Invacare® Dragon Invacare® Tiger SERVICE INSTRUCTIONS
Contents
1. 46 0 8 761 70 90 46 0 8 761 81 08 sweden invacare com finland invacare com Wwww 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 Page TABLE OF CONTENTS 5 1 INTRODUCTION D 1 1 General information 7 1 2 Notes on transport 7 1 3 Definition and representation of information and safety information in this manual 8 1 4 Hazard symbols and symbols used 9 1 5 Images in this manual 10 2 SAFETY AND FITTING INSTRUCTIONS 11 2 1 Before any inspection or repair work 11 2 2 Personal safety equipment 11 2 3 General safety information and information about fitting removal 11 A TIGHTENING TORQUES 13 4 ARRANGEMENT OF THE ASSEMBLY GROUPS AND COMPONENTS 14 5 SERVICE PLAN 1X ANNUALLY 15 6 OPERATIONAL FAULTS 17 6 1 Operational faults on a wheelchair fitted with Shark electronics 17 6 1 1 Diagnosis of actuation disorders 17 6 1 2 Shark error codes and diagnostic codes 19 6 2 Troubleshooting the Tornado with ACS 21 6 2 1 Diagnosing driving faults 21 6 2 2 Diagnosing problems with electric actuators 23 6 2 3 REM24 Error Codes and Diagnostic Codes 24 D REPAIR WORK 26 7 1 General warning information on installation work 26 7 2 Replacing the motor 26 7 3 ZA 7 5 7 5 1 7 5 2 7 6 T T 7 8 7 9 7 10 7 11 7 11 1 7 11 2 7 12 7 13 7 13 12. Pre requisites e Phillips screwdriver e To modify a drive programme you will need Programming software or a Handheld Programmer and the Installation Manual of the ACS Electronics available from Invacare NOTE All ACS remotes are supplied with a standard drive programme If the driving programme has been customised then you will have to perform this customisation again after installing the new electronic module 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 trained Invacare dealers e Invacare can only assume a warranty for the safe vehicle handling of the wheelchair in particular tipping stability for unaltered standard drive programmes e Switch off the remote e Pull the bus cable 1 out of the remote e Loosen the thumb screw 2 e Pull the remote and the remote holder out of the guiding device e Unscrew both remote holder screws 1 using the crosstip screwdriver 43 44 Installation of the remote is carried out in reverse order Update the software in case a newer version is available Customise the driving programme with the programming software if required Check all vehicle functions 7 10 Replacing the steering head bearings on the steering wheels WARNING Danger of crushing The mobility device is very heavy Injury h
3. Removing the wheel e Jack up the vehicle place a wooden wedge under the frame e Loosen and remove the screw 1 using the Allen key on one side and the open ended spanner on the other side for countering e Pull the wheel from the fork PLEASE NOTE Installation is carried out in reverse order Please ensure that the wheel is re fitted on the same side and in the same running direction as removed Repairing a flat tyre ATTENTION Explosion hazard There is considerable pressure in the tyre Danger of injury Parts can be thrown out and injure you if you do not evacuate all the air from the tyre e Press the release pin in the valve inwards and evacuate all the air from the tyre e Unscrew the valve cap e Exhaust the air from the tyre by pressing the spring pin in the valve e Use the flat screwdrivers or other tools to carefully remove the shoe from the rim Do not damage the tube if this is to be used again e Repair the tube and re fit or fit new tube PLEASE NOTE If the old tube is to be repaired and re fitted and has become wet during repair work powdering the hose with some talcum powder can simplify the fitting procedure e Re apply the shoe e Check the exact fit of the shoe e Inflate the tyre to the prescribed air pressure e Re check the exact fit of the shoe e Screw on the valve cap e Re install the wheel 49 7 12 Replacing a drive wheel A WARNING Danger of crushing The mo
4. DOCUMENTATION See Changing the batteries on page 34 siehe Replacing the motor on page 26 See Changing the batteries on page 34 See operating instructions for battery charger See Changing the batteries on page 34 6 1 2 Shark error codes and diagnostic codes The actuation electronics can automatically remedy certain disorders In this case the status display will stop flashing Please switch the remote on and off several times Please wait about 5 seconds every time before switching the remote on again If the error is not remedied by this please diagnose the cause on the basis on the following flashing codes FLASHING CODE Meaning Operational error Battery error Error on the right motor M1 Fault on the left M2 motor brake Fault on the right M1 motor brake Fault on the Shark remote Error on the left motor M2 Solution Please ensure that the joystick is in neutral central position simply release joystick and switch on again Check battery and power cable Charge batteries If you switch the wheelchair off for a few minutes the batteries are often able to re charge sufficiently to enable a short journey You should however only use this solution in an emergency as this leads to the batteries discharging excessively Replace the batteries Check the motor cable and U connector Check the motor Check the motor cable and U connect
