Invacare® Tornado SERVICE MANUAL
Contents
1. Tornado Service Manual 6 4 A W Replacing the main fuse If the main fuse is burnt out then this almost certainly indicates a short circuit in the battery cables If the cause is not a battery cable then there may be a short circuit inside the power module This is very unlikely but can occur under extreme conditions such as when the wheelchair has been cleaned using a high pressure cleaning device Needless to say using such a device against Invacare s strong recommendation not to in the User Manual will void the warranty CAUTION Danger of fire e Only ever use a fuse with the correct value ACS System 50 A Shark 40 A e Ifthe main fuse is burnt out then the cause must be fixed before inserting a new fuse Requirements e Combination wrench 8mm e Spare fuse e Large flat bladed screwdriver e Use the flat bladed screwdriver to carefully pry the rear plastic cover off as shown in the picture e Open the lid of the fuse compartment 1 e If the main fuse is burnt out then first determine what caused this Only when the problem has been fixed may the fuse be replaced e Check the battery cables 2 in their entirety for damage If damaged replace them e fthe battery cables are not damaged then the cause may be a short circuit inside the power module 3 partially hidden by cables in the picture This is not necessarily visible from the outside In this case exchange the power module for a2. 69 57 57 Fax 31 0 318 69 57 58 Invacare AB Fagerstagatan 9 163 91 Spanga Sverige Kundtjanst 46 0 8 761 70 90 Fax Kundtjanst 46 0 8 761 81 08 sweden invacare com Service Invacare JARFALLA K 46 0 8 621 08 44 Fax 46 0 8 621 08 45 Invacare jarfalla swipnet se MOLNDAL K 46 0 31 86 36 00 Fax 46 0 31 86 36 06 invacare goteborg swipnet se LANDSKRONA T 46 0 418 285 40 Fax 46 0 418 180 89 invacare la swipnet se OSKARSHAMN EI 46 0 491 101 40 Fax 46 0 491 101 80 invacare O hamn swipnet se Page 2 As at 19 03 2004 Tornado Service Manual Notes on transport e If the wheelchair has to be shipped back to the manufacturer for major repairs you should always use the original packaging for transport e You should also include as accurate a fault description as possible The following symbols are used in these repair instructions Note wv This symbol identifies general information which indicate special points or simplifications in dismantling reassembly CAUTION it is imperative that you observe any gt safety instructions lt identified with this symbol Y This symbol identifies service work bai Page 4 As at 19 03 2004 Service Manual Contents 1 SAFETY AND ASSEMBLY INSTRUCTIONS 1 1 Before any inspection or repair work 1 2 During dismantling reassembly 1 3 After completion of wo
3. Pay attention to small pieces and the order in which the components are disassembled Arrange them in an orderly fashion so they can easily be assembled again in the right order e Prop up the wheelchair by lifting it up on the side that you want to work on and then placing the wooden block underneath the battery box on that side e Unscrew the 4 bolts that hold the wheel 1 using the 5mm Allen key e Remove the wheel from the hub e Reassembly is done in reverse order Page 50 As at 19 03 2004
4. drive unit e Open the electronic panelling pushing the rear side panelling away slightly using a large flat screwdriver e Pull the motor plug 1 for the right hand or left hand drive out of the electronics As at 19 03 2004 Page 25 Tornado Service Manual e Secure the drive unit against falling out by placing a wooden block or styrofoam block underneath e Insert the hexagon socket 5mm through the bore and unscrew the rear bolts 1 on the drive suspension e Remove the drive unit from the suspension in a downward direction e Unscrew the six screws 1 on the bedding plate AN CAUTION Fire hazard Cables can be pinched and chafed e Please ensure correct cable layout The motor cable must be secured on the panelling by means of a plastic ring and may not protrude into the lifter area e The drive unit is installed in reverse order Page 26 As at 19 03 2004 Service Manual Tornado 6 2 Replacing components of the ACS or Shark electronics This chapter will explain how to replace the components of either the ACS or the Shark electronic systems on the Tornado Wi Requirements ES e Large flat bladed screwdriver e Phillips screwdriver e Hexagonal socket head key 4 mm e Use the flat bladed screwdriver to carefully pry the plastic cover off as shown in the picture The picture at right shows the positions of the CLAM and the Power Module of the ACS System The Shark Power Module is l
5. page 24 Batteries None Batteries may e Replace the See Replacing cannot be be defective batteries batteries on page 29 charged LEDs on the Charger may e Replace the See User Manual of charger are be defective charger the charger flashing Wheelchai_ None Batteries may e Replace the See Replacing r drives be defective batteries batteries on page 29 too slowly As at 19 03 2004 Page 21 Tornado Service Manual 5 2 2 Shark Error Codes and Diagnostic Codes The drive electronics are capable of rectifying some errors automatically In this case the status display will cease to flash Please switch the remote on and off several times Wait approx 5 seconds each time before switching the remote on again If this does not rectify the error identify the error using the flash codes shown below FLASH Meaning Solution Notes CODE 1 User error e Ensure that the joystick is in the neutral central position simply release the joystick and switch on again 2 Battery error e Check battery and supply cable See Checking the cables on page 36 e Charge batteries If you switch the See User Manual wheelchair off for a few minutes the batteries can often recharge to such an extent that a short run is still possible However you should only do this in an emergency as this causes the batteries to discharge excessively e Replace batteries See Replacing batteries on page 29 3 Fault on l
