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Invacare® FDX SERVICE MANUAL

1. Requirements e Spring ring pliers e Side cutting pliers e Cable ties Note Take careful note of the exact position of the seat Mark the position it is mounted in the angle the positions of all cables and so on If necessary make photographs with a digital camera Any modification of the adjustment of the seat affects the centre of gravity of the wheelchair Uninstalling the tilt actuator e f possible raise the lifter to the highest position e f possible tip the wheelchair with the tilt module as far backwards as it will go e Switch the electronic control system off The actuator module for the lifter and the tilt actuator are mounted to the front edge of the seat frame e Completely remove both knurled head screws 1 including the washers e Remove the cover 2 e Disconnect the plug from the actuator module e Open the cable clips on the underside of the seat e Free up the actuator cable so it can be removed from the tilt module later along with the actuator WARNING Danger of crushing The seat is very heavy Danger of injury to the hands if the seat falls down unintentionally e Leta second person help you e Carefully secure the seat against falling down unintentionally before removing the actuator If there is no means to secure the seat from falling down remove it entirely In a combined lifter tilt module the tilt actuator is located in the upper part of the module 2 e Remove the r
2. 0 972 49 32 20 contactsp invacare com Wwww invacare es 33 0 247 62 64 66 33 0 247 42 12 24 contactfr invacare com www invacare fr 44 0 1656 776 222 Fax Customer Service 44 0 1656 776 220 WWW uk invacare com eire invacare com www invacare co uk LL CE Invacare Mecc San s r l Via Dei Pini 62 36016 Thiene VI ITALIA Invacare Ireland Ltd Unit 5 Seatown Business Campus Seatown Rd Swords County Dublin Ireland Invacare AS Grensesvingen 9 Postboks 6230 N 0603 Oslo Norge Invacare B V Celsiusstraat 46 NL 6716 BZ Ede The Netherlands Invacare PORTUGAL Lda Rua Senhora de Campanha 105 P 4369 001 Porto PORTUGAL Kundeservice Fax Kundeservice WWW B Fax WWW 39 0445 38 00 59 39 0445 38 00 34 italia invacare com www invacare it 353 18 10 70 84 353 18 10 70 85 eire invacare com 47 0 22 57 95 10 47 0 22 57 95 01 norway invacare com www invacare no 31 0 318 69 57 57 31 0 318 69 57 58 csede invacare com www invacare nl 351 225105946 351 225105739 portugal invacare com www invacare pt iN terf rs ljare Invacare AB Fagerstagatan 9 S 163 91 Sp nga Sverige Tillverkare Invacare Deutschland GmbH KleiststraBe 49 D 32457 Porta Westfalica Deutschland Kundtj nst Fax Kundtj nst WWW MOLNDAL Fax
3. 8 1 Covers 8 1 1 Open front cover 8 1 2 Opening the rear cover 8 1 3 Opening the lateral cover 8 1 4 Opening the cover of the rear wheel cantilever arm 8 2 Electronic modules 8 2 1 Replacing remotes 8 2 2 Replacing electronic modules 8 2 3 Replacing the G Trac module 8 2 4 Drive program selection after component replacement 8 2 4 1 Profile selection with G90A remote 8 2 4 2 Profile selection with remote REM A or REM B 8 2 4 3 Profile selection with remote REM 550 8 3 Updating the driving program 8 4 Batteries cables amp battery chargers 8 4 1 Removing the batteries 8 4 2 Replacing batteries replacing battery cables 8 4 3 How to handle damaged batteries correctly 8 4 4 Replacing the main fuse 8 4 5 Checking the cables 8 5 Lighting system 8 5 1 Replacing light bulbs in the front conventional lighting system 8 5 2 Replacing the LEDs in the front LED lighting system 8 5 3 Replacing the complete head lamp assembly conventional lighting system 8 5 4 Replacing the head lamps completely LED lighting system 8 5 5 Replacing the head lamp bracket conventional lighting system 8 5 6 Replacing a light bulb in the rear conventional lighting system 8 5 7 Replacing the LEDs in the rear LED lighting system 8 5 8 Replacing the complete tail lamp assembly conventional lighting system 8 5 9 Replacing the tail lamp bracket conventional lighting system 8 5 10 Replacing the tail lamps completely LED lighting system
4. Installing the head lamp bracket e Assemble all parts again in reverse order e Tighten both screws hand tight e Check all vehicle functions e Perform an approximate adjustment of the head lamp using the ratchet plate as a guide The final adjustment can be performed by the user according to the instructions found in the User Guide 62 8 5 6 Replacing a light bulb in the rear conventional lighting system VA Requirements e Phillips screwdriver size 2 Loosen the Phillips head screw in the transparent cover of the tail lamp turn indicator combination Remove the transparent plastic cover Replace the defective light bulb e Reposition the cap and tighten the Phillips head screw hand tight 8 5 7 Replacing the LEDs in the rear LED lighting system e Individual LEDs are not intended to be replaced Replace the complete red tail lamp and or the yellow turn indicator as described in chapter 8 5 10 63 8 5 8 Replacing the complete tail lamp assembly conventional lighting system VA Requirements d e 8mm socket wrench Uninstalling the tail lamp e Remove the front cover and the rear covers as described in chapters 8 1 1 and 8 1 2 e Take exact note of the positions of all cables and the sockets 1 that they are connected to Mark the connectors and sockets or take a photograph with a digital camera e Disconnect the cable of the affected tail lamp from the lighting circuit board e Remove all cable tie
5. LANDSKRONA N Fax OSKARSHAMN Ey Fax 46 0 8 761 70 90 46 0 8 761 81 08 sweden invacare com finland invacare com www invacare se 46 0 31 86 36 00 46 0 31 86 36 06 ginvacare invacare com 46 0 418 285 40 46 0 418 180 89 linvacare invacare com 46 0 491 101 40 46 0 491 101 80 oinvacare invacare com Table of contents Chapter 1 INTRODUCTION 1 1 General information 1 2 Notes on transport 1 3 Definition and representation of information and safety information in this manual 1 4 Hazard symbols and symbols used 1 5 Images in this manual 2 SAFETY AND FITTING INSTRUCTIONS 2 1 Before any inspection or repair work 2 2 Personal safety equipment 2 3 General safety information and information about fitting removal 3 TIGHTENING TORQUES 4 ARRANGEMENT OF SUB ASSEMBLIES AND COMPONENTS 4 1 Overview 4 2 Electronic modules 4 2 1 ACS PMB70 ACS IlI PMB70OL electronic module 4 2 2 ACS II PMAS9OL electronic module 4 2 3 Actuator module ACT 4 2 3 1 Actuator module ACT2 4 2 3 2 Actuator module ACT 4 4 2 4 Lighting circuit board 4 3 Remotes 5 MAINTENANCE PLAN ONCE A YEAR 6 OPERATIONAL FAULTS 6 1 Drive fault diagnosis 6 2 Diagnosis of charging device faults Page 10 11 12 12 12 12 14 22 24 25 29 7 TEST PROCEDURES 7 1 Testing the motor 7 2 Testing the electro mechanical parking brake 8 REPAIR WORK
6. Remote status Various causes Assess error code See chapter 6 2 display blinking Mobility aid None Batteries Replace batteries See chapter 8 4 1 judders in defective drive mode unstable voltage Drive motor s Replace motor s See chapter 8 13 1 Geste Replace carbon See chapter 8 13 4 brushes Mobility aid None Drive motors Change See chapter 8 3 pulls to left running programming to or right asymmetrically synchronise motors Error None Bad connections Check all See chapter 8 4 5 message connecting cables BEES Motor brake Measure internal See chapters 7 2 and defective resistance of 8 13 1 brakes replace motor if defective Motors stop None Voltage decline Stop journey and and start allow electronics irregularly to cool down 25 26 PROBLEM OTHER POSSIBLE SOLUTION Documentation SYMPTOMS CAUSE decrease None to cool down voltage Motors stop None High motor Leave mobility aid and do not loading causes switched on and start again electronics allow electronics module to module to work decrease Charge batteries voltage overnight with mobility aid switched on None Fuse burnt out Check cabling and See chapters 8 4 5 and replace fuse 8 4 4 None Motor defective Check carbon See chapter 8 13 4 brushes and replace if necessary Measure internal See chapters 7 1 and resistance of 8 13 1 motor replace motor if defective None Electronics Replacing the
7. Service for repair An internal fuse might be burnt Send the battery charger to out Invacare Service for repair Fuse on mobility aid has burnt Check mobility aid fuses out See chapter 8 4 4 No mains supply Check the mains supply with a voltmeter Defective mains supply cable Replace damaged cables or send the battery charger to Invacare Service for repair Battery charger could be defective Use a battery charger which you know is working properly to charge the batteries Send the defective battery charger to Invacare Service for repair Check the mains supply cable Battery voltage is too low to Replace the batteries See operate mobility aid chapter 8 4 1 29 7 Test procedures 7 1 Testing the motor VA Requirements e Phillips screwdriver size 2 e digital multimeter with resistance measurement e Remove the rear panel as described in Chapter 8 1 2 e Pull the motor plug 1 out of the electronics module e Connect the digital multimeter to the motor plug contacts 3 and measure the resistance between the contacts Note i A resistance of between 0 5 and 5 ohms indicates a motor ready for operation A resistance of between 15 ohms and infinity indicates a defective motor High resistances are normally caused by bad connections or worn carbon brushes 30 7 2 Testing the electro mechanical parking brake Note i This test should only be carried out on mobility aids with conve
8. Collector Measure internal See chapters 7 1 and defective resistance of 8 13 1 motor replace motor if defective moror Bearing Replacing the See chapters 8 13 1 and blocked defective motor 8 13 3 Transmission Replace See chapters 8 13 1 and defective transmission 8 13 3 Transmissi None Transmission Replace See chapters 8 13 1 and on makes defective transmission 8 13 3 Scraping None Clutch es Replace clutch See chapter 8 13 3 noise or defective clicking Drive wheel Tighten drive See chapter 8 12 1 loose wheel secure bolts with Loctite if necessary Transmissi None Sealing ring on Replace See chapters 8 13 1 and on losing drive shaft transmission if 8 13 3 oil defective sealing ring defective Check carbon See chapters 8 13 1 brushes for oil 8 13 3 and 8 13 4 wetting replace motor if brushes wet 2 noise PROBLEM OTHER POSSIBLE SOLUTION Documentation SYMPTOMS CAUSE Irregular None Drive shaft Check drive shaft See chapters 8 13 1 and running movable or bent replace 8 13 3 transmission if defective None Parts lost Reattach parts once found Batteries None Fuse burnt out Check cabling and See chapters 8 4 5 and not being cable defective replace fuse 8 4 4 charged Batteries Replace batteries See chapter 8 4 1 defective LEDs blinking Charging unit Replace charging See charging unit on charging unit defective unit operating manual Short None One of the Replace batteries See
9. and plugs are correctly installed A schematic showing the correct positions can be found in the battery box cover 8 4 2 Replacing batteries replacing battery cables Note To replace the fuse the battery cable with the fuse attached to it must be replaced CAUTION Danger of injury and danger of damage to property if the batteries are handled incorrectly e The installation of new batteries may only be performed by authorised technicians e Pay attention to the warning notes on the batteries e Only use the battery type defined in the technical specifications CAUTION Risk of fire and burns if battery terminals are short circuited e Take special care that the battery terminals are NOT short circuited with a tool or metallic components of the wheelchair e Make sure that the battery terminal caps are fitted to the battery terminals at all times if you are not working on them CAUTION Danger of crushing The batteries are very heavy There is a danger that you may injure your hands e Take into account the heavy weight of the batteries e Handle the batteries carefully WARNING Risk of chemical burns Danger of injury by leaking acid e Wear acid resistant protective gloves when handling batteries e Wear protective goggles when handling batteries How to deal with a battery acid leak e Remove clothes that have been soiled or soaked with acid immediately e mmediately wash the affected area of ski