5. 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 e o eo EE EP Cem ess b X Hazard symbols and symbols used Different types of hazard symbols and symbols are used throughout this manual General hazards This symbol warns you of general hazards e Always 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 st
6. be carried out by trained Invacare dealers e Invacare can only assume a warranty for the safe vehicle handling of the wheelchair in particular tipping stability for unaltered standard drive programmes e Unscrew the handwheels screws 1 on both sides of the panelling for the electronics e Remove the electronic panelling e Disengage all the plugs 1 on the electronic module 31 32 Remove the screws 1 on both sides of the power module Pull out the module Installation of the electronics is carried out in the reverse order Update the software in case a newer version is available Customise the driving programme with the programming software if required Check all vehicle functions ZA W a Updating the driving program 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
7. page 24 21 22 PROBLEM Wheelchai r does not drive smoothly Batteries cannot be charged Wheelchai r drives too slowly OTHER SYMPTOMS None None LEDs on the charger are flashing POSSIBLE CAUSE Batteries may be defective voltage not stable Drive motor s may be defective Batteries may be defective Charger may be defective Remote may be defective SOLUTION e Replace the batteries e Replace the drive motor s e Replace the batteries e Replace the charger e Replace the remote Batteries may e Replace the be defective batteries REFERENCE See Changing the batteries on page 34 See Replacing the motor on page 26 See Changing the batteries on page 34 See User Manual of the charger See Replacing the Shark Remote on page 41 See Changing the batteries on page 34 6 2 2 Diagnosing problems with electric actuators In case an electric actuator will not function identify the source of the problem using the following table PROBLEM OTHER POSSIBLE SOLUTION REFERENCE SYMPTOMS CAUSE Electric Remote CLAM is Replace the See Replacing the Actuator displays a defective CLAM Shark Electronics on does not flashing E page 31 function status diode on the CLAM does not go out even if the remote is switched off or disconnected Cable may Check that See Checking the be the cable is cables on page 39 disconnected not or damaged dis
8. to reach the battery poles e Use the open ended spanner to loosen the battery pole clamps e f your powerchair is equipped with ACS Electronics you will need to lift the device support in the rear fastened with Velcro strips e Remove the batteries to the rear 35 GOP gC wh 36 How to handle damaged batteries correctly WARNING BURN HAZARD Injury hazard due to discharged acid e Always wear acid proof protective gloves when handling batteries e Always wear protective goggles when handling batteries What to do if acid is discharged e Always take clothing which has been soiled by or dipped in acid off immediately e Rinse any areas of your skin which has come into contact with battery acid off immediately with plenty of water If contact with eyes is made e Rinse the affected eye under running water for several minutes You should also consult an eye specialist immediately afterwards Requirements e Safety goggles e Acid resistant gloves e Acid resistant receptacle for transportation e Always wear appropriate safety clothing when handling damaged batteries e Place damaged batteries in an acid resistant receptacle immediately after removing them e Only ever transport damaged batteries in an appropriate acid resistant receptacle e Wash all objects that have come into contact with acid with lots of water Always dispose used or damaged batteries correctly Used and damaged batteries will
9. 7 14 7 15 Replacing the Shark Electronics Updating the driving program Changing the batteries Removing the batteries How to handle damaged batteries correctly Checking and replacing the main fuse Checking the cables Replacing the Shark Remote Replacing the ACS Remote Replacing the steering head bearings on the steering wheels Repairing a flat tyre Repairing the flat tyre pneumatic tyre equipment type 127 x 27 Repairing a flat tyre pneumatic tyre equipment type 220 120 x 50 Replacing a drive wheel Adjusting the seat angle seat height Adjustment tables Replacing the safety belt Testing an actuator motor 31 33 34 36 37 39 41 43 45 47 48 50 51 53 56 56 Introduction General information e Service and maintenance work must be carried out taking this service manual into account e tis imperative that you observe safety information e Information about operation or about general maintenance and care work on the mobility aid should be taken from the operating manual e You can find information about ordering spare parts in the spare parts catalogue e Only use original Invacare spare parts The guarantee will become invalid if other spare parts are used e We reserve the right to make any alterations on the grounds of technical improvements e The mobility aid may only be maintained and overhauled by qualified personnel e The minimum requirement for service technicians is
