drive shaft) as possible yet while providing a minimal
amount of backlash. Backlash is the rotation one gear has to make before
contacting the other. Having the gear mesh set too tight will cause excess load
on the electrical components and may cause premature failure. Having gear
mesh set too loose will cause excess wear and possible skipping of teeth during
operation thus causing excess wear and premature failure.
Checking the gear mesh and setting proper backlash.
1. Remove the spur gear cover.
2. Check how much movement is allowed (backlash) of the spur gear before
the pinion gear moves (this is mostly feel, not visual). Check this movement
in multiple places by rotating the spur gear approximately 1/6 rotation and
rechecking.
3. If the spur gear is allowed to move more than a very small amount, or if
there is no backlash, the gear mesh must be adjusted. If there is a lot of
movement, it is recommended to attempt to tighten the mesh. Attempted
adjustment should only improve the situation; if the mesh was correct to
begin with, you will know what that feels like, and if it wasn’t correct, it will
be when you are done after following these procedures.
Setting the Gear Mesh
1. Loosen the clamping screw securing the motor plate’s rotation in the motor
mount, only enough to allow the motor to rotate in the mount. Check and
ensure there is no debris in the gears affecting the mesh.
2. Rotate the top of the motor away from the center of the chassis, insert a
strip of notebook paper between the pinion and spur gear, then rotate the
motor plate back until there is no backlash. You will have to push/twist
relatively hard to ensure the paper is pressed all the way into the teeth.
3. Hold the motor snugly in position while retightening the screw. Only tighten
the screw until the motor won’t move. There should be a slight gap between
the coils of the spring.
4. Rotate the spur gear (turn the tires) to feed the paper out of the mesh, re-
check the gear mesh and adjust again if necessary.
5. Re-install the spur gear cover when the mesh is properly set.
WARNING: NEVER OPERATE YOUR VEHICLE WITH THE SPUR GEAR COVER
REMOVED. SEVERE INJURY, DAMAGE TO ELECTRICAL COMPONENTS, AND
EXCESSIVE WEAR AND TEAR ON DRIVETRAIN MAY RESULT.
Shocks
Periodically inspect the shocks for smooth motion, leaking oil and dirt residue
build up around the shaft or caps. Do not allow dirt to build up around the