10. chapter 8 4 1 charging batteries could period be defective Mobility aid None Remote Replace remote See chapter 8 2 1 runs too defective ROWY Batteries Replace batteries See chapter 8 4 1 defective Remote shows Lighting Replace lighting See chapter 8 2 2 blinking E or actuator module actuator module blink code 2f defective Status diode on lighting actuator module does not go out even if the remote has been switched off or disconnected Actuator does not react Cable Safeguard cable See chapter 8 4 5 disconnected or connection damaged replace cable if necessary Electrical Check adjusting adjusting motor motor defective Remote Replace remote See chapter 8 2 1 defective Only applies to remote SD24 All remotes except SD24 28 6 2 Diagnosis of charging device faults SYMPTOM No LEDs illuminating on battery charger Batteries do not charge POSSIBLE CAUSE SOLUTION Charging device not Ensure that the battery connected to mains supply charger has been plugged in No mains supply voltmeter Defective mains supply cable Battery charger not connected Ensure that the battery to mobility aid charger has been connected to the mobility aid Check the mains supply with a Check the mains supply cable Replace damaged cables or send the battery charger to Invacare Service for repair LEDs are burnt out Send the battery charger to Invacare
11. described in chapter 8 4 1 e Check the fuse cable 1 the battery cable 2 and the battery connections 3 for visible damage and pinches e Replace damaged cables as described in chapter 8 4 2 Note i The positions of the plugs are described in chapter 4 2 55 56 Check all cables for visible damage and crushing Replace damaged cables Pull on each plug 1 carefully The plug must not come out of the socket If a plug is loose apply slight pressure to push the plug into the socket The plug must snap in place securely Check whether the connector is fitted firmly If not repeat the previous step Assemble the parts in reverse order Check all functions of the vehicle and go for a test drive 8 5 Lighting system 8 5 1 Replacing light bulbs in the front conventional lighting system d Requirements i e Phillips screwdriver size 2 e Loosen the concealed Phillips head screw on the back of the head lamp turn indicator combination e Remove the transparent plastic cover e Replace the defective light bulb e Reposition the cap and tighten the Phillips head screw hand tight 8 5 2 Replacing the LEDs in the front LED lighting system e Individual LEDs are not intended to be replaced Replace the complete lighting system as described in chapter 8 5 4 57 8 5 3 Replacing the complete head lamp assembly conventional lighting system VA Requirements e Phillips screwdriver size 2 e Side cut
12. the hands and feet e Leta second person help you Danger of injury due to uncontrolled movement of the wheelchair e Switch the vehicle s power system off ON OFF key e Engage the drive motors e Secure the vehicle against rolling away by placing wedges under the wheels VA Requirements 5 mm Allen key 10 mm socket wrench 13 mm socket wrench Torque wrench 0 10 Nm or similar Torque wrench 5 30 Nm or similar Torque wrench 10 80 Nm or similar Two oblong wooden blocks at least 14 x 14 x 30 cm Uninstalling the motor gear box unit Remove the drive wheel as described in chapter 8 12 1 Remove the front rear and lateral covers as described in chapter 8 1 1 8 1 2 and 8 1 3 Disconnect the motor cable plug Remove the wheel hub as described in chapter 8 12 3 D Ca As 5 z A ro A CAUTION Danger of crushing The motor gearbox unit is very heavy Danger of injury to the hands e Pay attention to the heavy weight 105 106 Use the 13 mm socket wrench to loosen the four screws 1 Hold the motor gearbox unit with one hand Completely remove the four screws including the washers Remove the motor gearbox unit Installing the motor gearbox unit Replace the defective components Before installing a new motor gearbox unit make sure the sealing ring 2 is correctly mounted The sealing ring securely attaches the motor 3 and the gearbox 5 The ring must be ins
13. the positions of all cables and so on If necessary make photographs with a digital camera Any modification of the adjustment of the seat affects the centre of gravity of the wheelchair e f possible raise the lifter to the highest position e If possible tip the wheelchair with the tilt module as far backwards as it will go e Switch the electronic control system off The actuator module for the lifter and the tilt actuator are mounted to the front edge of the seat frame 80 e Completely remove both knurled head screws 1 including the washers e Remove the cover 2 e Disconnect the plug from the actuator module e Open the cable clips on the underside of the seat e Free up the actuator cable so it can be removed from the lifter module later along with the actuator WARNING Danger of crushing The seat is very heavy Danger of injury to the hands if the seat falls down unintentionally e Leta second person help you e Carefully secure the seat against closing or falling down unintentionally before removing the actuator If there is no means to secure the seat from falling down remove it entirely In a combined lifter tilt module the lifter actuator is located in the lower part of the module 2 e Remove the retaining rings 1 with a pair of spring ring pliers e Push the bolts 4 out of the guides Pay attention to the bushings 3 on the front bolt e Remove the actuator from the lifter module
14. 8 6 Seat seat frame without lifter 8 7 Replacing the tilt module lifter module 8 7 1 Replacing the tilt module without lifter 8 7 2 Replacing the lifter tilt module 8 7 3 Replacing the tilt actuator 8 7 4 Replacing the lifter actuator 8 7 4 1 Method 1 uninstalling the lifter actuator with the lifter raised 8 7 4 2 Method 2 uninstalling the lifter actuator with the lifter lowered 30 30 31 8 8 8 8 1 8 8 2 8 8 3 8 8 4 8 8 5 8 9 8 10 8 11 8 11 1 8 11 3 8 15 8 16 8 16 1 8 16 2 8 17 Centre mounted legrest electric amp manual Replacing the manually operated centre mounted legrest Replacing the electrically operated centre mounted legrest Replacing an electric legrest actuator Replacing the calf plate on the centre mounted legrest electric amp manual Replacing the foot plate on the centre mounted legrest electric amp manual Replacing the restraining belt Replacing the anti tipper wheels Rear wheels Replacing a rear wheel Replacing a rear wheel fork Adjusting the wheel fork Drive wheels Replacing a drive wheel Replacing a tyre Replacing a drive wheel hub Drive unit Replacing the motor gearbox unit Replacing or rotating the motor gearbox unit sealing ring Replacing the motor gearbox coupling Replacing the carbon brushes Running the motor in Replacing the motor gearbox fixation and rear wheel cantilever arm Replacing the spring in the rear Fixation rings Replacing a fron
15. E replace e Fixation of the e Se screws LE armrests e Damage tothe side e Replace the side e Fixation screws of e Tighten screws O a the side parts Damage to the e Replace parts if backrest damaged Seams Tighten screws Fastening Replace cable or Check cable motor if necessary Check function Check fastenings Tighten screws welding seams and Replace parts if battery box necessary drive wheels and e Adjust replace See chapter 8 12 1 wheel hubs and 8 12 3 axial run out e Check tight fit of e Replace wheels See chapter 8 11 steering wheels wheel fork or Check required wheel bearing motor to body clearance and axial run out E E t if damaged if damaged e Check directional e Replace wheels See chapter 8 11 Stability wheel fork or and 8 12 wheel bearing GEN e Check functions e Check the carbon see chapter 8 13 1 during drive brushes replace if and 8 13 4 operation and when necessary pushing Replace motor if Check coupling necessary Restraining belt Electric backrest if available Frame chassis battery compartment e Check tight fit of the Wheel suspension and wheels mechanism Tighten screws nuts adjust or replace if necessary Component Check for Measures Remarks aw e Check welding seams locking Legrests devices screws and foot plates e Check cable Electric legrests e Check contacts if available e Check functions FEROE e Check cable Ligh
16. Insert the carriage bolt through the sealing ring e Install the washer and the self locking nut e Do not tighten the self locking nut completely as the motor orientation must be adjusted during installation e Install the motor gearbox unit as described in chapter 8 13 1 109 8 13 4 Replacing the carbon brushes d A V 110 Note Always replace all carbon brushes on both motors at the same time WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Leta second person help you Requirements Flat screwdriver 10 mm socket wrench Torque wrench 5 30 Nm or similar Two oblong wooden blocks at least 14 x 14 x 30 cm Uninstalling carbon brushes Switch the wheelchair off Remove the drive wheels as described in chapter 8 12 1 Disengage the motor by setting the coupling lever to Pushing Loosen and remove the self locking nut 4 of the retaining ring 2 with a 10 mm socket wrench so that the motor 3 can be rotated against the gearbox 1 This way the carbon brushes are easier to access e Loosen all four plastic caps 3 with a flat screwdriver and remove the caps e Pull the carbon brushes 4 out of their holders slightly Take note of the installation position and orientation of the carbon brushes Note If the carbon brushes are just to be checked and not replaced then you must take note of the position and orientation of
17. Installing the lifter actuator e Assemble all parts in reverse order e Perform a function test 81 8 7 4 2 Method 2 uninstalling the lifter actuator with the lifter lowered A WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Leta second person help you VA Requirements 4 e Spring ring pliers e Side cutting pliers e Cable ties e Bent nose pliers e 6mm Allen key Note Take careful note of the exact position of the seat Mark the position it is mounted in the angle the positions of all cables and so on If necessary make photographs with a digital camera Any modification of the adjustment of the seat affects the centre of gravity of the wheelchair e Switch the electronic control system off The actuator module for the lifter and the tilt actuator are mounted to the front edge of the seat frame e Completely remove both knurled head screws 1 including the washers e Remove the cover 2 e Disconnect the plug from the actuator module e Open the cable clips on the underside of the seat e Free up the actuator cable so that you can remove the seat 82 e Loosen and remove the hexagon socket head screw 1 of the seat frame on the left and on the right side of the wheelchair WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Leta second person help you Lean the seat back and push the rear brackets 2 out of t
18. Invacare FDX SERVICE MANUAL CE These instructions contain information about testing work repair work Edition 14 07 10 gt S S S m Mobitec Mobilitatshilfen GmbH Herzog Odilostrasse 101 A 5310 Mondsee Austria Invacare n v Autobaan 22 B 8210 Loppem Brugge Belgium Mobitec Rehab AG BenkenstraBe 260 CH 4108 Witterswil Switzerland Invacare Aquatec AlemannenstraBe 10 88316 Isny Deutschland Invacare A S Sdr Ringvej 37 DK 2605 Br ndby Danmark Invacare SA c Areny s n Poligon Industrial de Celr 17460 Celr Girona ESPA A Invacare Poirier SAS Route de St Roch F 37230 Fondettes France Invacare Ltd Pencoed Technology Park Pencoed Bridgend CF35 5HZ United Kingdom a Fax WWW T Fax WWW Kundeservice Fax Kundeservice WWW T Fax WWW Customer Service 43 6232 55 35 0 43 6232 55 354 office mobitec austria com austria invacare com www mobitec austria com 32 0 50 83 10 10 32 0 50 83 10 11 belgium invacare com www invacare be 41 0 61 48 77 080 41 0 61 48 77 08 1 office mobitec rehab ch switzerland invacare com www mobitec rehab ch 0 75 62 7 00 251 08 00 6 73 81 72 info invacare aquatec de www invacare aquatec de 45 0 36 90 00 00 45 0 36 90 00 01 denmark invacare com www invacare dk 34 0 972 49 32 00 34