10. Invacare Dragon Invacare Tiger SERVICE INSTRUCTIONS These instructions contain information on Inspection work Repair work Issue 21 04 10 89 00 S Mobitec Mobilitatshilfen GmbH Herzog Odilostrasse 101 A 5310 Mondsee Austria Invacare n v Autobaan 22 B 8210 Loppem Brugge Belgium Mobitec Rehab AG Benkenstrake 260 CH 4108 Witterswil Switzerland Invacare Aquatec Alemannenstrakge 10 88316 Isny Deutschland Invacare A S Sdr Ringvej 37 DK 2605 Br ndby Danmark Invacare SA c Areny s n Pol gon Industrial de Celr E 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 Kundeservice Fax Kundeservice WWW ZS Customer Service Fax Customer Service WWW 43 6232 55 35 0 43 6232 55 35 4 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 08 0 41 0 61 48 77 08 1 office mobitec rehab ch switzerland invacare com www mobitec rehab ch 49 0 75 62 7 00 0 49 0 75 62 7 00 66 info invacare aquatec com 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 0 972 49 32 20 contactsp invacare com Wwww invacar
11. andardised 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 order 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 2 1 Safety and fitting instructions 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
12. azard to hands and feet e You should seek help from a second person Injury hazard caused by uncontrolled movement of the mobility device 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 A CAUTION Incorrect reassembly can damage the bearings and cause the steering wheels to fall out The single row angular ball bearing rings are not identical on both sides There is only one correct way to insert them e Follow the assembly instructions precisely VI Required parts tools de e 19mm socket wrench e Torque spanner e Large screwdriver flat e Wooden chock approx 12 x 12 x 30 cm for jacking up the vehicle Use the wooden chock 1 to jack up the wheelchair on the side on which the ball bearings are to be replaced e Carefully remove the plastic cap 1 using the large screwdriver 45 46 e Use the socket wrench to loosen and remove the 19 mm nut Hold the wheel in such a way that it is not able to rotate when the nut is removed e Pull the steering head shaft downward and out of the steering head tube e Remove the shim and the ball race from the head of the tube The other ball race should be on the shaft IMPORTANT ASSEMBLY INFORMATION The illustrations show the wide edge on the outside of the ball race A and the narrow edge on the inside B The bearings must always be installed in such a way that the
13. be taken back by your medical equipment supplier or Invacare 7 6 a V A Checking and replacing the main fuse CAUTION Fire hazard A short circuit can cause extremely high currents which can result in spark formation and fire e Always use an original strip fuse with the approved amperage e Ifthe main fuse has blown first rectify the cause before fitting a new one CAUTION Fire hazard Fitting the incorrect strip fuse causes a fire hazard e Only ever assemble the fuse in the order shown in the illustration at right e Always tighten nuts to between 3 3 and 3 5 Nm Until 03 2004 After 03 2004 1 Fuse 1 Fuse 2 Fuse compartment 2 Fuse compartment 3 Washer 3 Nut DIN 6923 4 Nut M5 Pre requisites e 8mm open ended spanner e 40A strip fuse Information If the fuse holder is damaged this can be replaced completely together with the battery cables e Remove the battery cover 3 38 If your powerchair is equipped with the Shark Electronic System then the fuse holder is located on top of the batteries 1 if you have ACS Electronics then it is located on the device support Open the fuse holder cover If the strip fuse has blown determine the cause of the fault and remedy if necessary The main fuse should only be replaced when the fault has been remedied Use the 8mm open ended spanner to unscrew the nuts 2 on the strip fuse Replace the strip fuse Installation is ca
14. bility and the seat are very heavy Danger of injury hazard to hands and feet caused by uncontrolled tilting oder other movement e You should seek help from a second person e Remove the seat and place the mobility device upside down so that the wheels are facing upwards This guarantees mobility device stability during repair work e Please see the following work steps for further important information e Use a wooden chock underneath the battery box that is large enough to provide the wheelchair with large area support when jacking up the wheelchair This improves the tipping Stability of the wheelchair during repair work 1 A Required parts tools gei e 5mm Allen key e Wooden chock approx 12 x 12 x 30 cm for jacking up the vehicle Information Please take care of the small parts and observe the sequence in which the component parts are installed Please set them out in an orderly fashion so that they can be installed again easily in the correct sequence e Jack up the vehicle using the wooden chock 1 e Loosen the 4 screws fastening the wheel 1 using the 5mm Allen key e Remove the wheel from the hub e Installation is carried out in the reverse order 50 Adjusting the seat angle seat height There are three perforated plates under the seat for adjusting the seat angle and the seat height These perforated plates in connection with the adjustable rear holding plates result in a multitude of different ad