6. please proceed as follows Troubleshooting the Tornado with ACS Tornado e Identify the possible cause of the fault by using the troubleshooting tables below e Check the Status Display on the remote Identify the error code if it is flashing e Perform the necessary checks and repairs as recommended in the table below 5 1 1 Diagnosing driving faults PROBLEM OTHER SYMPTOMS POSSIBLE CAUSE SOLUTION REFERENCE Wheelchai r will not drive As at 19 03 2004 Status display on remote lights up normally and does not show an error code Drive motors may be disengaged e Engage the drive motors See User Manual Status display on remote does not light up Batteries may be defective e Replace the batteries See Replacing batteries on page 29 Batteries may e Charge the See User Manual be completely batteries discharged Power supply e Check the See Replacing the main to the remote main fuse fuse on page 34 may be interrupted e Check cables See Checking the between cables on page 36 modules for loose connections or damage Remote may e Exchange See Replacing the be defective the remote on the wheelchair for a different one to eliminate the possibility that the remote may be the cause remote on page 38 Status display on remote is flashing Various causes Identify the error code See REM24 Error Codes and Diagnosti
7. pressing in the pin in the valve e Remove the 5 cylinder head screws back of the wheel 2 e Remove the rim halves from the tyre e Remove the inner tube from the tyre e Repair inner tube and replace or insert a new one NOTE wv If the old inner tube is to be repaired and re used and has become wet during repair you can make replacement easier by sprinkling the inner tube with a little talcum powder NOTE wv Re assembly is done in reverse order Ensure that the tyre is replaced on the same side and in the same travel direction as it was previously mounted e Insert the wheel rim halves from outside into the tyre e Pump alittle air into the inner tube e Insert the cylinder head screws in the rim and tighten the wheel rims firmly e Ensure that the tyre outer is seated correctly e Pump the tyre up to the prescribed pressure e Check that the tyre is seated correctly once again e Screw the valve cap back on e Heft the wheel As at 19 03 2004 Page 49 Tornado Service Manual 6 12 A VW Replacing a drive wheel CAUTION Danger of the wheelchair tipping over or rolling away e Secure the wheelchair from tipping over by propping it up with a wooden block under the battery box that is long and wide enough Using a wooden block that is too short or too high could cause the wheelchair to tip over e Switch the wheelchair off at the remote Requirements e 5mm Allen key Note
8. repair manual and the associated operating manual e Observe the minimum requirements for carrying out the work see chapter entitled General information A Caution e Please note the heavy weight of some components This applies especially to removal of drive units an d batteries e The wheelchair must be switched off before removal of voltage carrying components To do this disconn ect the batteries or remove them e When making measurements on voltage carrying components avoid short circuiting the contacts Danger of fire and combustion e Use only undamaged tools in good condition 1 2 During dismantling reassembly e Mark all current settings for the wheelchair seat armrests backrest etc and the cable connecting plugs associated before any removals This makes reassembly easier A v As at 19 03 2004 Caution Prop up the lifted wheelchair with appropriate supports before starting the disassembly or assembly Never use standard nuts instead of self locking nuts Always use correctly dimensioned washers or spacers Note All plugs are fitted with mechanical safety devices which prevent release of the connecting plugs during operation To release the connecting plugs the safety devices must be pressed in When reassembling ensure that these safety devices are correctly engaged Cable binders which have been cut off during disassembly should be replaced by new ones during reassembl
9. wheel e Loosen and remove the 19 mm nut using the socket wrench Hold the wheel so it does not rotate while removing the nut e Pull the steering head shaft down and out of the steering head tube e Remove the washer and the bearing race from the top of the tube The other bearing race should be on the shaft IMPORTANT REASSEMBLY INFORMATION The pictures show the wide rim on the outside of the bearing race O A and the narrow rim on the inside B The bearings must always be assembled so that the narrow rims are facing each other inwards The steering head bolt and the nut must always press against the wide rims from the outside Otherwise the bearings will be forced out apart by the pressure of the bolt The steering wheels should swivel freely after assembly but there should be no play in the bearings e First tighten the nut to 20 Nm 2 Nm e Loosen the nut a little e Retighten to 15 Nm 1 5 Nm Page 42 As at 19 03 2004 Service Manual Tornado 6 9 2 Rear Castor Wheels e Use the flat bladed screwdriver to carefully pry the rear plastic cover off as shown in the picture e Prop up the wheelchair by lifting it up on the side that you want to work on and then placing the wooden block underneath the battery box on that side e Loosen and remove the 19 mm nut 1 that holds the castor wheel using the socket wrench Hold the wheel so it does not rotate while removing the nut e Pull the ste