19. See chapter 8 2 2 module electronics module defective Motors lose None Bad connections Switch mobility aid See chapter 8 4 5 power off wait 10 during seconds switch journey mobility aid on again Check all cabling Motor None Carbon brushes Check carbon See chapter 8 13 4 judders or brushes and runs replace if irregularly necessary Eed Clutch es Replace clutch See chapter 8 13 3 defective Bearing Replacing the See chapter 8 13 1 defective motor Stop journey and allow electronics High motor loading causes electronics module to Motor runs but loses power Collector Measure internal See chapters 7 1 and defective resistance of 8 13 1 motor replace motor if defective PROBLEM OTHER POSSIBLE SOLUTION Documentation SYMPTOMS CAUSE Motors do None Bad connections Check all cabling See chapter 8 4 5 ER Fuse burnt out Check cabling and See chapters 8 4 5 and replace fuse 8 4 4 Batteries Replace batteries See chapter 8 4 1 defective Cabling to check cabling See chapter 8 4 5 electronics module or joystick defective Electronics Replacing the See chapter 8 2 2 module electronics module defective Corroded Water salt or Check cabling See chapter 8 4 5 contacts urine has replace if penetrated necessary Motor None Clutch es Replace clutch See chapter 8 13 3 makes defective clicking Bearing Replacing the See chapter 8 13 1 noise defective motor
20. Take exact note of the positions of all cables and the sockets 1 that they are connected to Mark the connectors and sockets or take a photograph with a digital camera e Disconnect the cable of the affected head lamp from the lighting circuit board e Remove all cable ties and pull the cable out of the wheelchair e Loosen the hexagon socket head screw 1 with a 3 mm Allen key and remove the head lamp from the bracket e Replace the head lamp 60 Installing head lamps e Assemble all parts again in reverse order e Install the cables carefully and secure them with cable ties Make sure that the cables not are not pinched or stretched e Tighten both screws hand tight e Check all vehicle functions e Perform an approximate adjustment of the head lamp using the ratchet plate as a guide The final adjustment can be performed by the user according to the instructions found in the User Guide 61 8 5 5 Replacing the head lamp bracket conventional lighting system VA Requirements e Phillips screwdriver size 2 e 8 mm socket wrench Uninstalling the head lamp bracket e Loosen both of the cap nuts 1 with an 8 mm socket wrench and remove the head lamp with the bracket from the rubber mounting e Not shown in the illustration are two Phillips head screws with which the head lamp is secured to the bracket Loosen both of these Phillips head screws to remove the head lamp from the bracket e Replace the bracket
21. al VA Requirements H e 1 64 Allen key e 1 4 Allen key A manual legrest can be seen in the illustration The method of fixation to the seat is almost identical with both legrests Uninstalling the footplate e f possible raise the lifter to the highest position e If possible tip the wheelchair with the tilt module as far backwards as it will go e Switch the electronic control system off e Use the 1 64 Allen key to loosen and remove both screws 3 e Replace the foot plate 1 Installing the footplate e Assemble the parts in reverse order e Tighten the hexagon socket head screws 3 till they are tight enough that the footplate can barely be moved In the area denoted by the 2 there is an adjustment screw that can only be reached when the footplate is swivelled upwards e Use the 1 64 Allen key to adjust the angle of the footplate to the needs of the user with this screw 93 8 9 V 0 94 Replacing the restraining belt Requirements e 10 mm socket wrench e 4mm Allen key Uninstalling the restraining belt e Loosen the screw 3 and the corresponding nut not shown in the illustration with a 4 mm Allen key and a 10 mm socket wrench e Remove the nut including the washer e Remove the screw together with the restraining belt and the washer 2 and also the washer behind it Note Another nut is used between the washers as a spacer so that the belt bracket can move freely
22. and the self locking nut Do not tighten the self locking nut completely as the motor orientation must be adjusted during installation 107 8 13 3 V 108 Replacing the motor gearbox coupling CAUTION Danger of crushing The motor gearbox unit is very heavy Danger of injury to the hands e Pay attention to the heavy weight Requirements e 10mm socket wrench Uninstalling the motor gearbox coupling e Uninstall the motor gearbox unit as described in chapter 8 13 1 e Use the 10 mm socket wrench to loosen and remove the self securing nut 4 e Remove the carriage bolt which secures the sealing ring 2 e Carefully bend the sealing ring apart and remove it WARNING Danger of damage to the wheelchair if the coupling is not serviced correctly e Becareful not to damage the coupling mechanism during maintenance work e Carefully pull the motor 3 and the gearbox 1 apart e Remove the component parts of the coupling e f necessary replace the coupling Installing the motor gearbox coupling e Place the new coupling 2 on the motor axle 3 Pay attention to the position of the groove e Carefully insert the motor into the gearbox Pay attention to the position of the groove in the axle of the gearbox 4 If necessary rotate the motor and gearbox to the correct position e Install the sealing ring so that the square hole for the carriage bolt is on the inside of the wheelchair e
23. crews 1 that attach the seat to the tilt module using a 4 mm Allen key and a 13 mm open end wrench Together with a second person lift the seat up off of the lifter module tilt module S Al A es Gees E a Praa ee ees V S RE Ee He GI G ooooooo i CO GOGOGGOG Use the 6 mm Allen key to loosen and remove the four hexagon socket head screws 3 on both sides of the wheelchair Remove the screws and the washers Lift the tilt module 1 up off of its brackets 2 If one of the seat tilt mounting brackets 2 are to be replaced Use the 6 mm Allen key to loosen both screws 4 on the corresponding side of the wheelchair Remove the screws and the washers Remove the tilt mounting bracket If one of the seat frame mounting brackets 5 are to be replaced Disassemble the seat frame mounting brackets as described in chapter 8 6 starting from the section header Uninstalling the seat frame Installing the tilt module Install the tilt module in reverse order Make sure that seat tilt mounting brackets 2 are affixed with screws to the top holes in the seat frame brackets 5 Tighten the connecting screws of the seat tilt mounting brackets and the seat frame mounting brackets to 18 Nm When installing the cables again make sure that they are placed in such a way that they cannot be crushed or damaged in any position of the tilt module WARNING Danger of crushing The seat i
24. ds to confirm the selection e The system switches itself off and starts again automatically During this process the selected profile is stored in the remote as well as in the electronic module 8 2 4 2 Profile selection with remote REM A or REM B e Plug the plug into the remote or the ACS II controller e LEDs 1 and 4 blink e Use the bottom rocker switch 5 to select where the required controller profile is saved LED 1 remote LED 4 ACS II control system e The relevant LED illuminates permanently the other LED is off e Press the Horn 2 and 3 buttons on the speed selection and hold them down for 3 seconds to confirm the selection e The system will switch itself off and restart automatically During the process the selected profile will be saved both in the remote and in the electronics module 45 8 2 4 3 Profile selection with remote REM 550 46 Plug the plug into the remote or the ACS II controller The display 2 shows that you need to select a profile Use the bottom rocker switch 3 to select where the required controller profile is saved remote Il electronics module The display will show which profile you have selected Press the Horn 4 and 1 buttons on the speed selection and hold them down for 3 seconds to confirm the selection The system will switch itself off and restart automatically During the process the selected profile will be saved both in the rem
25. e Replace the restraining belt 1 Installing the restraining belt e Assemble the parts in reverse order 8 10 Replacing the anti tipper wheels V Requirements e Small flat screwdriver e Two 13 mm socket wrenches Uninstalling an anti tipper wheel Carefully remove the black plastic cap 3 from the middle of the anti tipper wheel 2 with a small flat screwdriver Loosen the self securing axle nut which is located underneath the plastic cap not visible in the illustration using a 13 mm socket wrench Secure the axle 4 against slippage using a second 13 mm socket wrench Remove the axle nut and the washer Pull the wheel 2 off of the axle Replace the wheel and or the ball bearing The ball bearings are inserted in the wheel They can be removed using a small screwdriver Installing an anti tipper wheel Assemble the parts in reverse order When installing the ball bearings make sure you do not forget to insert the distance sleeve between the ball bearings When repositioning the wheel on the axle make sure you do not forget the spacer washer 5 Tighten the self securing axle nuts just tight enough that the wheel can still rotate without resistance When rotated very quickly it must not start to wobble 95 8 11 Rear wheels 8 11 1 Replacing a rear wheel VA Requirements e Small flat screwdriver e 16mm socket wrench e Two oblong wooden blocks at least 14 x 14 x 30 cm WARNING Danger of cr
26. e Use the 10 mm socket wrench to loosen and remove the self securing nuts 3 including the washers e Pull the G Trac module 2 off of the carriage bolt 1 which is inserted in the spring seat 42 e Replace the G Trac module Installing the G Trac module e Assemble the parts in reverse order e Reconnect all cable connectors to their former positions e The G Trac module must be installed with the cable pointing upwards e The last step is to test all functions of the vehicle 43 8 2 4 Drive program selection after component replacement E 8 2 4 1 44 The drive program is saved in the REM remote and also in the DX ACS or ACS II electronics module If one of these two components is replaced the system must be told which of the components has not been replaced so that it knows which contains the current controller profile Note The system allows normal usage of the mobility aid after component replacement only if the profile is selected afterwards Profile selection with G90A remote e Connect the plug to the remote or the ACS II electronics system respectively e The display 1 will indicate that you should select a profile e Use the arrow keys 2 to select the location where the desired controller profile is stored Remote Il Electronic module e The display will indicate which profile you have selected e Press the Horn key 3 and the Drive Mode key 2 and keep them pressed for 3 secon
27. e other side of the wheelchair e Allow the motors to run for an hour in the forward direction e Allow the motors to cool off for 30 minutes e Allow the motors to run for an hour in the backward direction e Lift the wheelchair off of the wooden blocks 8 14 Replacing the motor gearbox fixation and rear wheel cantilever arm WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Leta second person help you Danger of injury due to uncontrolled movement of the wheelchair e Switch the vehicle s power system off ON OFF key e Engage the drive motors e Secure the vehicle against rolling away by placing wedges under the wheels Requirements 22 mm socket wrench 5 mm Allen key Torque wrench 20 80 Nm or similar Two oblong wooden blocks at least 14 x 14 x 30 cm Dismantling the motor gearbox fixation and rear wheel cantilever arm Lift the wheelchair on one side and have a second person place a 14 cm high wooden block underneath the battery compartment so that the wheels are off the ground and can rotate freely Repeat this on the other side of the wheelchair Remove the drive wheel as described in chapter 8 12 1 Remove the front rear and lateral covers as described in chapter 8 1 1 8 1 2 and 8 1 3 Remove the drive wheel as described in chapter 8 12 1 Use the 5 mm Allen key to loosen and remove both screws 1 Remove the black plastic stop that is