15. connected or damaged If necessary replace the cable Electric Test the See Testing an actuator actuator may actuator motor on page 56 be defective Remote may Exchange See Replacing the be defective the remote Shark Remote on page on the 41 wheelchair for a different one to eliminate the possibility that the remote may be the cause 23 6 2 3 24 REM24 Error Codes and Diagnostic Codes The drive electronics are capable of rectifying some errors automatically In this case the status display will cease to flash Please switch the remote on and off several times Wait approx 5 seconds each time before switching the remote on again If this does not rectify the error locate the error using the flash codes shown below FLASHCODE MEANING Module defective Accessory error e g actuator short circuit Fault in left hand motor Connection loose defective or motor defective Fault in right hand motor Connection loose defective or motor defective Fault brake fault on left hand motor Connection loose defective or motor defective Fault brake fault on right hand motor Connection loose defective or motor defective Battery voltage too high Faulty data transmission between modules SOLUTION Replace defective module Check accessory connections check accessories Check plug in connections Replace motor Check plug in connections Replace motor Check plug i
16. display on Actuation motors ls Clutch in actuation See operating will not start the remote may be motors instructions up illuminated as disengaged normal and does not indicate a disorder code Status display on Batteries may be Replace the batteries See Changing the the remote is not faulty batteries on page illuminated 34 Batteries may be Charge batteries See User Manual almost empty Power supply to Check the main fuse See Checking and the remote may replacing the main be interrupted fuse on page 37 e Check the cable Siehe Checking between the the cables on modules for any page 39 loose connections or damage Remote may be Change the remote See Replacing the faulty on the wheelchair to Shark Remote on be able to exclude page 41 the remote being the cause of the fault Status display on Various causes Analyse error code See Shark error remote flashing codes and diagnostic codes on page 19 17 PROBLEM OTHER SYMPTOMS Wheelchair None jerky in drive operation Batteries not being charged LEDs flashing on charger Wheelchair drives too slowly POSSIBLE CAUSE Batteries may be faulty instable voltage Actuation motor s may be faulty Batteries may be faulty Charger may be faulty Batteries may be faulty SOLUTION Replace the batteries Replace motor s Replace batteries Replace charger Replace batteries
17. e Remove the nut incl the washer e Remove the screw incl the safety belt the washer 2 and the washer arranged behind Note Another nut is fixed between the two washers 2 and 4 as a spacer so that the belt mounting can rotate freely e Replace the safety belt 1 Refitting the safety belt e Refit the parts in reverse order 7 15 Testing an actuator motor VU Required parts tools Al e Multimeter e The electric resistance of the adjustment motor is to be checked at the connection assembly In case this is close to infinite the motor is probably burnt out If it is less than 1Q the motor has short circuited In either case the motor must be replaced 56
18. e es 33 0 247 62 64 66 33 0 247 42 12 24 contactfr invacare com Wwww invacare fr 44 0 1656 776 222 44 0 1656 776 220 uk invacare com eire invacare com www invacare co uk 3B 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 Etterstad N 0603 Oslo Norge Invacare B V Celsiusstraat 46 NL 6716 BZ Ede Nederland Invacare Portugal Lda Rua Estrada Velha 949 P 4465 784 Lega do Balio Portugal B Fax WWW T Kundeservice Fax Kundeservice WWW ge a 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 www invacare ie 47 0 22 57 95 00 47 0 22 57 95 01 norway invacare com www invacare no 31 0 318 69 57 57 31 0 318 69 57 58 nederland invacare com www invacare nl 351 225 1059 46 351 225 1059 47 351 225 1057 39 portugal invacare com www invacare pt terf rs ljare Invacare AB FIN Fagerstagatan 9 S 163 91 Spanga Sverige Tillverkare Invacare Deutschland GmbH Kleiststrake 49 D 32457 Porta Westfalica Deutschland Kundtj nst Fax Kundtjanst WWW MOLNDAL a Fax LANDSKRONA B Fax OSKARSHAMN B Fax
19. e nn ea e Armrestdamage e Tighten screws replace and fastening padding if damaged e Side panel e Tighten screws replace damage and fixing side panels if damaged Cushion e Replace covers Check seat angle upholstery if damaged adjustment e Replace parts if damaged Damage and Replace parts if seams damaged Fixing e Tighten screws Check cabling e Replace cable or motor if Check function necessary Armrests and side panels Seat unit seat angle adjustment Backrest unit mechanical Backrest unit electrical if installed Frame chassis Check fixings Tighten screws replace welded seams and components battery box battery box Wheel e Check drive e Adjust replace wheel See Replacing a wheels for tight fit hubs drive wheel on suspension and and side play page 50 wheels e Check steering e Replace wheels wheel See Replacing wheels for tight fit fork or wheel bearings the steering head float side play and bearings on the correct torque 15 steering wheels Nm 1 5 Nm on page 45 e Pneumatic tyres if e Repair or replace if See Repairing a a available damaged flat tyre on page e Check functions in e Replace motor if drive and push necessary modes e Tighten screws nuts e Check disengager adjust or replace if necessary e Check welded e Tighten replace if seams necessary interlocking screws footplates Drive units disengager Legrests Electrical ges pare A if