10. Invacare Tornado SERVICE MANUAL These instructions contain information about Troubleshooting Repair Edition 03 2004 Service Manual Tornado General information These repair instructions contain all the information necessary for maintenance and overhaul of the wheelchair e All maintenance and overhaul work must be carried out in accordance with these repair instructions e Please observe all safety instructions e Information about operation or about general maintenance and care work should be taken from the wheelchair Operating Manual e You can find information about ordering spare parts in the spare parts catalogue e Use only genuine Invacare spare parts Using parts from any other source will void the warranty e We reserve the right to make any alterations on the grounds of technical improvements e The wheelchair may only be maintained and overhauled by qualified personnel e The minimum requirement for service technicians is relevant training such as in the cycle or orthopaedic mechanics fields or suitably long term job experience Experience and knowledge of electrical measuring devices Multimeter is also a requirement Special Invacare training sessions are recommended e Alterations to the wheelchair which occur as a result of incorrectly or improperly executed maintenance or overhaul work lead to the exclusion of all liability on the part of INVACARE e lf you have any problems or questions please
11. When replacing the batteries the battery poles MUST NOT come into contact with metal parts of the wheelchair causing bridging e Be sure to replace the battery pole caps after the batteries have been replaced CAUTION Environmental contamination e Used batteries should not be disposed of with domestic waste or outdoors Please dispose of the batteries professionally by giving them to your local harmful substance point of acceptance Pre requisites e 11mm open jawed wrench 5mm and 6mm hexagon socket Diagonal nosed cutting pliers Rubber hammer Water resistant marker Cable binder Replacement battery ies Optional new battery belts Large flat screwdriver Please note It is easier to carry out a few work steps with the assistance of another person in particular when lifting the lifter and unlocking the retaining mechanism As at 19 03 2004 Page 29 Tornado Service Manual e Move the lifter to the uppermost position e Raise the lifter just a little more so that the retaining mechanism 1 locks into place e Check whether the retaining mechanism 1 is fully locked into place e Move the regulating motor to the lowest position The regulating motor slides out of the upper guiding device e Use a5mm or 6mm hexagon socket to unscrew the screws 1 and 2 on both sides of the vehicle e Remove the front panelling to the front e Open the plug in connection on the regulating motor cable e Pull
12. and the order in which the components are disassembled Arrange them in an orderly fashion so they can easily be assembled again in the right order e Prop up the wheelchair by lifting it up on the side that you want to work on and then placing the wooden block underneath the battery box on that side 1 e Use the 5 mm Allen key to loosen and remove the screw that holds the wheel 2 e Pull the wheel off the axle e Use the 6 mm Allen key to loosen and remove the bolts 1 that hold the outer shroud e Release the rear plastic clip 2 that attaches the inner and outer shrouds e Remove the outer shroud As at 19 03 2004 Page 45 Tornado Service Manual e Release the forward plastic clip 1 that holds the inner shroud e Remove the inner shroud e Use the 6 mm Allen key and the 13 mm open ended wrench to remove the lower bolt 1 that attaches the Walking Beam and the steering head tube of the front castor wheel e Use the 13 mm open ended wrench to remove the bolt 1 that holds the lower plastic guide of the anti dive spring e The two halves of the Walking Beam can now be moved independently from each other Lift the upper part which is still attached to the steering head tube of castor wheel to release the pressure on the anti dive spring 1 e Replace the anti dive spring and or the plastic guide s if necessary Page 46 As at 19 03 2004 Service Manual Tornado e Reassembly is done
13. be defective batteries batteries on page 29 Page 16 As at 19 03 2004 Tornado Service Manual 5 1 2 Diagnosing problems with electric actuators In case an electric actuator will not function identify the source of the problem using the following table PROBLEM OTHER POSSIBLE SOLUTION REFERENCE Electric Actuator does not function SYMPTOMS CAUSE Remote CLAM is e Replace the See Replacing displays a defective CLAM components of the ACS or flashing E Shark electronics on page status diode on 27 the CLAM does not go out even if the remote is switched off or disconnected None Cable may e Check that See Checking the cables be the cable is on page 36 disconnected not or damaged disconnected or damaged If necessary replace the cable Electric e Test the See Testing an actuator actuator may actuator motor on page 39 be defective Remote may e Exchange See Replacing the be defective the remote on the wheelchair for a different one to eliminate the possibility that the remote may be the cause remote on page 38 As at 19 03 2004 Page 17 Tornado 5 1 3 Service Manual REM24 Error Codes and Diagnostic Codes The drive electronics are capable of rectifying some errors automatically In this case the status display will cease to flash Please switch the remote on and off several times Wait approx 5 seconds each time before s