28. e screw 1 e Remove the transparent cover from the top side not visible in the illustration e Carefully bend both mounting brackets 2 apart e Push the tail lamp 3 including cable and plug out of the bracket Installing the tail lamp e Assemble all parts again in reverse order e Tighten both screws hand tight e Check all vehicle functions 67 8 6 ib A V d 68 Seat seat frame without lifter Note This chapter describes how to replace the seat frame on a wheelchair without a lifter or tilt module To replace a lifter or tilt module please follow the procedures explained in chapter 8 7 WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Leta second person help you Requirements e 6mm Allen key e Torque wrench 5 30 Nm or similar e Protractor e Side cutting pliers e Cable ties e Wooden block Note Take careful note of the exact position of the seat Mark the position it is mounted in the angle and so on If necessary make photographs with a digital camera Any modification of the adjustment of the seat affects the centre of gravity of the wheelchair Removing the seat e Switch the wheelchair off e Remove the front cover and the rear covers as described in chapters 8 1 1 and 8 1 2 e Take exact note of the positions of all cables and the sockets 1 that they are connected to Mark the connectors and sockets or take a photog
29. e washers and tighten the screws hand tight 37 38 8 1 4 Opening the cover of the rear wheel cantilever arm VA Requirements e 4mm Allen key Removing the rear cover Use the 4 mm Allen key to loosen and remove the hexagon socket head screw 1 E Pull the cover up in the rear and remove it The cover is held in place by additional Velcro fasteners Installing the rear cover e Assemble the parts in reverse order 8 2 8 2 1 8 2 2 Electronic modules Replacing remotes Note The procedure to replace remotes is trivial and is not described in detail However when replacing a REM remote in connection with a DX ACS or ACS II electronic module please make sure to select the correct drive programme as described in chapter 8 2 4 Replacing electronic modules Note When replacing a REM remote in connection with a DX ACS or ACS II electronic module please make sure to select the correct drive programme as described in chapter 8 2 4 Various different types of electronic modules can be installed in connection with different remotes in the wheelchair The electronic modules that might be installed are described in chapter 4 2 The procedure to replace components is described using the ACS II electronic module with an optional lighting circuit board and optional actuator module as an example The procedure is identical for other electronic modules The only difference is the position of the plug in conn
30. e wheels until the anti tipper wheels prevent it from tipping any farther Swivel the wheels 5 so that they point upward Release the wheels so that they can swing downwards Adjust the nut 2 using a 22 mm socket wrench so that the wheel forks are not too loose but can still rotate freely The wheels should swing up to the other side a maximum of one time before coming to rest pointed downward Place the wheelchair back on all of its wheels Test the manoeuvrability of the wheelchair Repeat the individual steps if necessary until the coasters are correctly adjusted Install the cover again 8 12 Drive wheels 8 12 1 Replacing a drive wheel A WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Leta second person help you Danger of injury due to uncontrolled movement of the wheelchair e Switch the vehicle s power system off ON OFF key e Engage the drive motors e Secure the vehicle against rolling away by placing wedges under the wheels VA Requirements e 6mm Allen key e Two oblong wooden blocks at least 14 x 14 x 30 cm e Torque wrench 5 30 Nm or similar Uninstalling a drive wheel e Lift the wheelchair on one side and have a second person place a 14 cm high wooden block underneath it so that the drive wheel is off the ground and can rotate freely e Repeat this if necessary on the other side of the wheelchair e Loosen the five 6 mm hexagon sock
31. ections WARNING Every alteration to the drive programme can influence vehicle handling and the tipping stability of the wheelchair e Alterations to the drive programme must only be carried out by authorised Invacare dealers e nvacare can only assume a warranty for the safe vehicle handling of the wheelchair in particular tipping stability for this standard unaltered drive programme Note All electronic modules are supplied with a standard drive programme If you have performed customer specific modifications to the drive programme then these will need to be recreated manually after installing the new electronic module Requirements e mm socket wrench e 8 mm socket wrench e To modify a drive programme you will need Programming software or a hand held programming device and the installation manual available from Invacare 39 Uninstalling electronic modules e Remove the rear cover as described in chapter 8 1 2 e Take exact note of the positions of all cables and the sockets that they are connected to Mark the connectors and sockets or take a photograph with a digital camera e The illustration shows the electronic module 1 and the optional actuator module 2 The optional lighting circuit board is not shown in the picture but it would be installed at position 3 if it was present e Disconnect the plugs 1 from the electronic module and if installed from the optional actuator module and t
32. entre mounted legrest e Te ln An electric legrest can be seen in the illustration The method of fixation to the seat is identical with both legrests e Uninstall the locking lever for the height adjustment of the legrest by loosening the grub screws with a 5 mm Allen key e Use the 6 mm Allen key to loosen and remove the two hexagon socket head screws 2 on both sides of the wheelchair e Completely remove both hexagon socket head screws including the washers e Pull the entire legrest forwards out of the seat e Loosen both hexagon socket head screws which attach the adapter brackets 1 to the legrest e Remove both adapter brackets Installing the manually operated centre mounted legrest e Assemble the parts in reverse order e Test all functions of the wheelchair 87 8 8 2 Replacing the electrically operated centre mounted legrest A WARNING Danger of crushing The legrest is very heavy Danger of injury to hands and feet e Pay attention to the heavy weight A Requirements e 6mm Allen key e Side cutting pliers e Cable ties Uninstalling the electrically operated centre mounted legrest e f possible raise the lifter to the highest position e If possible tip the wheelchair with the tilt module as far backwards as it will go e Switch the electronic control system off The actuator module for the lifter and the tilt actuator are mounted to the front edge of the seat frame e Comp
33. er Similar tasks are described In the following chapters e Replacing the seat frame alone chapter 8 6 Replacing a lifter tilt module chapter 8 7 2 Replacing just the tilt actuator chapter 8 7 3 Replacing just the lifter actuator chapter 8 7 4 WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Leta second person help you W Requirements dai e 13 mm open ended wrench e 4mm Allen key e 6mm Allen key e Side cutting pliers e Cable ties Note Take careful note of the exact position of the seat Mark the position it is mounted in the angle and so on If necessary make photographs with a digital camera Any modification of the adjustment of the seat affects the centre of gravity of the wheelchair Uninstalling the tilt module e If possible tip the wheelchair with the tilt module as far backwards as it will go e Switch the electronic control system off The actuator module for the lifter and the tilt actuator are mounted to the front edge of the seat frame 71 72 Completely remove both knurled head screws 1 including the washers Remove the cover 2 Disconnect the plug from the actuator module Open the cable clips on the underside of the seat Free up all cables so that you can lift the seat off WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Leta second person help you Loosen the four s
34. er to carry out certain work Please do not attempt to carry out the work if you do not have the listed tools available Always dispose used or damaged batteries correctly The symbol refers to information for the correct disposal of used or damaged batteries 1 5 Images in this manual The detailed images in this manual are given digits to identify various components Component numbers in text and operational instructions always relate to the image directly above 11 2 Safety and fitting instructions 2 1 These safety instructions are intended to prevent accidents at work and it is imperative that they are observed Before any inspection or repair work e Read and observe this repair manual and the associated operating manual e Observe the minimum requirements for carrying out the work see chapter entitled General information 2 2 Personal safety equipment O Safety shoes The mobility device and some of its components are very heavy These parts can result in injuries to the feet if they are allowed to drop e Wear standardised safety shoes during all work Eye protection It is possible that battery acid can be discharged when working on defective batteries or when handling batteries improperly e Always wear eye protection when working on any defective or possibly defective batteries Safety gloves It is possible that battery acid can be discharged when working on defective batteries or when handl
35. et head screws 1 e Pull the wheel 2 off the hub Installing a drive wheel e Install the wheel in reverse order e Tighten the screws to a torque of 25 Nm 101 8 12 2 102 V dr Replacing a tyre Requirements 5 mm Allen key Two oblong wooden blocks at least 14 x 14 x 30 cm Three c clamps with plastic caps Torque wrench 5 30 Nm or similar Talcum powder Uninstalling a tyre Remove the wheel as described in chapter 8 12 1 CAUTION EXPLOSION HAZARD The tyre is under high pressure There is danger of injury Parts can be projected at you causing serious injury if you do not secure the wheel rims Secure the wheel rim halves with c clamps Secure the wheel rim halves with three c clamps to prevent them from unintentionally popping apart Be careful not to scratch the rims in the process Loosen the five 5 mm hexagon socket head screws 2 on the inside of the wheel Carefully loosen the c clamps in small increments one after the other until you can safely remove the rim halves Remove the inner ring 3 and outer ring 1 of the rim from the tyre 4 Replace defective or worn out components Installing a tyre Assemble the tyre in reverse order on the rim When assembling the rim halves make sure that the smooth and threaded holes for the screws are aligned exactly on top of each other Apply the three c clamps Tighten the c clamps in small increments one after the other un
36. etaining rings 1 with a pair of spring ring pliers e Push the bolts 4 out of the guides Pay attention to the bushings 3 on the front bolt e Remove the actuator from the tilt module Installing the tilt actuator e Assemble all parts in reverse order e Perform a function test 19 8 7 4 Replacing the lifter actuator Note This chapter only describes how to replace the lifter actuator To replace the complete lifter module please follow the procedures explained in chapter 8 7 2 Possible methods The lifter actuator is very easy to replace when the lifter is in a raised position It is a little more complicated to replace when the lifter is in a lowered position and cannot be raised due to a fault The individual work steps for both methods are described hereafter e To replace the raised lifter please follow the procedures explained in chapter 8 7 4 1 e To replace the lowered lifter please follow the procedures explained in chapter 8 7 4 2 8 7 4 1 Method 1 uninstalling the lifter actuator with the lifter raised A WARNING Danger of crushing The seat is very heavy Danger of injury to the hands if the seat falls down unintentionally e Leta second person help you e Carefully secure the seat before removing the actuator VA Requirements 4 e Spring ring pliers e Side cutting pliers e Cable ties Note Take careful note of the exact position of the seat Mark the position it is mounted in the angle