20. emely heavy This results in injury hazards to your hands e Bear in mind that the batteries are sometimes very heavy e Please handle the batteries with care WARNING BURN HAZARD Injury hazard due to discharged acid e Always wear acid proof protective gloves when handling batteries e Always wear protective goggles when handling batteries What to do if acid is discharged e Always take clothing which has been soiled by or dipped in acid off immediately e Rinse any areas of your skin which has come into contact with battery acid off immediately with plenty of water If contact with eyes is made e Rinse the affected eye under running water for several minutes You should also consult an eye specialist immediately afterwards 7 9 1 V U Removing the batteries ATTENTION Fire and burns hazard if battery terminal is bypassed e Please take great care to ensure that the battery terminals are never short circuited with tools or mechanical mobility device parts e Ensure that the battery terminal caps have been replaced if you are not working on the battery terminals ATTENTION Danger of crushing The batteries are extremely heavy This results in injury hazards to your hands e Bear in mind that the batteries are sometimes very heavy e Please handle the batteries with care Requirements e Open end spanner 11 mm e Remove the battery cover e Pull the battery pole caps 1 upward and push back in order
21. footrests if Pe eat ee y installed e Check functions Te e Check cabling e Replace bulbs or cables Lighting if e Check batteries e Replace batteries if See Changing the for damage necessary batteries on page Batteries 34 Component Check e Check contacts and terminals for corrosion Remote status display blinking Fixing Cable connecting plug Joystick function Power supply Check the programme version of the Remote electronics Driving Programme driving electronics Is there a newer version available Clean contacts and terminals Evaluate flash code Tighten replace Replace Replace joystick Replace cable connector plug or console Update the software ee e Check battery e Charge batteries See User Manual CG charge See Changing the batteries on page 34 for safety information when handling batteries see Updating the driving program on page 33 Operational Faults Operational faults on a wheelchair fitted with Shark electronics Please proceed as follows in the event of operational faults e First of all analyse the possible cause of the disorder on the basis of the following tables e Check the status display on the remote Analyse the flashing error code e Carry out the necessary checks and repairs as recommended in the following table Diagnosis of actuation disorders PROBLEM OTHER POSSIBLE e SOLUTION DOCUMENTATION SYMPTOMS CAUSE Wheelchair Status
22. hammer to carefully knock the splint 2 out of the decoupling leverage 1 e Remove the decoupling leverage 1 together with the decoupling rod cannot be seen in the picture on the right from the old motor A CAUTION Damage to the motor is possible e Only apply moderate pressure to the decoupling lever when fitting to the metal rod on the new motor e Do not use a hammer Information The simplest way to install the decoupling lever is to do this before the motor and other parts are assembled together 29 30 e Carefully press the decoupling leverage 1 onto the rod 2 protruding from the new motor e Press the splint 3 in e The motor is installed in the reverse order e Secure the motor cable by means of a new cable binder 7 3 W Replacing the Shark Electronics Pre requisites e Phillips screwdriver e To modify a drive programme you will need Programming software or a Handheld Programmer and the Installation Manual of the Shark Electronics Part Number 1436160 available from Invacare NOTE All electronic modules are supplied with a standard drive programme If the driving programme has been customised then you will have to perform this customisation again after installing the new electronic module 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
23. justment possibilities The adjustable range of the seat height at 0 seat angle is 42 5 cm to 50 cm The adjustable range of the seat angle is 12 to 22 Please observe The higher the seat adjustment the smaller the adjustable range of the seat angle Pre requisites e 5 mm Allen key e 6mm Allen key e 13mm open ended spanner e Torque spanner e Loctite medium hard e The picture on the right shows the position of the perforated plates 1 and the fastening screws on the holding plates 2 for adjusting the seat height and the seat angle The picture on the right shows the front perforated plates The approach is similar for the rear perforated plates To adjust the front perforated plates a 13 mm open ended spanner is required in addition to the 5 mm Allen key e To adjust the seat height seat angle loosen the screw 1 with the spanners and pull out e Set the perforated plates to the desired height angle e Apply the Loctite to the screw re insert the screw and tighten to 40 Nm using the spanners 51 The seat height and seat angle can also be adjusted via the rear holding plates e Loosen the rear fastening screw on one side in threaded bush 1 so that the holding plate can be swivelled upward or downward e Loosen the front fastening screw and remove depending on the position the screw is either in threaded bush 2 or 3 e Repeat the procedure on the other side e Low adjustment Hole c