14. c Codes on page 18 Page 15 Tornado Service Manual PROBLEM OTHER POSSIBLE SOLUTION REFERENCE SYMPTOMS CAUSE Status display Speed e Replace See Adjusting and on remote reduction cable or replacing the speed flashes 2x switch on the switch reduction switch on drive mode lifter may be page 40 display shows defective or U disconnected Wheelchai None Batteries may e Replace the See Replacing r does not be defective batteries batteries on page 29 drive voltage not smoothly stable Drive motor s e Replace the See Replacing the drive may be drive motor s motors on page 24 defective Batteries None Batteries may e Replace the See Replacing cannot be be defective batteries batteries on page 29 charged LEDs on the Charger may e Replace the See User Manual of the charger are be defective charger charger flashing Wheelchai Status display Seat lifteris not e Return seat See User Manual r drives on remote in driving lifter to driving too slowly flashes 2x position either position drive mode too high or too display shows low and has U activated the automatic speed reduction Speed e Adjust the See Adjusting and reduction micro switch replacing the speed micro switch on reduction switch on the seat lifter page 40 may be badly adjusted None Remote may e Replace the See Replacing the be defective remote remote on page 38 Batteries may e Replace the See Replacing
15. contact INVACARE SERVICE Invacare Deutschland GmbH Invacare A S KleiststraBe 49 Sdr Ringvej 39 32457 Porta Westfalica 2605 Br ndby Deutschland Danmark Technische Hotline 01 80 5 26 22 64 T Kundeservice 45 0 3690 0000 Fax Technische Hotline 01 80 5 26 22 75 Fax Kundeservice 45 0 3690 0001 Invacare SA Invacare POIRIER E E Les Roches F 37230 Fondettes Poligon Industrial de Celra France 17460 Celr Girona T Service Apr s Vente 33 0 2 47 62 64 66 ESPANA Fax Service Apr s Vente 33 0 2 47 42 12 24 T 34 0 972 49 32 00 Fax 34 0 972 49 32 20 As at 19 03 2004 Page 1 Tornado Invacare Ltd South Road Bridgend Mid Glamorgan CF31 3PY United Kingdom Customer Service 44 0 1656 647 327 Fax Customer Service 44 0 1656 649 016 Invacare AS Grensesvingen 9 0603 Oslo Norge Kundeservice 47 22 57 95 10 Fax Kundeservice 47 22 57 95 01 Service Manual Invacare Mecc San s r l Invacare PORTUGAL Lda Rua Senhora de Campanha 105 4369 001 Porto PORTUGAL T 351 225105946 Fax 351 225105739 Via Dei Pini 62 36016 Thiene VI ITALIA T 39 0 445 380059 Fax 39 0 445 380034 Invacare B V Celsiusstraat 46 NL 6716 BZ Ede The Netherlands Invacare n v Autobaan 14 8210 Loppem Brugge BELGIUM T 32 50 831010 Fax 32 50 831011 B 31 0 318
16. eft hand e Check motor cable and connecting See Checking the motor M2 plugs cables on page 36 e Check motor See Replacing the drive motors on page 24 4 Fault on right hand e Check motor cable and connecting See Checking the motor M1 plugs cables on page 36 e Check motor See Replacing the drive motors on page 24 5 Error on left hand e Check cable and connecting plugs See Checking the M2 wheel lock cables on page 36 6 Error on right hand e Check cable and connecting plugs See Checking the M1 wheel lock cables on page 36 7 Error in Shark e Check remote bus cable and all See Checking the remote connecting plugs cables on page 36 e Replace remote See Replacing the remote on page 38 Page 22 As at 19 03 2004 Service Manual FLASH Walz 8 Meaning Error in Shark power module Solution Check all cables and connecting plugs in the Shark system Replace power module Tornado Notes See Checking the cables on page 36 See Replacing components of the ACS or Shark electronics on page 27 Communication error in Shark system Check all cables and connecting plugs in the Shark system Replace remote See Checking the cables on page 36 See Replacing the remote on page 38 10 Unknown error Check all cables and connecting plugs See Checking the cables on page 36 11 Incompatible remote The wrong remote
17. er of Please note The battery inserters can be inserted between the battery and the carrying belt They are thus easier to install wi Please note The battery poles on the rear battery must point backward and those on the front battery to the front The batteries cannot be connected in any other fitting direction e Assemble in accordance with this installation sequence e Push the batteries 3 together with the carrying belt 5 and battery inserter 4 into the chassis e Push the regulating motor 2 together with the nest into the chassis and allow to lock into place in the bottom plate Secure using lateral Allen screws e Apply the front panelling 1 and secure using lateral Allen screws e Screw the battery cable onto the plus and minus pole Slide the pole caps over the poles e Plug all cables into the electronic components until you hear a slight click AN CAUTION Danger of crushing e Please ensure that the regulating motor slides into the upper guiding device e Move the regulating motor to the uppermost position and ensure that it slides into the upper guiding device 1 Page 32 As at 19 03 2004 Service Manual Tornado e Raise the lifter slightly and unlock the retaining mechanism 1 The entire lifter load is now on the regulating motor again e Test all vehicle functions e Check the charge status of the new batteries and charge fully As at 19 03 2004 Page 33
