Problems With The Coupler on Chopper Weed-Victa Electric Mower Conversion
After the adapter plate was bolted to the crankcase and the Electric Motor with the U-channel coupler bolted to the adapter plate, the Electric Mower was wired up and a small patch of grass was mowed. However, the motor locked up and ground to a halt. After unbolting the motor from the mower, it was evident that the coupler was wearing and digging into the motor. The nut was also getting tighter. I would remove the Electric Motor, loosen the nut a bit and bolt the Electric Motor back onto Chopper Weed. The problem would repeat itself shortly after being in operation.
In trying to solve the problem, several ideas were attempted such as:
- using two nuts on the shaft so that the nuts would not tighten any further into the coupler;
- drilling a hole across the shaft and putting in split pin to hold the washers which in turn holds the coupler in place and
- having a nut loosely on with split pin through the hole in the shaft.
The problem with using two nuts was that the second nut interfered with the crankshaft of the engine. As a result, I was not able to bolt down the Electric Motor to the mower.
The problem with having the coupler held in with washers and a split pin was that the coupler was not firm on the shaft and it flopped around. I also did not washers of the correct thickness.
The problem with having the nut loosely on with the split pin through the shaft was that the nut would tighten up during operation of the motor, causing the coupler to dig into the motor. The split pin was not even required.
There was also another problem with the coupler. Being made from aluminum, the key way wore out meaning eventually, the mower blades were not rotating in synch with the Electric Motor.
It was evident that this coupler made from U-channel aluminum was not a successful implementation and something different totally different had to be done. The lesson learned was to use a material that is harder. The solution: use the original pulley that came with the motor and drill a hole in pulley to so it can engage the bolt in the crankshaft.
This is Al Bunzel signing out.