24. n connections Replace motor Check plug in connections Replace motor Switch lights on to lower battery voltage e Check battery charger DOCUMENTATION See Replacing the Shark Electronics on page 31 See Testing an actuator motor on page 56 See Checking the cables on page 39 See Replacing the motor on page 26 See Checking the cables on page 39 See Replacing the motor on page 26 See Checking the cables on page 39 See Replacing the motor on page 26 See Checking the cables on page 39 See Replacing the motor on page 26 See User Manual of the charger Remove all electronic modules except the Power Module and the Remote Re attach modules one by one to determine which one is causing the fault See Replacing the Shark Electronics on page 31 FLASHCODE MEANING Motors overloaded overheated Module used has compatibility problems SOLUTION Switch remote on and off wait if necessary Remove incorrect module DOCUMENTATION See Replacing the Shark Electronics on page 31 25 Lae 26 a Repair Work General warning information on installation work CAUTION Danger of damage to vehicle Collisions can be caused if the adjusting washers are removed during fitting work to the drive wheels Adjusting washers are often fitted between the drive shaft and the wheel hub to even out tolerances If these adjusting washers are rem
25. n the same running direction as removed 47 Repairing the flat tyre ATTENTION Explosion hazard There is considerable pressure in the tyre Danger of injury Parts can be thrown out and injure you if you do not evacuate all the air from the tyre e Press the release pin in the valve inwards and evacuate all the air from the tyre e Unscrew the valve cap e Exhaust the air from the tyre by pressing the spring pin in the valve e Unscrew 5 cylinder head bolts reverse side of the wheel 2 e Remove the rim halves from the shoe e Remove the inner tube from the tyre e Repair the tube and re fit or fit new tube PLEASE NOTE If the old tube is to be repaired and re fitted and has become wet during repair work powdering the hose with some talcum powder can simplify the fitting procedure e Re insert the rim halves into the tyre from the outside e Inflate the inner tube slightly with air e Re apply the cylinder head bolts and screw rim together tightly e Check the exact fit of the shoe e Inflate the tyre to the prescribed air pressure e Re check the exact fit of the shoe e Screw on the valve cap e Re install the wheel 7 11 2 Repairing a flat tyre pneumatic tyre equipment type 220 120 x 50 13 A Pre requisites Al e 6mm Allen key e 13mm open ended spanner e 2x small ring spanners or flat screwdrivers for removing the shoe e Repair kit for inner tube tyres or a new inner tube e Talcum powder 48
26. narrow edges are facing each other inside The steering head bolt and the nut must always press against the wide outside edges The bearings would otherwise be pressed apart by the bolt pressure The steering wheels should be able to rotate freely after assembly but there must not be any clearance on the bearings e Tighten the nut primarily to 20 Nm 2 Nm e Slacken the nut slightly e Re tighten to 15 Nm 1 5 Nm 7 11 7 11 1 Repairing a flat tyre WARNING Danger of crushing The mobility device is very heavy Injury hazard to hands and feet e You should seek help from a second person Injury hazard caused by uncontrolled movement of the mobility device 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 Repairing the flat tyre pneumatic tyre equipment type 1212 x 21 WARNING Danger of crushing The mobility device is very heavy Injury hazard to hands and feet e You should seek help from a second person Pre requisites e 5mm hexagon socket wrench e Repair kit for inner tube tyres or a new inner tube e Talcum powder Dismantling the wheel e Jack up the vehicle place a wooden wedge under the frame e Unscrew the countersunk screw 1 e Remove the wheel from the axle PLEASE NOTE Installation is carried out in reverse order Please ensure that the wheel is re fitted on the same side and i
27. ombination 1 and 2 e High adjustment Hole combination 1 and 3 ba e Apply the Loctite to the screw re position the SS screws and tighten to 25 Nm 3 Nm The rear swivelling perforated plates have five positions In the illustration on the right these are PO marked by the letters A to E Ki KH e If the holding plates are in the low position see _ above all five positions can be used e e H Ce bes Only positions B C D and E are possible in the high H ki fe position In position A there would be a collision So VO 4 between the holding plate and the seat frame Se K d This results in the following seat heights d ki Holding plate in the low position 9 Se Position of the perforated plate seat height Se E A 42 5cm Le B 44 cm fra e C 44cm D O e DiA8 om Xx E 45 5 cm E O Cen eat Holding plate in the high position QO Position of the perforated plate seat height B 49 cm at a seat angle of 6 C 47 cm D 48 cm E 50 cm 7 13 1 7 13 1 1 Adjustment tables All combination possibilities of the perforated plates are shown in the following tables These values refer to a seat frame that has been secured in the second drill hole from the front The measurements were carried out as follows e Adjust the rear swivelling perforated plates hole A to E e Move the front perforated plate to the lowest possible position e Change the sea