18. ering head shaft down and out of the steering head tube e Remove the washer and the bearing race from the top of the tube The other bearing race should be on the shaft IMPORTANT REASSEMBLY INFORMATION The pictures show the wide rim on the outside of the bearing race a A and the narrow rim on the inside B The bearings must always be assembled so that the narrow rims are facing each other inwards The steering head bolt and the nut must always press against the wide rims from the outside Otherwise the bearings will be forced out apart by the pressure of the bolt As at 19 03 2004 Page 43 Tornado Service Manual The steering wheels should swivel freely after assembly but there should be no play in the bearings First tighten the nut to 20 Nm 2 Nm e Loosen the nut a little e Retighten to 15 Nm 1 5 Nm Page 44 As at 19 03 2004 Service Manual Tornado 6 10 ve z Se lt Replacing the Anti Dive Spring and or its plastic guides CAUTION Danger of the wheelchair tipping over or rolling away e Secure the wheelchair from tipping over by propping it up with a wooden block under the battery box that is long and wide enough Using a wooden block that is too short or too high could cause the wheelchair to tip over e Switch the wheelchair off at the remote Requirements e 13mm open ended wrench e 5mm Allen key e 6mm Allen key Note Pay attention to small pieces
19. ess than 1Q then motor has a short circuit In either case the motor needs to be replaced As at 19 03 2004 Page 39 Tornado Service Manual 6 8 Adjusting and replacing the speed reduction switch Find out here how you can adjust and replace the switch that reduces the speed when in the upper lifter position V 4 Pre requisites e Small pliers e Move the lifter to the upper and lower position several times In doing so check whether the contact switches e Ifthe contact does not switch bend the plate 1 slightly e If the contact is faulty replace the entire cable harness e Check all vehicle functions Page 40 As at 19 03 2004 Service Manual Tornado 6 9 Replacing the steering head bearings on the front or rear castor wheels AN CAUTION Incorrect reassembly can damage the bearings or cause the steering wheels to fall out e The single row angular ball bearing races are not the same on both sides For this reason there is only one correct way to fit them It is imperative that you observe the reassembly information Yz Requirements AM e Socket wrench 19 mm e Torque wrench 6 9 1 Front Castor Wheels e Release the plastic clips 1 that hold the shroud e Pull the shroud outwards and forward to remove As at 19 03 2004 Page 41 Tornado Service Manual e Prop the wheelchair up on the side that you want to change the bearings on by placing an object underneath the drive
20. in reverse order As at 19 03 2004 Page 47 Tornado Service Manual 6 11 A A W Repairing a flat tyre CAUTION Danger of the wheelchair tipping over or rolling away e Secure the wheelchair from tipping over by propping it up with a wooden block under the battery box that is long and wide enough Using a wooden block that is too short or too high could cause the wheelchair to tip over e Switch the wheelchair off at the remote CAUTION Injury hazard If the wheel has been insufficiently tightened during assembly it can become loosened during driving e When reassembling the drive wheels tighten the Allen screws at a torque of 30 Nm e Secure all screws using a suitable blocker e g Loctite 243 Requirements e Open ended spanner 5 mm e Repair kit for tyre repair or a new inner tube e Talcum powder e Screw blocker Loctite e g Loctite 243 Note Pay attention to small pieces and the order in which the components are disassembled Arrange them in an orderly fashion so they can easily be assembled again in the right order e Prop up the wheelchair by lifting it up on the side that you want to work on and then D placing the wooden block underneath the i battery box on that side e Unscrew the 4 bolts that hold the wheel 1 using the 5mm Allen key e Remove the wheel from the hub Page 48 As at 19 03 2004 Service Manual Tornado e Unscrew valve cap e Depressurise tyre by
21. ion plugs the cables on loose defective or motor page 36 defective o See Replacing the drive motors on page 24 Page 18 As at 19 03 2004 Service Manual Tornado lower battery voltage e Check battery charger Flash code Meaning Solution Notes 7 x flashes Completely discharge e Pre charge battery See User Manual battery 8 x flashes Battery voltage too high e Switch lights on to See User Manual of battery charger 9 or 10 x flashes Faulty data transmission between modules Remove all electronic modules except the Power Module and the Remote Re attach modules one by one to determine which one is causing the fault See Replacing components of the ACS or Shark electronics on compatibility problems module page 27 11 x flashes Motors overloaded e Switch remote on overheated and off wait if necessary 12 x flashes Module used has e Remove incorrect See Replacing components of the ACS or Shark electronics on page 27 As at 19 03 2004 Page 19 Tornado Service Manual 5 2 Troubleshooting the Invacare Tornado with Shark Remote If a problem occurs with the wheelchair then please proceed as follows e Identify the possible cause of the fault by using the troubleshooting tables below e Check the Status Display on the remote Identify the error code if it is flashing e Perform the necessary checks and repairs as recommended in the table be