37. he optional lighting circuit board 40 Use the 8 mm socket wrench to loosen and remove the nuts 1 Remove the actuator module together with the mounting plate 2 If the actuator module is to be replaced Use the 7 mm socket wrench and a Phillips screwdriver to loosen and remove the nuts 3 If the electronic module is to be replaced Remove the electronic module Replace the defective modules Installing electronic modules Install the various modules in reverse order Reconnect all cable connectors to their former positions If you have replaced ACS II electronic module please select the correct drive program as described in chapter 8 2 4 Update the drive program in case a new software version is available as described in chapter 8 3 Modify the drive program using the programming software as needed The last step is to test all functions of the vehicle 41 8 2 3 Replacing the G Trac module VA Requirements e 10mm socket wrench e Side cutting pliers e Cable ties Uninstalling the G Trac module e Switch the electronics of the wheelchair OFF e Remove the front rear and right lateral covers as described in chapter 8 1 1 8 1 2 and 8 1 3 The G Trac module is located on the spring seat of the right hand spring e Trace the cable of the G Trac module 1 to the electronic module and disconnect it there e Pull the cable out of the wheelchair If necessary remove any attached cable ties
38. heelchair off e Remove the front cover and the rear covers as described in chapters 8 1 1 and 8 1 2 e Use both 13 mm socket wrenches to loosen and remove both screws 1 e Pull the fixation ring 2 backwards out of the bracket Installing a rear fixation ring e Assemble all parts in reverse order e Tighten the screws 1 to a torque of 25 Nm e Check all functions of the vehicle and go for a test drive 118 8 17 Replacing the battery boxes Requirements 7 mm socket wrench 8 mm socket wrench 10 mm socket wrench 13 mm socket wrench 16 mm socket wrench 22 mm socket wrench 13 mm open ended wrench 3 mm Allen key 4 mm Allen key 5 mm Allen key 6 mm Allen key Small flat screwdriver Torque wrench 5 30 Nm or similar Torque wrench 10 80 Nm or similar Side cutting pliers Cable ties Two oblong wooden blocks at least 14 x 14 x 30 cm Uninstalling the battery box Remove the drive wheels as described in chapter 8 12 1 Uninstall all plastic covers as described in chapter 8 1 Remove all electronic modules that are fitted in the rear on the battery box as described in chapter 8 2 2 Remove the seat including the seat frame as described in chapter 8 6 and 8 7 Remove the batteries as described in chapter 8 4 1 If necessary remove the conventional rear lighting system as described in chapters 8 5 6 and 8 5 9 Remove the anti tipper wheels as described in chapter 8 10 Remove the m
39. heir guides Remove the seat e Remove the retaining rings 1 with a pair of spring ring pliers e Push the bolt 4 out of the guide Pay attention to the bushings 3 83 e Swing the tilt lever arm 1 forwards e Remove the retaining rings 1 from the front bolt 4 of the lifter actuator 2 with the spring ring pliers e Pull the bolt out of the guide with a pair of bent nose pliers until the bolt almost touches the tilt actuator 5 Pay attention to the bushings 3 84 e Lift the tilt actuator 5 up a little e Pull the bolt 4 of the lifter actuator under the tilt actuator and out of the guide 2 e Remove the retaining rings 1 from the rear bolt 3 of the lifter actuator 2 with the spring ring pliers e Push the bolt out of the guides e Remove the actuator from the lifter module Installing the lifter actuator e Assemble all parts in reverse order e Perform a function test 85 8 8 8 8 1 86 Centre mounted legrest electric amp manual Note The centre mounted legrest is the only part of the wheelchair in which screw sizes are indicated in inches Replacing the manually operated centre mounted legrest WARNING Danger of crushing The legrest is very heavy Danger of injury to hands and feet e Pay attention to the heavy weight Requirements e 5mm Allen key e 6mm Allen key e Side cutting pliers e Cable ties Uninstalling the manually operated c
40. held by the screws Push the rear wheel cantilever arm 4 downwards Remove the spring 3 113 114 e Use the 22 mm socket wrench to loosen and remove the self securing nut 2 e Remove the washer e Pull the motor gearbox fixation and rear wheel cantilever arm off of the pivot point Assembling the motor gearbox fixation and rear wheel cantilever arm e Assemble the parts in reverse order e Tighten the self locking nut 2 hand tight and check the whole assembly moves freely 8 15 Replacing the spring in the rear i Note Invacare recommends always replacing both springs to ensure optimum performance of the wheelchair WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Leta second person help you Danger of injury due to uncontrolled movement of the wheelchair e Switch the vehicle s power system off ON OFF key e Engage the drive motors e Secure the vehicle against rolling away by placing wedges under the wheels Requirements e 5mm Allen key e Two oblong wooden blocks at least 14 x 14 x 30 cm Uninstalling the suspension e Lift the wheelchair on one side and have a second person place a 14 cm high wooden block underneath the battery compartment so that the wheels are off the ground and can rotate freely e Repeat this on the other side of the wheelchair e Remove the drive wheel as described in chapter 8 12 1 e Remove the front rear and late
41. ing acid e Wear acid resistant protective gloves when handling batteries e Wear protective goggles when handling batteries How to deal with a battery acid leak e Remove clothes that have been soiled or soaked with acid immediately e mmediately wash the affected area of skin that has come into contact with battery acid with lots of water After contact with eyes e mmediately rinse eyes under running water for several minutes Consult an eye doctor immediately afterwards Requirements e Safety goggles e Acid resistant gloves e Acid resistant container for transportation e Always wear appropriate safety clothing when handling damaged batteries e Place damaged batteries in an acid resistant container immediately after removing them e Only ever transport damaged batteries in an appropriate acid resistant container e Wash all objects that have come into contact with acid with lots of water Disposing of dead or damaged batteries correctly Dead or damaged batteries can be given back to your dealer or directly to Invacare 53 8 4 4 Replacing the main fuse Note i To replace the fuse the battery cable with the fuse attached to it must be replaced e Replace the battery cables as described in chapter 8 4 2 54 8 4 5 Checking the cables VA Requirements e Side cutting pliers e Cable ties e Remove the covers disconnect the battery plug connections and pull the batteries out of the battery compartment as
42. ing batteries improperly e Always wear acid proof safety gloves when working on any defective or possibly defective batteries 2 3 General safety information and information about fitting removal A A WARNING Danger of crushing Various components such as the drive unit batteries seat etc are very heavy This results in injury hazards to your hands e Please note the high weight of some components This applies especially to the removal of drive units batteries and the seat WARNING Injury hazard if the vehicle starts moving unintentionally during repair work e Switch the power supply off ON OFF key e Engage the drive e Before raising the vehicle secure the wheels by blocking them with wedges ATTENTION Fire and burn hazard due to electrical short circuit e The mobility device must be completely switched off before removal of voltage carrying components To do this remove the batteries e Avoid short circuiting the contacts when carrying out measurements on voltage carrying components ATTENTION Injury hazard and danger of damage to vehicle due to improper or incomplete maintenance work e Use only undamaged tools in good condition e Some moving parts are mounted in sockets with PTFE coating Teflon Never grease these sockets Never use normal nuts instead of self locking nuts Always use correctly dimensioned washers and spacers When reassembling always replace any cable ties
43. letely remove both knurled head screws 1 including the washers e Remove the cover 2 e Pull the plug of the legrest actuator out of the actuator module 88 e Use the 6 mm Allen key to loosen and remove the two hexagon socket head screws 2 on both sides of the wheelchair e Completely remove both hexagon socket head screws including the washers e Pull the entire legrest forwards out of the seat e Loosen both hexagon socket head screws which attach the adapter brackets 1 to the legrest e Remove both adapter brackets Installing the electrically operated legrest e Assemble the parts in reverse order e Test all functions of the wheelchair 89 8 8 3 Replacing an electric legrest actuator A WARNING Danger of crushing The legrest is very heavy Danger of injury to hands and feet e Pay attention to the heavy weight VA Requirements d 1 2 socket wrench 3 8 Allen key Side cutting pliers Cable ties Uninstalling the electrically operated legrest e f possible raise the lifter to the highest position e If possible tip the wheelchair with the tilt module as far backwards as it will go e Switch the electronic control system off The actuator module for the lifter and the tilt actuator are mounted to the front edge of the seat frame e Completely remove both knurled head screws 1 including the washers e Remove the cover 2 e Pull the plug of the legrest actuator out of the actuator
44. lways follow the instructions to avoid injury to the user or damage to the product BURN HAZARD This symbol warns you of the danger of chemical burns for example due to the discharge of battery acids e Always follow the instructions to avoid injury to the user or damage to the product DANGER OF CRUSHING This symbol warns you of crushing hazards due to inattentive working with heavy components e Always follow the instructions to avoid injury to the user or damage to the product EXPLOSION HAZARD This symbol warns you of an explosion hazard which can be caused by excessive tyre pressure in a pneumatic tyre e Always follow the instructions to avoid injury to the user or damage to the product Wear safety shoes The symbol refers to the requirement for wearing safety shoes e Wear standardised safety shoes during all work Wear eye protection This symbol refers to the requirement for wearing eye protection for example when working with batteries e Wear eye protection when this symbol is shown Wear safety gloves This symbol refers to the requirement for wearing safety gloves for example when working with batteries e Wear safety gloves when this symbol is shown Note This symbol identifies general information which is intended to simplify working with your product and which refers to special functions Requirements e This symbol identifies a list of various tools components and items which you will need in ord
45. mm socket wrench e 4 mm Allen key e Oblong wooden blocks at least 14 x 14 x 30 cm Uninstalling a wheel fork e Use the 4 mm Allen key to loosen and remove the hexagon socket head screw 1 Pull the cover up in the rear and remove it The cover is held in place by additional Velcro fasteners 97 98 e Prop up the wheelchair on multiple wooden blocks with the help of a second person e Use the 22 mm socket wrench to loosen and remove the self securing nut 2 e Pull the wheel fork 4 downwards out of the rear wheel cantilever arm 1 Pay attention to the washers 3 spacer washers and the separable ball bearings not visible in the illustration Installing a wheel fork e Assemble the parts in reverse order e When installing the ball bearings make absolutely sure that the wide inner rings are visible on the outside e Adjust the wheel fork as described in chapter 8 11 3 e The last step is to test all functions of the vehicle 8 11 3 Adjusting the wheel fork WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Leta second person help you d Requirements Ai e 22 mm socket wrench e Use the 4 mm Allen key to loosen and remove the hexagon socket head screw 1 e Pull the cover up in the rear and remove it The cover is held in place by additional Velcro fasteners 99 100 Let a second person tilt the wheelchair forward over the driv
