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13.6 Drive Coupling Removal and Replacement
If it is only necessary to remove part of the drive assembly the following procedure applies.
Support the rear of the powerchair on suitable stands and disconnect the motor wiring loom from
the main loom. Bend the tab washer (M-158) away from the bolt head and using a 10mm spanner
remove the drive securing bolt (F-95). This is made easier if the drive is engaged.
The drive components can now be withdrawn from the motor drive shaft and care should
be taken not to lose any parts.
Examine the components for damage or wear as indicated from the previous checks. If the
wheel bushes need replacing these can be removed by the use of a soft drift and hammer.
Replacement of wheel bushes requires the use of a press to prevent burring the edges of the
bushes.
If it is necessary to replace the stub axle (D-01L) the motor will require removal from the
mounting plate. Using a 7/16 A/F spanner release the three retaining bolts and withdraw, being
careful not to lose the spacers. The motor can now be removed by sliding the drive shaft out of
the stub axle. Using a 35mm AF spanner remove the stub axle nut (D-09). Replace the stub axle
(D-01L), apply thread locking compound and tighten to 35 lbs/ft (47Nm) torque. Refit the motor to
the mounting plate, insert spacers and tighten bolts to 10 lbs/ft (13.5Nm) torque.
Re-assemble the thrust washers, metal wavy (F-65) first, large nylon washer (F-67)
second. Fit the wheel and small nylon washer (F-66). Fit the drive collar (M-159), cup washer
(M-157), spring (M-156) and drive dog (M-155). Use a new tab washer (M-158) and bolt (F-95).
Apply threadloc compound (Grade 66) to the bolt threads and tighten 10 lbs/ft (13.5Nm) torque.
Finally bend the tabs up ensuring that they are in contact with the bolt head.
13.7 Power System Removal
If it is necessary to remove the complete drive assembly as one unit the following
procedure applies.
Support the rear of the powerchair on suitable stands and disconnect the motor wiring
loom from the main loom. Using 7/16 AF spanners release the four nuts/bolts which attach the
mounting plate to the side frame. Withdraw the bolts and remove the assembly.
13.8 Power System Replacement
Replacement is a straightforward reversal of the above procedure. The attachment nuts
and bolts should be renewed and tightened to a torque of 35 lbs/ft (47Nm).
IMPORTANT
Motor and gearbox maintenance is limited to
complete assembly replacement except
replacing motor brakes and brushes.