22. low 5 2 1 Diagnosing driving faults PROBLEM OTHER POSSIBLE SOLUTION REFERENCE SYMPTOMS CAUSE Wheelchai Status display Drive motors e Engage the drive See User Manual r will not on remote may be motors drive lights up disengaged normally and does not show an error code Status display Batteries may e Replace the See Replacing on remote be defective batteries batteries on page 29 does not light up Batteries may e Charge the See User Manual be completely batteries discharged Power supply e Check the main See Replacing the to the remote fuse main fuse on page may be 34 interrupted Check cables See Checking the between modules cables on page 36 for loose connections or damage Remote may Exchange the See Replacing the be defective remote on the remote on page 38 wheelchair for a different one to eliminate the possibility that the remote may be the cause Status display Various causes e Identify the error See Shark Error on remote is code Codes and flashing Diagnostic Codes on page 22 Page 20 As at 19 03 2004 Service Manual Tornado PROBLEM OTHER POSSIBLE SOLUTION REFERENCE SYMPTOMS CAUSE Wheelchai None Batteries may e Replace the See Replacing r does not be defective batteries batteries on page 29 drive voltage not smoothly stable Drive motor s e Replace the See Replacing the may be drive motor s drive motors on defective
23. nd grease free threads Thread diameter Unit M5 M6 M8 M10 M12 M16 Torque Nm 3 4 4 9 5 9 7 8 14 19 25 34 44 61 115 155 mkp 0 35 0 80 0 60 0 80 1 4 1 9 2 6 3 5 4 5 6 2 11 5 16 Spanner width mm 8 10 13 17 19 24 For comparison Lever arm on ring mm 180 190 215 240 265 285 spanner DIN 838 Therefore achievable Nm 56 63 70 84 101 125 torque Caution All other nuts or plastic connectors not noted here must be tightened FINGERTIGHT Caution Tighten the front wheel on the castor fork fingertight and without play Apply micro encapsulated adhesive to the thread INVACARE uses VIBRATITE VC3 for this purpose Caution When reassembling the front wheel fork in the head tube ensure that the fork is free moving The union should be tightened fingertight and should not result in stiff movement of the head tube bearing Page 10 As at 19 03 2004 Service Manual Tornado 3 Layout of components and modules The following image shows the Tornado from above rear with the seat lifter raised and the rear cowling removed 1 Seat tilt actuator 2 Seat frame rear cowling anti collision switch Speed reduction switch Power module CLAM Combined Light and Actuator Module 1 Cable loom connectors 2 Seat lifter and tilt actuator end position switch Speed reduction switch Seat frame rear cowling anti collision switch As at 19 03 2004 Page 11 Tornado Service Man
24. nother one to determine whether this is the cause e Loosen and remove the nuts that hold the fuse with the 8mm combination wrench e Insert a new fuse re position the nuts and tighten e Close the lid of the fuse compartment Page 34 As at 19 03 2004 Service Manual Tornado e Reassemble all parts such as the rear cover in reverse order e Test all wheelchair functions to make sure everything is working properly As at 19 03 2004 Page 35 Tornado Service Manual 6 5 A W Checking the cables Find out here how you can check the plug connections on the Tornado electronics CAUTION Cables can pull off e Remove the electronic panelling carefully on vehicles with a lighting system so that the cables are not pulled off the light circuit board The connectors do not have to be removed Pre requisites e Large flat screwdriver Please note Use the screwdriver carefully in order to avoid scratches on the panelling e Move the lifter to the uppermost position e Remove the electronic panelling In doing so press the cover out of the rear side panelling on one side using a large flat screwdriver e Check all cables for signs of damage and crushing e Be careful with every connector It must not come away from the bush e lf aconnector is loose use slight pressure to press the connector into the bush It must lock into place e Check whether the connector is fitted firmly int
25. o the bush If not please repeat the preceding work step e Close the electronic panelling In doing so push the rear side panelling away slightly using a large flat screwdriver Page 36 As at 19 03 2004 Service Manual Tornado e Check all vehicle functions As at 19 03 2004 Page 37 Tornado Service Manual 6 6 Replacing the remote A Pre requisites aki e Crosstip screwdriver e Wizard software or hand programming device wi Please note All remotes are supplied with a standard drive programme This does not enable lighting and regulating motors to function If you do not wish to re adjust all parameters preferably save the current drive programme before replacing the remote e Switch off the remote d e Pull the bus cable 1 out of the remote e Loosen the thumb screw 2 e Pull the remote and the remote holder out of the guiding device Unscrew both remote holder screws 1 using the crosstip screwdriver e Installation of the remote is carried out in reverse order e Adapt the drive programme using the hand programming device or Wizard software or transcribe the copy onto the new remote e Check all vehicle functions Page 38 As at 19 03 2004 Service Manual Tornado 6 7 Testing an actuator motor Wi Requirements We e Multimeter e Check the electrical resistance of the actuator If it is close to infinite then the motor is likely to be burnt out If it is l