46. module 90 e Use the 3 8 Allen key and a 1 2 socket wrench to loosen the screw 3 e Use the 3 8 Allen key and a 1 2 socket wrench to loosen the screw 1 e Remove the nuts including the washers but leave the screw inserted in the screw hole do not pull it completely out e Pull the actuator 2 toward the side off of the screws 1 and 3 e Replace the actuator Installing the electrically operated legrest e Assemble the parts in reverse order e Test all functions of the wheelchair 91 8 8 4 Replacing the calf plate on the centre mounted legrest electric amp manual VA Requirements da e 1 64 Allen key A manual legrest can be seen in the illustration The method of fixation to the seat is almost identical with both legrests Uninstalling the calf plate e f possible raise the lifter to the highest position e If possible tip the wheelchair with the tilt module as far backwards as it will go e Switch the electronic control system off e Use the 1 64 Allen key to loosen and remove both screws 2 e Remove the calf plate 1 Installing the calf plate e Assemble the parts in reverse order e Using the different adjustment holes 3 in the calf plate and in the calf plate brackets the calf plates can be mounted at different heights and widths This must be adjusted to fit the needs of the user 92 8 8 5 Replacing the foot plate on the centre mounted legrest electric amp manu
47. n that has come into contact with battery acid with lots of water After contact with eyes e Immediately rinse eyes under running water for several minutes Consult an eye doctor immediately afterwards Requirements e 11mm socket wrench e Side cutting pliers e Cable ties 51 52 Uninstalling batteries battery cables Remove the batteries as described in chapter 8 4 1 Positive terminal Remove the cable ties 1 with side cutting pliers Lift the battery terminal cap 2 off and move it up the cable and out of the way Use an 11 mm socket wrench to loosen the battery terminal screw 3 Remove the battery terminal screw together with both washers and the cable lug 5 from the battery terminal 4 Negative terminal Repeat the steps of the procedure for the positive terminal on the negative terminal of the battery Replace the batteries and or the battery cables Installing batteries battery cables Assemble the parts in reverse order Connect the negative terminal first then the positive terminal Make sure the battery box sockets and plugs are correctly installed A schematic showing the correct positions can be found in the battery box cover Carefully reposition the battery terminal caps and secure them with a cable tie to prevent them from possibly slipping out of place 8 4 3 How to handle damaged batteries correctly A N WARNING Risk of chemical burns Danger of injury by leak
48. n the corresponding side of the wheelchair Remove the screws and the washers Remove the tilt mounting bracket e f one of the seat frame mounting brackets 5 are to be replaced Disassemble the seat frame mounting brackets as described in chapter 8 6 starting from the section header Uninstalling the seat frame Installing the tilt module e Install the tilt module in reverse order Make sure that seat tilt mounting brackets 2 are affixed with screws to the top holes in the seat frame brackets 5 e Tighten the connecting screws of the seat tilt mounting brackets and the seat frame mounting brackets to 18 Nm e When installing the cables again make sure that they are placed in such a way that they cannot be crushed or damaged in any position of the tilt module WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Leta second person help you e Install the seat e Install all covers again e Check all functions of the vehicle and go for a test drive 11 8 7 3 78 Replacing the tilt actuator Note This chapter only describes how to replace the tilt actuator To replace the complete tilt module please proceed as described in chapters 8 7 1 and 8 7 2 WARNING Danger of crushing The seat is very heavy Danger of injury to the hands if the seat falls down unintentionally e Leta second person help you e Carefully secure the seat before removing the actuator
49. ntional motor transmission units V d Requirements e Phillips screwdriver size 2 e digital multimeter with resistance measurement e Remove the rear panel as described in Chapter 8 1 2 e Pull the motor plug 1 out of the electronics module ame fey d e Connect the digital multimeter to the adjacent central motor plug contacts 3 and measure the resistance between the contacts e lf there is a defect replace the motor and send it to Invacare Service for inspection or repair 31 ER Note A resistance of between 40 and 80 ohms indicates an intact brake A resistance of 0 ohms or a very high resistance mega ohms or infinity indicates a short circuit a bad connection or a defective brake CAUTION Material damage can be caused to the electronics module due to short circuits in the electro mechanical brake e NEVER connect an electro mechanical brake to an intact electronics module with a short circuit e Always replace short circuited brakes immediately Note A defective motor can damage the electronics module but not the other way around 8 Repair Work 8 1 Covers 8 1 1 Open front cover Removing the front cover e Remove the legrests e Loosen and remove both of the knurled head screws 1 e Press the front cover 2 slightly upward then pull the cover forward and off Installing the front cover e Assemble the parts in reverse order When installing the plastic cover make
50. ote and in the electronics module 8 3 Updating the driving program d A V du LO ie The driving programs for electric wheelchairs are continually updated and improved by Invacare For this reason you should check whether the version number is still up to date each time a wheelchair comes in for repairs and also during regular inspections If a newer version is available the driving program must be updated The procedure for updating the driving program is described in the user manual of the Wizard software Note The electronic system is supplied with a standard drive program If the driving program has been customised you have to perform this customisation again after installing the new driving program WARNING Every alteration to the drive program can influence vehicle handling and the tipping stability of the wheelchair e Alterations to the drive program must only be carried out by trained Invacare dealers e nvacare can only assume a warranty for the safe vehicle handling of the wheelchair in particular tipping stability for unaltered standard drive programs Requirements e Dynamic Wizard software e User manual for the Wizard software e For further information on other requirements such as the minimum system configuration of the PC to be used for programming necessary programming cables see the user manual of the Wizard software You find the latest version of the user manual in the do
51. otor gearbox mounting including suspension as described in chapter 8 14 Remove the fixation rings as described in chapter 8 16 Replace the battery box Installing the battery box Install the fixation rings as described in chapter 8 16 Install the motor gearbox mounting including suspension as described in chapter 8 14 Install the drive wheels as described in chapter 8 12 1 Install the anti tipper wheels as described in chapter 8 10 If necessary install the conventional rear lighting system as described in chapters 8 5 6 and 8 5 9 Install the batteries as described in chapter 8 4 1 Install the seat including the seat frame as described in chapter 8 6 and 8 7 Install all electronic modules that are fitted in the rear on the battery box as described in chapter 8 2 2 Install all plastic covers as described in chapter 8 1 Install the drive wheels as described in chapter 8 12 1 Perform a comprehensive driving and function test with the wheelchair 119
52. ould always use the original packaging for transport Please attach a precise description of the fault 1 3 Definition and representation of information and safety information A in this manual Different types of information and signal words are used throughout this manual HAZARD The signal word HAZARD refers to immediate hazards e The following lines in italics refer to actions which serve to avoid such hazards WARNING The signal word WARNING refers to possibly occurring hazards which can lead to death or serious injuries if they are not avoided e The following lines in italics refer to actions which serve to avoid such hazards ATTENTION The signal word ATTENTION refers to possibly occurring hazards which can lead to minor injuries and or material damage if they are not avoided e The following lines in italics refer to actions which serve to avoid such hazards CAUTION The signal word CAUTION refers to hazards which could lead to material damage if they are not avoided e The following lines in italics refer to actions which serve to avoid such hazards Note The signal word Note is used to denote general information which simplifies the handling of your product and refers to special functions 1 4 Hazard symbols and symbols used A V Different types of hazard symbols and symbols are used throughout this manual General hazards This symbol warns you of general hazards e A
53. ous electronics modules can be fitted in connection with differing remotes in the mobility aid Rectification of operational faults is dependent on the electronics module fitted The electronics modules used are described in Chapter 4 2 Note The tables for rectification of operational faults listed in the following chapters are only an excerpt from the original manufacturer s manuals You can obtain the original manuals from Invacare If you have problems with the mobility aid please proceed as follows e First assess the possible cause of the problem using the following table e Check the remote status display Evaluate the error code e Carry out the necessary checks and repairs as recommended in the following table 6 1 Drive fault diagnosis PROBLEM OTHER POSSIBLE SOLUTION Documentation SYMPTOMS CAUSE The remote status display illuminates normally and displays blink code 5 6 Mobility aid will not start Drive motors See operating manual disengaged Engage drive motors Remote status Batteries Replace batteries See chapter 8 4 1 display does not defective Completely Pre charge See operating manual illuminate discharge batteries battery Power supply to Check master fuse See chapter 8 4 4 remote Check cables See chapter 8 4 5 interrupted between the modules for loose connections and damage Remote Replace remote See chapter 8 2 1 defective
54. owing table provides an overview ACS II PMB70 ACS II PMB70L ACS II PMAS0LG ACS Il with actuator Kai module ACT Actuator module ACT Lighting circuit board G Trac module The actuator module is optional The actuator module is optional The lighting circuit board is optional The G Trac module is optional 17 4 2 1 4 2 2 ACSIIPMA9OL electronic module 4 2 3 4 2 3 1 ACS II PMB70 ACS II PMB70L electronic module Connections Battery 24V 2 Bus cable to remote or ACT gl ee eg 3 Bus cable to remote or ACT a z 4 Motor M1 5 Light 6 Motor M2 Connections Battery 24V 2 Cable to G Trac module GYRO 3 Bus cable to remote or ACT 4 Motor M1 5 6 I it pot JIRI m Light Motor M2 _ A i W ee Actuator module ACT Various types of adjustment motors also called actuators can be installed on the wheelchair These actuators are either connected directly to the electronic module or to a separate actuator module The actuator module is connected to the electronic module via a bus cable Actuator module ACT2 Connections 1 AC pe Fe ee 2 Bus cable to remote or ACT 3 Bus cable to remote or ACT 4 Adjustment motor actuator channel 2 5 Adjustment motor actuator channel 1 Ch a Fh DU The ACI connection serves to limit the movement of an actuator or to reduce velocity 4 2 3 2 Actuato