28. ooting the Tornado with ACS lf a problem occurs with the wheelchair then please proceed as follows e identify the possible cause of the fault by using the troubleshooting tables below e Check the Status Display on the remote Identify the error code if it is flashing e Perform the necessary checks and repairs as recommended in the table below Diagnosing driving faults PROBLEM Wheelchai r will not drive OTHER SYMPTOMS Status display on remote lights up normally and does not show an error code Status display on remote does not light up Status display on remote is flashing POSSIBLE CAUSE Drive motors may be disengaged Batteries may be defective Batteries may be completely discharged Power supply to the remote may be interrupted Remote may be defective Various causes SOLUTION Engage the drive motors Replace the batteries Charge the batteries Check the main fuse Check cables between modules for loose connections or damage Exchange the remote on the wheelchair for a different one to eliminate the possibility that the remote may be the cause Identify the error code REFERENCE See User Manual See Changing the batteries on page 34 See User Manual See Checking and replacing the main fuse on page 37 See Checking the cables on page 39 See Replacing the Shark Remote on page 41 See REM24 Error Codes and Diagnostic Codes on
29. or Check the motor Check cable and connector Check cable and connector Check the bus cable on the remote and U connector Replace the remote FLASHING CODE See Checking the cables on page 39 See operating instructions See Changing the batteries on page 34 See Checking the cables on page 39 See Replacing the motor on page 26 See Checking the cables on page 39 See Replacing the motor on page 26 See Checking the cables on page 39 See Checking the cables on page 39 See Checking the cables on page 39 See Replacing the Shark Remote on page 41 ZU FLASHING CODE Meaning Fault on Shark main module Communication error on the Shark system Unknown error Incompatible remote Solution Check all cables and connectors on the Shark system Replace the main module Check all cables and connectors on the Shark system Replace the remote Check all cables and U connectors An incorrect remote has been connected Ensure that main module and remote code are concordant FLASHING CODE See Checking the cables on page 39 See Replacing the Shark Electronics on page 31 See Checking the cables on page 39 See Replacing the Shark Remote on page 41 See Checking the cables on page 39 See Replacing the Shark Remote on page 41 See Replacing the Shark Electronics on page 31 6 2 6 2 1 Troublesh
30. oved and not replaced again collisions can be caused e Always replace the adjusting washers exactly as they were before you started dismantling Replacing the motor WARNING Danger of crushing The mobility and the seat are very heavy Danger of injury hazard to hands and feet caused by uncontrolled tilting oder other movement e You should seek help from a second person e Remove the seat and place the mobility device upside down so that the wheels are facing upwards This guarantees mobility device stability during repair work e Please see the following work steps for further important information e Use a wooden chock underneath the battery box that is large enough to provide the wheelchair with large area support when jacking up the wheelchair This improves the tipping Stability of the wheelchair during repair work ATTENTION Fire and burns hazard if battery terminal is bypassed e Please take great care to ensure that the battery terminals are never short circuited with tools or mechanical mobility device parts e Ensure that the battery terminal caps have been replaced if you are not working on the battery terminals Pre requisites Small flat screwdriver 5 mm Allen key 8 mm Allen key 11 mm open ended spanner 19 mm open ended spanner Aglet diameter 2 5 mm for knocking the splint out of the decoupling leverage Small hammer Edge cutter Cable binder Wooden chock approx 12 x 12 x 30 cm for jacking up
31. pletely 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 11 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 e Never use normal nuts instead of self locking nuts e Always use correctly dimensioned washers and spacers e When reassembling always replace any cable ties which were cut during dismantling e 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 du
32. ring 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 Tightening torques The 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 3 Nm 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 13 4 Arrangement of the assembly groups and components Under the seat 1 Decoupling mechanism 2 Power module 3 Perforated plates for adjusting the seat height and seat angle Under the battery cover 4 Main battery fuse 5 Service plan 1X annually ee Tet e