26. ocated in exactly the same position as it s ACS counterpart 1 CLAM or Lighting Module 2 Power Module partly hidden by cables e Remove all electrical connectors from the module that needs to be replaced As at 19 03 2004 Page 27 Tornado Service Manual If replacing the Power Module ACS or Shark e Remove the hexagonal socket head screws 1 on both sides of Power Module e Pull the Module up and out If replacing the CLAM Lighting Module e Detach the CLAM from it s holder by simply pulling it upwards Replace the defective module and re assemble all components in reverse order Page 28 As at 19 03 2004 Service Manual Tornado 6 3 VW Replacing batteries Find out here how to replace the Tornado batteries CAUTION Risk of chemical burns e Please look out for damaged batteries or ensure that you do not damage the batteries Leaking acid can cause chemical burns to the skin and eyes e If acid should come into contact with the skin rinse immediately using plenty of freshwater e f acid should get into the eyes rinse immediately using plenty of fresh water and consult a physician CAUTION Danger of crushing e Secure the lifter against unintentional folding by using the mechanism intended for this purpose e Check whether the battery belts are damaged and lift the batteries carefully CAUTION Risk of fire and burns if battery poles are short circuited e
27. or replace if necessary Tighten replace if necessary Replace cable if necessary See Replacing a drive wheel on page 50 See Replacing the steering head bearings on the front or rear castor wheels on page 41 See Repairing a flat tyre on page 48 Lighting e Check cabling Y Replace bulbs or cables if i necessary e Check function As at 19 03 2004 Page 13 Tornado Service Manual ze es em rs Te Batteries e Check batteries for Y Replace batteries if See Replacing damage necessary batteries on page 29 WE e Check battery charge Y Charge batteries See User Manual WW e Check contacts and Y Clean contacts and See Replacing terminals for corrosion terminals batteries on page 29 for Safety Information on working with batteries Remote Remote Y Evaluate flash code electronics status display blinking Fixing Tighten replace Replace Cable connecting plug Seef Joystick function y Replace cable connector Power supply plug or console Walking Beam Check spring for damage Replace if damaged See Replacing the Anti Dive Spring Check that the bolts that Replace spring guides if and or its plastic hold the spring guides damaged guides on page 45 have become loosened Lifter Check correct function Y Repair if necessary Check function of the Stability Lock Page 14 As at 19 03 2004 Service Manual 5 Troubleshooting the Tornado If a problem occurs with the wheelchair then
28. rk before operating the wheelchair 2 TOOL LIST 2 1 Tightening torques and Loctite 3 LAYOUT OF COMPONENTS AND MODULES 4 SERVICE PLAN 1X ANNUALLY 5 TROUBLESHOOTING THE TORNADO 1 Troubleshooting the Tornado with ACS 5 1 1 Diagnosing driving faults 5 1 2 Diagnosing problems with electric actuators 5 1 3 REM24 Error Codes and Diagnostic Codes 5 2 Troubleshooting the Invacare Tornado with Shark Remote 5 2 1 Diagnosing driving faults 5 2 2 Shark Error Codes and Diagnostic Codes 6 REPAIR WORK 6 1 Replacing the drive motors 6 2 Replacing components of the ACS or Shark electronics 6 3 Replacing batteries 6 4 Replacing the main fuse 6 5 Checking the cables 6 6 Replacing the remote 6 7 Testing an actuator motor 6 8 Adjusting and replacing the speed reduction switch 6 9 Replacing the steering head bearings on the front or rear castor wheels 6 9 1 Front Castor Wheels 6 9 2 Rear Castor Wheels As at 19 03 2004 Page 5 Tornado 10 11 13 24 24 27 29 34 36 38 39 40 41 43 Tornado Service Manual 6 10 Replacing the Anti Dive Spring and or its plastic guides 45 6 11 Repairing a flat tyre 48 6 12 Replacing a drive wheel 50 Page 6 As at 19 03 2004 Service Manual Tornado 1 Safety and assembly instructions These safety instructions are intended to prevent accidents during work and it is imperative that they are observed 1 1 Before any inspection or repair work e Read and obs erve this
29. the nest together with the regulating motor slightly to the front 1 and then lift 2 Now remove the regulating motor and the nest completely e Open the electronic panelling In doing so push the rear side panelling away slightly using a large flat screwdriver Page 30 As at 19 03 2004 Service Manual Tornado AN CAUTION Electronics can be damaged e Disconnect all electronic components from the batteries before commencing work on the batteries A short circuit during the following work could otherwise damage the electronics e Disconnect all plugs from the electronic components wi Please note Please make a note of the cable layout In case the cable layout is not flexible enough the cable binders can be opened e Remove all pole caps from the poles e Unscrew the screws 1 on the minus poles using an 11mm open jawed wrench e Unscrew the screws 2 on the plus poles using an 11mm open jawed wrench AN CAUTION Danger of crushing e The batteries are very heavy Please ensure that they do not hit the ground when being removed from the chassis e Pull the battieres out to the front using the carrying belt AN CAUTION Fire hazard Cables can be pinched and chafed e Please ensure correct cable layout They may not protrude into the lifter area Use cable binders if necessary As at 19 03 2004 Page 31 Tornado Service Manual e Installation is carried out in the reverse ord