55. pletely remove both knurled head screws 1 including the washers e Remove the cover 2 e Disconnect the plug from the actuator module e Open the cable clips on the underside of the seat e Free up all cables so that you can lift the seat off WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Leta second person help you e Loosen the four screws 1 that attach the seat to the lifter tilt module using a 4 mm Allen key and a 13 mm open end wrench e Together with a second person lift the seat up off of the lifter module tilt module 19 Open the power supply chain of the lifter Flip the cover 1 up Pull the flap 2 out of the cover Repeat this procedure link by link Remove both cable ties that secure the cable at the ends of the power supply chain Pull the cable out of the power supply chain Use the Phillips screwdriver to loosen the screws 1 Remove the power supply chain 2 Use the Phillips screwdriver to loosen the screws 4 Remove the magnet 3 Remove the sensor 5 eae0000 fj 0000000 o e Use the 6 mm Allen key to loosen and remove the four hexagon socket head screws 3 on both sides of the wheelchair e Remove the screws and the washers e Lift the tilt module 1 up off of its brackets 2 e f one of the seat tilt mounting brackets 2 are to be replaced Use the 6 mm Allen key to loosen both screws 4 o
56. r module ACT 4 Connections An Les ech d ri 2 CC fr tar en 1 ACI Ge SS a el GI E 2 Bus cable to remote or electronic module wee The ACI connection serves to limit the movement of an actuator or to reduce velocity 3 Bus cable to remote or electronic module Actuator channel 4 Actuator channel 3 Actuator channel 2 Actuator channel 1 4 5 6 T7 kb r S SN 4 2 4 Lighting circuit board The connections of the lighting circuit board are located directly on the board Or 19 ZU 4 3 Remotes Various types of remotes can be installed on the wheelchair Before you connect components of the wheelchair such as adjustment motors or actuators make sure you know exactly which remote is installed The following table provides an overview Remotes Designations Remarks REM G90A Can be connected to vi 3 ACS II PMB70 y ACS II PMB70L 7 ACS DMAOOL CG i power modules REMA Can be connected to ACS II PMB70 ACS II PMB70L ACS PMAS0LG power modules REMB Can be connected to ACS II PMB70 ACS II PMB70L ACS PMA9S0LG power modules ze en en REM 550 Can be connected to ACS II PMB70 ACS II PMB70L ACS PMA90LG power modules 21 5 22 Maintenance plan once a year Component Check for Measures Remarks restraining belt damaged replace it buckle damaged replace it e Damage to the e fthe arm pad is armrests S
57. ral covers as described in chapter 8 1 1 8 1 2 and 8 1 3 e Remove the drive wheel as described in chapter 8 12 1 e Use the 5 mm Allen key to loosen and remove both screws 3 e Remove the black plastic stop 1 e Push the rear wheel cantilever arm downwards e Remove the spring 2 115 116 Installing the suspension e Assemble the parts in reverse order 8 16 Fixation rings 8 16 1 Replacing a front fixation ring VA Requirements ge e 13mm socket wrenches two of them e Torque wrench 0 30 Nm or similar Removing a front fixation ring e Switch the wheelchair off e Remove the front cover and the rear covers as described in chapters 8 1 1 and 8 1 2 e Remove the seat as described in chapter 8 6 and 8 7 _ KK gt Se O w Ee me Ai SR e Loosen and remove both of the self locking nuts 3 e Pull the fixation ring 2 up and off of the seat frame 1 Installing a front fixation ring e Assemble all parts in reverse order e Tighten the screws 3 to a torque of 25 Nm e When installing the seat pay attention to its heavy weight e When installing the seat pay attention to the adjustment settings of the seat tilt e Check all functions of the vehicle and go for a test drive 117 8 16 2 Replacing a rear fixation ring VA Requirements i e 13mm socket wrenches two of them e Torque wrench 0 30 Nm or similar Removing a rear fixation ring e Switch the w
58. raph with a digital camera e Detach all cables from the electronic modules which run from the seat to the chassis e Place the cables so that they do not get in the way when you remove the seat e Insert a suitable wooden block 2 between the seat 1 and the chassis 3 This will prevent the seat from falling down when you loosen and remove the screws WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Leta second person help you e Use the 6 mm Allen key to loosen and remove the screws 4 on both sides in the front at the same time e Hold the seat securely and loosen the rear hexagon socket head screw 5 on both sides with a6 mm Allen key at the same time e Lift the seat off 69 Uninstalling the seat frame 70 A front seat frame B rear seat frame Use a 6 mm Allen key to loosen the hexagon socket head screws 2 Pull the seat frame 1 up and off Installing the seat and seat frame Assemble all parts in reverse order When installing the seat pay attention to its heavy weight When installing the seat pay attention to the adjustment settings of the seat tilt Tighten the screws to a torque of 25 Nm Check all functions of the vehicle and go for a test drive 8 7 Replacing the tilt module lifter module 8 7 1 Replacing the tilt module without lifter Note i This chapter describes how to replace the tilt module on a wheelchair without a lift
59. s and pull the cable out of the wheelchair e Remove both plastic covers 2 e Use an 8 mm socket wrench to loosen both nuts 64 e Remove the nuts together with the washers e Pull the tail lamp 1 towards the rear and remove from the tail lamp bracket 3 Installing the tail lamp e Assemble all parts again in reverse order e Tighten both screws hand tight e Check all vehicle functions 65 66 8 5 9 Replacing the tail lamp bracket conventional lighting system V Requirements e 3 mm Allen key Uninstalling the head lamp bracket e Remove the front rear and lateral covers as described in chapter 8 1 1 8 1 2 and 8 1 3 Uninstall the complete tail lamp assembly as described in chapter 8 5 8 e Use the 3 mm Allen key to loosen and remove both screws 2 e Replace the lamp bracket 1 Installing the head lamp bracket e Assemble all parts again in reverse order e Check all vehicle functions 8 5 10 Replacing the tail lamps completely LED lighting system Note i Individual LEDs are not intended to be replaced The LEDs are replaced along with the complete bracket assembly This means that the complete red or yellow tail lamp is replaced VA Requirements e Phillips screwdriver size 1 Uninstalling the tail lamp e Remove the front rear and the applicable lateral cover as described in chapters 8 1 1 8 1 2 and 8 1 3 e Use a Phillips screwdriver to loosen and remove th
60. s very heavy Danger of injury to hands and feet e Leta second person help you Install the seat Install all covers again Check all functions of the vehicle and go for a test drive 73 8 7 2 Replacing the lifter tilt module Note This chapter describes how to replace the seat frame on a wheelchair with a lifter tilt module Similar tasks are described In the following chapters e Replacing the seat frame alone chapter 8 6 Replacing a tilt module chapter 8 7 1 Replacing just the tilt actuator chapter 8 7 3 Replacing just the lifter actuator chapter 8 7 4 A WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Leta second person help you VA Requirements ge e 13 mm open ended wrench e 4mm Allen key e 6mm Allen key e Side cutting pliers e Cable ties Note Take careful note of the exact position of the seat Mark the position it is mounted in the angle and so on If necessary make photographs with a digital camera Any modification of the adjustment of the seat affects the centre of gravity of the wheelchair Uninstalling the lifter tilt module e f possible raise the lifter to the highest position e If possible tip the wheelchair with the tilt module as far backwards as it will go e Switch the electronic control system off The actuator module for the lifter and the tilt actuator are mounted to the front edge of the seat frame 74 e Com
61. sure that the slots on the sides 3 and the lower hooks on the cover latch onto the chassis 4 e Tighten both knurled head screws hand tight 8 1 2 Opening the rear cover Removing the rear cover e Loosen and remove both of the knurled head screws 1 e Remove the rear cover 2 Installing the rear cover e Assemble the parts in reverse order e Tighten both knurled head screws hand tight 34 8 1 3 Opening the lateral cover A Requirements d e 10mm socket wrench e 6mm Allen key e Two oblong wooden blocks at least 14 x 14 x 30 cm Removing the lateral cover Remove the drive wheel as described in chapter 8 12 1 Remove the front cover and the rear covers as described in chapters 8 1 1 and 8 1 2 Use the 10 mm socket wrench to loosen both screws 1 Hold the cover firmly with one hand Completely remove both screws 1 including the washers Pull the cover off towards the side Disconnect the plug in connections if there are tail lights installed in the lateral cover see illustration below 35 Installing the lateral cover e Connect the plug in connections if there are tail lights installed in the lateral cover Make sure that the markings 1 red tail light and 2 yellow flasher on the power supply cable and on the tail light plug in connection are aligned with each other 36 Push the cover from the side between the seat and the chassis Position both screws 1 including th
62. t fixation ring Replacing a rear fixation ring Replacing the battery boxes 117 118 119 1 Introduction 1 1 General information Service and maintenance work must be carried out taking this service manual into account lt is imperative that you observe safety information Information about operation or about general maintenance and care work on the mobility aid should be taken from the operating manual You can find information about ordering spare parts in the spare parts catalogue Only use original Invacare spare parts The guarantee will become invalid if other spare parts are used We reserve the right to make any alterations on the grounds of technical improvements The mobility aid may only be maintained and overhauled by qualified personnel The minimum requirement for service technicians is suitable training such as in the cycle or orthopaedic mechanics fields or sufficiently long term job experience Experience in the use of electrical measuring equipment multimeters is also a requirement Special Invacare training is recommended Alterations to the mobility aid which occur as a result of incorrectly or improperly executed maintenance or overhaul work lead to the exclusion of all liability on the side of INVACARE If you have any problems or questions please contact Invacare Service 1 2 Notes on transport If the mobility aid has to be shipped back to the manufacturer for major repairs you sh
63. talled such that the self locking nut 4 is located on the outside If the sealing ring is incorrectly installed rotate it around as described in chapter 8 13 2 Install the motor gearbox unit in reverse order Check the orientation of the motor and adjust it The motor must be installed in such a way that the motor cable protrudes from the motor on the top pointed slightly towards the wheelchair The coupling lever must be able to move to the positions Driving as well as Pushing Tighten the self locking nut 4 of the sealing ring to a torque of 4 Nm Connect the motor cable plug Reinstall all components that were removed beforehand in reverse order 8 13 2 V Replacing or rotating the motor gearbox unit sealing ring CAUTION Danger of crushing The motor gearbox unit is very heavy Danger of injury to the hands e Pay attention to the heavy weight Requirements e 10mm socket wrench Uninstalling the sealing ring Uninstall the motor gearbox unit as described in chapter 8 13 1 Use the 10 mm socket wrench to loosen and remove the self securing nuts 4 including the washers Remove the carriage bolt which secures the sealing ring 2 Carefully bend the sealing ring apart and remove it Installing the sealing ring Install the sealing ring so that the square hole for the carriage bolt is on the inside of the wheelchair Insert the carriage bolt through the sealing ring Install the washer