33. rried out in the reverse order Check all vehicle functions 7 7 Checking the cables Unscrew the handwheels screws 1 on both sides of the panelling for the electronics Remove the panelling for the electronics Check all cables for visible damage and crushing Replace damaged cables Pull on each plug 1 carefully It must not come out of the socket If a plug is loose apply slight pressure to push the plug into the socket It must lock in place Check whether the plug is now fitted firmly inside the socket If not please repeat the preceding work step Remove the battery cover 39 40 Check the battery cables 1 for visible damage and crushing Replace damaged cables Re install the panelling for the electronics and the battery cover Check all vehicle functions 7 8 Replacing the Shark Remote VI Pre requisites e 3mm Allen key e Switch off the remote e Loosen the wing screw 1 e Pull the remote out of the guide together with the remote holder e Use the Allen key to unscrew both screws 1 on the remote holder e Unscrew the handwheels screws 1 on both sides of the panelling for the electronics e Remove the panelling for the electronics 41 42 e Disengage the remote plug e The installation of the remote and the panelling for the electronics is carried out in the reverse order e Check all vehicle functions Replacing the ACS Remote
34. 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 e 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 e lf you have any problems or questions please contact Invacare Service Notes on transport e Ifthe mobility aid has to be shipped back to the manufacturer for major repairs you should always use the original packaging for transport e Please attach a precise description of the fault P D Definition and representation of information and safety information 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
35. t angle and the seat height via the front perforated plate Table 1 The first table refers to the rear holding plates in the low a position see illustration on the right O e E oF bk a fe o f Position of the rear swivelling Seat angle in Seat height in cm perforated plates OO 4 OO RE KE Bo SE Ooo MA 53 54 Position of the rear swivelling Seat angle in perforated plates Seat height in cm 11 n e sch sch N AIOINI l l l l l l NI sech 1 ech N AIOINI l l l NI N Om Al O1 O1 01 O1 O1 O7 BH HSB BR BR BR BR BR BR BR OO OO O1 O01 1 OF7 OF1 O17 GT CHE HRP BR HRB BR BR BR BR BR OO O1 O1 01 01 O1 UE CHE CHE CHE BR CHE SA NAAN SF S CO Go NJ Ni Od Gr BY Go G9 9 S C N Gi BR San E GO 60 Od Gi G2 KJ S G Go NJ NJ 01 01 O1 01 01 01 O1 01 01 01 01 O1 01 O1 GUY Ql 01 01 01 O1 GUY 7 13 1 2 Table 2 The second table refers to the rear holding plates in the high position see illustration on the right eo 7 o Ka Position of the rear swivelling Seat angle in Seat height in cm perforated plates ee 55 7 14 Replacing the safety belt VI Requirements e 10mm socket spanner e 4mm Allen key Dismantling the safety belt e Remove the plastic cap 5 e Loosen the bolt 3 and the associated nut in the figure this is covered with a 4 mm Allen key and a 10 mm socket spanner
36. 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 Pre requisites 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 download area on http www dynamiccontrols com 33 7 9 A 34 Changing the batteries ATTENTION Injury hazard and possible material damages if batteries are handled improperly e The installation of new batteries may only be carried out by authorised specialists e Observe the warning information on the batteries e Only use battery versions stated in the specifications ATTENTION Fire and burns hazard if battery terminal is bypassed e Please take great care to ensure that the battery terminals are never short circuited with tools or mechanical mobility device parts e Ensure that the battery terminal caps have been replaced if you are not working on the battery terminals ATTENTION Danger of crushing The batteries are extr
37. the vehicle Information Please take care of the small parts and observe the sequence in which the component parts are installed Please set them out in an orderly fashion so that they can be installed again easily in the correct sequence Jack up the vehicle using the wooden chock Loosen the socket head screw 1 using a 5mm Allen key Remove the screw and the hub cap Pull the complete wheel from the wheel hub Remove the battery cover Pull off the battery pole caps and push back to gain access to the battery poles Loosen the battery pole clips with the 11 mm open ended spanner Remove the batteries 27 28 In order to remove the motor the front decoupling rod connection 1 must be disconnected Release the retaining ring 1 using the small flat screwdriver and pull out Disengage the decoupling leverage from the motor Unscrew handwheels screws 1 on both sides of the panelling for the electronics Remove the panelling for the electronics Pull the motor plug on the motor to be replaced out of the electronics The motor cable is secured to the frame with a cable binder Use the edge cutter to cut through the cable binder e Loosen the motor suspension 1 using the 8 mm Allen key and the 19 mm open ended spanner and remove e Remove the motor from the suspension in a downward direction Loosen the four screws 1 on the motor suspension and remove e Use the aglet and the
38. work see chapter entitled General information Personal safety equipment 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 handling batteries improperly e Always wear acid proof safety gloves when working on any defective or possibly defective batteries General safety information and information about fitting removal 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 com
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