30. type is connected Ensure that the power module type code matches the remote type code See Replacing the remote on page 38 See Replacing components of the ACS or Shark electronics on page 27 As at 19 03 2004 Page 23 Tornado Service Manual Repair Work 6 1 Replacing the drive motors Find out here how to replace the Tornado drive motors CAUTION Danger of tipping over and crushing e Secure the vehicle with wedges and a jack up device to prevent it rolling and tilting as it tends to do this following removal of a drive wheel gt Pre requisites e Large screwdriver e 5mm and 6mm hexagon socket e Diagonal nosed cutting pliers e Material for jacking up the vehicle wi Please note Please pay attention to the plain washers during dismantling Put small parts aside in such a way that they can be re fitted in the correct order vm P SCH e Jack up the vehicle for instance by placing a block of wood under the chassis e Loosen the wheel nut 1 using a 5mm hexagon socket e Remove the Allen screw and the hub cap e Pull the complete wheel from the wheel hub e Loosen the screws 1 using a 6mm hexagon socket and remove the outer side panelling Page 24 As at 19 03 2004 Service Manual Tornado e Loosen the turn lock fasteners 1 and remove the inner side panelling e Remove the securing ring 1 and release the uncoupling rod assembly from the
31. ual The following image shows the Tornado from the front right with the lifter raised 1 Lifter actuator Page 12 As at 19 03 2004 Service Manual Tornado 4 Service plan 1x annually compen own e meV Armrest damage and Y Tighten screws replace GA Armrests and bs side panels fastening padding if damaged e Side panel damage and fixing Tighten screws replace side panels if damaged Cushion Replace covers upholstery if damaged Seat unit seat angle e Check seat angle adjustment adjustment Replace parts if damaged Damage and seams Replace parts if damaged Backrest unit s mechanical Fixings Tighten screws Check cabling Replace cable or motor if necessary Backrest unit electrical e Check function Check fixings welded seams and battery box Tighten screws replace components Frame chassis battery box Wheel suspension and wheels Drive units disengager Electrical footrests Check drive wheels for tight fit and side play Check steering wheels for tight fit float and side play Check pneumatic tyres on the drive wheels Check functions in drive and push modes Check disengager Check welded seams interlocking screws footplates Check cabling Check contacts Check functions Adjust replace wheel hubs Replace wheels wheel fork or wheel bearings Repair or replace if damaged Replace motor if necessary Tighten screws nuts adjust
32. witching the remote on again If this does not rectify the error locate the error using the flash codes shown below Flash code Meaning Solution Notes 1 x flash Module defective Replace defective See Replacing module components of the ACS or Shark electronics on page 27 2 x flashes Accessory error e g e Check accessory See Testing an actuator short circuit connections check actuator motor on accessories page 39 Lifter raised or lowered e If lifter is raised See User Manual too far seat not at driving lower in stages until height the status display stops flashing If lowered too far raise lifter in stages until the status display stops flashing If at all possible only drive when the seat is at driving height 3 x flashes Fault in right hand motor e Check connecting See Checking Connection plugs the a on loose defective or motor e Check motor page defective See Replacing the drive motors on page 24 4 x flashes Fault in left hand motor e Check connecting See Checking Connection plugs the cables on EE or motor GE page 36 See Replacing the drive motors on page 24 5 x flashes Fault brake fault on right e Check connecting See Checking hand motor Connection plugs the cables on loose defective or motor page 36 defective a See Replacing the drive motors on page 24 6 x flashes Fault brake fault on left e Check connecting See Checking hand motor Connect
33. y Page 7 Tornado Service Manual 1 3 After completion of work before operating the wheelchair A Caution e Check all fixings for tight fit e Check all parts for correct interlocking e Only operate wheelchair with correct tyre pressure 2 5 bar e Check electrical components for correct functioning incorrect polarity of cables can result in damage to the electronics As a last check always carry out a test drive Page 8 As at 19 03 2004 Service Manual 2 Tool list You will need a standard tool set with at least the following set of open and ring spanners 6 24 mm set of Allen keys 1 5 10 mm torque wrench commercial socket spanner set set of screwdrivers 0 5 1 6 mm oblique pliers flat nosed pliers circlip pliers pointed pliers cable lug pliers wooden or plastic hammer tyre repair kit commercial tyre pressure indicator valve removal tool wheel bearing puller multimeter with probes and various cable clips soldering iron 30 W front wheel hub puller available from INVACARE Service circlip pliers for star lock caps commercially available make Tigtemeyer pop riveting tool stepped mandrel As at 19 03 2004 Page 9 Tornado Tornado Service Manual 2 1 Tightening torques and Loctite The tightening torques stated in the following table are dependent on the thread diameters for the nuts and bolts for which no special values are determined All values apply to dry a
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