64. ter for several minutes Consult an eye doctor immediately afterwards 1 A Requirements U e Phillips screwdriver size 2 e Side cutting pliers e Cable ties Uninstalling the batteries e Remove the legrests e Remove the front cover as described in chapter 8 1 1 48 e Disconnect the plug in connection 1 of the front battery 2 e Remove the rear cover as described in chapter 8 1 2 e Take exact note of the positions of all cables and the sockets that they are connected to Mark the connectors and sockets or take a photograph with a digital camera e f necessary remove the cable ties that secure the bundles of cables to the chassis on both sides of the electronic modules e Position the bundles of cables so that they lie outside of the fixation screws 1 of the electronic module brackets e Loosen and remove both fixation screws of the electronic module brackets including the washers with a Phillips screwdriver 49 50 e Disconnect the plug in connection 1 of the rear battery 2 e Disconnect the battery cable from the electronic module e Lift the electronic module bracket up and remove it Pull the bracket towards the rear and let it hang over the back end of the wheelchair e Pull both batteries backwards out of the chassis and remove them Take into account the heavy weight of the batteries Installing batteries e Install the batteries in reverse order e Make sure the battery box sockets
65. the brushes Used carbon brushes must be reinstalled in exactly the same position and orientation as they are in before to ensure optimum contact with the collector e Mark the motor and the carbon brush to ensure correct installation e Completely remove the carbon brush from the socket 2 e Check the carbon brush and the tension spring for wear broken pieces and discolouration Installing carbon brushes e Depending on the condition of the carbon brush and the tension spring Reinstall the same carbon brush exactly as it was before or Install a new carbon brush e Reposition the plastic caps and tighten them e Install the drive wheels as described in chapter 8 12 1 e Run the motor in as described in chapter 8 13 5 111 8 13 5 Running the motor in d A W 112 Note The following procedure is necessary to run in the motor after replacing the carbon brushes to guarantee maximum performance WARNING Danger of accidents Danger to people the surroundings and wheelchair e Never leave the wheelchair unattended during the following procedure e Make sure that BOTH drive wheels are raised and CANNOT touch the ground e Secure the surrounding area Requirements e Two oblong wooden blocks at least 14 x 14 x 30 cm e Lift the wheelchair on one side and have a second person place a 14 cm high wooden block underneath it so that the drive wheel is off the ground and can rotate freely e Repeat this on th
66. tightening torques stated in the following list are based on the thread diameter for the nuts and bolts for which no specific values have been determined All values assume dry and de greased threads Tightening torque 3Nm 6Nm 10Nm 25Nm 49Nm 80 Nm 120 Nm 180 Nm in Nm 10 CAUTION Damage can be caused to the mobility device due to improperly tightened screws nuts or plastic connections e Always tighten screws nuts etc to the stated tightening torque e Only tighten screws or nuts which are not listed here fingertight 4 Arrangement of sub assemblies and components 4 1 Overview In the rear under the seat Electronic modules The electronic modules are located under the rear cover 1 Electronic module 2 Actuator module optional e 3 Lighting circuit board optional amp not e shown in the illustration The electronic modules that are installed are described in chapter 4 2 In the front under the seat 1 Actuator module optional 2 Lifter actuator optional 3 Tilt actuator optional 15 On the right next to the spring seat 1 G Trac module optional 4 2 Electronic modules Various different types of electronic modules can be installed in the wheelchair Before you connect components of the wheelchair such as adjustment motors or actuators to the electronic module make sure you know exactly which electronic module is installed The foll
67. til the rim halves are squarely pressed together Tighten the hexagon socket head screws 2 to a torque of 25 Nm 8 12 3 Replacing a drive wheel hub A WARNING Danger of damage to the wheelchair Collisions can be caused if shim rings are removed from the drive wheels during installation work e Shim rings are frequently placed between the drive shaft and the wheel hub to compensate tolerances Collisions can be caused if these shim rings are removed and not re installed e Please install all shim rings in exactly the same positions they were before disassembly f Requirements W e 19 mm socket wrench e Torque wrench 10 80 Nm or similar Uninstalling a drive wheel hub e Use the 19 mm socket wrench to loosen and remove the axle nut 4 e Remove the washer 3 e Pull the wheel hub 5 off of the axle 2 e Remove the feather key 1 from the axle Installing a drive wheel hub 103 e Assemble the parts of the wheel hub in reverse order e Between the wheel and the motor drive unit distance rings of various widths are inserted to adjust the clearance between the wheel and the motor Select the correct width for the distance rings e Use a thin film of lubricant to replace the wheel hub on the axle e Tighten the screws to a torque of 60 Nm 104 8 13 Drive unit 8 13 1 Replacing the motor gearbox unit A WARNING Danger of crushing The wheelchair is very heavy Danger of injury to
68. ting if e Check function available Batteries e Check battery voltage e Check battery voltage e Check contacts and terminal clamps e Remote status display flashing e Fixations Remote electronic module e Cables and plug in connections Joystick function Power supply Check the version of the programme in the driving electronics Drive programme e Tighten replace if e Replace if e Check battery box Battery box and fastening belt for n damage e Check batteries for e Replace batteries sae chapter 8 4 1 damage if necessary and 8 4 3 e Charge batteries e Charge batteries See instruction manual e Clean contacts e Analyse the error See chapter 6 flash code e Tighten fixations e Check all cables See chapter 8 8 amp necessary the User Guide e Replace cable if See chapter 8 8 amp necessary the User Guide e f necessary replace light or cable See chapter 8 5 A necessary See the safety notes in chapter 8 4 1 and 8 4 3 for information on correctly handling batteries and terminal clamps replace if necessary and plug in connections for secure fit replace if necessary Replace joystick if necessary Replace remote if necessary Check all cables and plug in connections for secure fit replace if necessary Update the software if a newer version Is available See chapter 8 3 23 6 Operational faults ib 24 The vari
69. ting pliers e Cable ties Uninstalling head lamps e Remove the rear cover as described in chapter 8 1 2 e Take exact note of the positions of all cables and the sockets 1 that they are connected to Mark the connectors and sockets or take a photograph with a digital camera e Disconnect the cable of the affected head lamp from the lighting circuit board e Remove all cable ties and pull the cable out of the wheelchair 58 Loosen both of the cap nuts 1 with an 8 mm open end wrench and remove the head lamp with the bracket from the rubber mounting Not shown in the illustration are two Phillips head screws with which the head lamp is secured to the bracket Loosen both of these Phillips head screws to remove the head lamp from the bracket Replace the head lamp Installing head lamps Assemble all parts again in reverse order Install the cables carefully and secure them with cable ties Make sure that the cables not are not pinched or stretched Tighten both screws hand tight Check all vehicle functions Perform an approximate adjustment of the head lamp using the ratchet plate as a guide The final adjustment can be performed by the user according to the instructions found in the User Guide 59 8 5 4 Replacing the head lamps completely LED lighting system 4 Requi m Alen key e Side cutting pliers e Cable ties Uninstalling head lamps e Remove the rear cover as described in chapter 8 1 2
70. ushing The wheelchair is very heavy Danger of injury to the hands and feet e Leta second person help you Danger of injury due to uncontrolled movement of the wheelchair e Switch the vehicle s power system off ON OFF key e Engage the drive motors e Secure the vehicle against rolling away by placing wedges under the wheels Uninstalling a rear wheel e Lift the wheelchair on one side and have a second person place a 14 cm high wooden block underneath it so that the rear wheel is off the ground and can rotate freely e Carefully remove the black plastic cap from the middle of the anti tipper wheel 1 with a small flat screwdriver The cap is not shown in the above illustration e Use the 16 mm socket wrench to loosen the self securing axle nut 2 e Remove the axle nut and the washer e Pull the wheel off the axle Installing a rear wheel e Assemble the parts in reverse order e Tighten the self securing axle nuts just tight enough that the wheel can still rotate without resistance 96 8 11 2 W Replacing a rear wheel fork WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Leta second person help you Danger of injury due to uncontrolled movement of the wheelchair e Switch the vehicle s power system off ON OFF key e Engage the drive motors e Secure the vehicle against rolling away by placing wedges under the wheels Requirements e 22
71. which were cut during dismantling After completing your work before renewed start up of the mobility device check all connections for tight fitting e After completing your work before renewed start up of the mobility device check all parts for correct locking e Only operate the vehicle with the approved tyre pressures see technical data e Check all electrical components for correct function Please note that incorrect polarity can result in damage to the electronics e Always carry out a trial run at the end of your work Note Mark all current settings for the mobility aid Seat armrests backrest etc and the associated cable connecting plugs before dismantling This makes reassembly easier 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 WARNING Any changes to the drive program can affect the driving characteristics and the tipping stability of the vehicle e Changes to the drive program may only be carried out by trained Invacare specialist dealers e nvacare supplies all mobility aids with a standard drive program ex works Invacare can only give a warranty for safe vehicle driving behaviour especially tipping stability for this standard drive program 13 3 Tightening torques The
72. wnload area on http www dynamiccontrols com 47 8 4 Batteries cables amp battery chargers 8 4 1 Removing the batteries AN CAUTION Danger of injury and danger of damage to property if the batteries are handled incorrectly e The installation of new batteries may only be performed by authorised technicians e Pay attention to the warning notes on the batteries e Only use the battery type defined in the technical specifications CAUTION Risk of fire and burns if battery terminals are short circuited e Take special care that the battery terminals are NOT short circuited with a tool or metallic components of the wheelchair e Make sure that the battery terminal caps are fitted to the battery terminals at all times if you are not working on them CAUTION Danger of crushing The batteries are very heavy There is a danger that you may injure your hands e Take into account the heavy weight of the batteries e Handle the batteries carefully WARNING Risk of chemical burns Danger of injury by leaking acid e Wear acid resistant protective gloves when handling batteries e Wear protective goggles when handling batteries How to deal with a battery acid leak e Remove clothes that have been soiled or soaked with acid immediately e mmediately wash the affected area of skin that has come into contact with battery acid with lots of water After contact with eyes e mmediately rinse eyes under running wa

Invacare® FDX SERVICE MANUAL

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Invacare&reg; FDX SERVICE MANUAL

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Invacare® FDX SERVICE MANUAL