Mirage - Invacare
Contents
1. WU NI omMNoaus Tyre Inner Tube Inner Rim Outer rim Screws Washer Wheel Bolts Motor shaft Wheel Hub Tools Required 5mm Hex Wrench Mallet Pressure Ga uge Pump Vice Valve Remover Flat Bladed Screwdriver Torque Wrench SONAURBWNE Inspection 1 Check wheel isnot buckled or physically damaged Replace if required 2 Check tyresforwearand correct inflation both wheels should allow the same degree of wear see side of tyre for pressure rating Disassembly Caution e Take care while supporting the wheelchair in orderto remove the wheel e The Batteries should be removed before continuing with this procedure 1 Jackup one of the gearboxes to lift one wheel off the floor 2 Remove the four Wheel Bolts 6 securing the Wheel to the Wheel Hub 8 using a 5mm Hex Wrench Remove the Wheel 3 Deflate the tyre 1 locate loosen and remove Socket Head Cap Screws 4 securing the two halves of the Wheel Rims 3 together using a 5mm Hex Wrench Caution e Ensure the tyre is fully deflated before attempting to separate to the two halves of the Wheel Rims 4 Remove the tyre 1 and tube 2 5 To remove the Wheel Hub from the Axle Shaft locate loosen and remove the Motor shaft Bolt 7 and washer 5 that securesthe Wheel Hub to the Axle Shaft using a 5mm Hex Wrench 6 Gently tap the end of the Axle Shaft with a mallet and pull the hub 8 off the gearbox shaft take care not to loose the key2. 2 Armrest top assembly 3 Armpad screws 4 Hand wheel Amrest Lower Parts 41 Tools Required 1 No 2 Cross Point Screwdriver 2 Flat Headed Screwdriver 42 Inspection 1 Check that the skirt guard 5 is fixed and not physically damaged If the panel is loose retighten the fixing screws 7 installa new panel if necessary 2 Check forarmpad 1 wearordamage Replace if necessary 3 Check forcornosion orpaint damage to the bracketry and replace affected parts where necessary 43 Disassembly Assembly 1 Release the hand wheels 11 by rotating anti cloc kwise 2 Remove the top and lower amrest assemblies N ff Anmrest Top Assembly 1 Remove the hand wheel 4 2 Release the screws 3 with a No2 Cross Point Screwdriver to remove the ampad V Amres Lower Assembly 1 Remove screws 7 with a Cross Point Screwdriver and take away skirt guard 5 and clamps 8 2 Remove hand wheel 11 3 Push fixing nut 9 into tube to release plastic ring and remove both from armrest lowertube 4 Repeat step 3 for amrest socket fixing nut To re assemble reverse the above stepstaking care not to over tighten the fixing Screws 5 Legrests Legrest Hanger Parts Su Q 1 Hangertube pr 2 Hanger support Assy a 4 3 Hanger pivot 4 Screw 2 5 Screw FG 6 Screw 7 HangerLock 8 Hanger Lock screw and n6 gG nut a s r S 7 N 8 Standard Footplate Parts 9 Lower footplate tube 10 Footplate 11 Screw 12 Spacer
3. Yes you can acare amp Mirage ervice manual CE Introduction This manual provides basic detailsto enable the Invacare amp MIRAGE Wheelchair to be maintained It is not intended to be a comprehensive maintenance guide policy but is intended for use by competent personnel to enable the chair to be adequately maintained The wheelc hair is manufactured by INVACARE Ltd South Road Bridgend Industrial Estate Bridgend Mid Glamorgan CF31 3PY Sales Telephone 01656 647327 Sales Fax 01656 649016 Technical Services Fax 01656 753299 Email uk invacare com Web http www invacare com For TECHNICAL ADVICE repairs servicing contact Technical Services For SPARE PARTS orders contact Sales Quote the following details at all times o Part Number see Spare Parts Catalogue Description Quantity required Serial Number Chair Type O 000 Policy INVACARE Ltd Policy is as follows e Repairsto any component other than those detailed in this manual are not covered Repairs to any tube metal work isnot generally permitted without express permission of INVACARE Ltd All fastenersi e bolts Nyloc nuts and any fastener showing damage must be renewed e Underno circumstancesattempt to repaira crash damaged chair Contact Technical Services for further Information e Alterationsto the wheelchair which occurasa result of incorrectly orimproperiy executed maintenance or overhaul work lead to the exclusio
4. 14 15 Battery Rail Rear Tie Down Clamp 11 Seat Stay 12 Plastic Side Frame Side Frame RH U Bracket Hand wheel 16 Backrest Insert 4mm Hex Wrench 5mm Hex Wrench Flat Bladed Screwdriver Mallet 1 Checkall tubing for misalignment damage or bending of the frame or crossbar assembly 2 Check that no misalignment is present at the castor mount area castor fork and socket 3 Check all brazed welded joints for fractures or damage Check the paint finish fordamage 4 Check the crossbarassembly isnot damaged pivot bolt should not be over tightened 5 Check that the chair folds easily and that the crossbar pivots and folding mechanisms operate correctly Disassembly Note e Remove batteries backrest legrest and armrest before proceeding with the following It isoptional to remove the wheels or motors before proceeding with the following 17 9 4 10 18 e See Section 11 for information on how to remove motor gearbox 1 Push buttons on the side of anti tipper soc ket 2 and remove anti tipper 1 2 The anti tipper bottom section may be removed from the tube by using 2 x 8mm open ended spanners and completely removing the bolt 3 The anti tipper sockets 2 can be removed by using a 10mm open ended spannerand a 4mm Hex Wrench Completely remove the bolt and slide out anti tipper socket from the side frames 3 and 13 4 Remove hand wheel 15 and withdraw backrest insert 16
5. Axle bolt Axle nut Bearing Castor wheel Tyre Inner tube Hub centre FPrFUOONOAUBWNEFE O 7 1 Tools Required 19mm Open Ended Spanner 19mm Socket Wrench 13mm Open Ended Spanner x 2 Flat Bladed Screwdriver Mallet Pressure Gauge Pump Drift 7 2 Inspection 1 Au FW N Check castor wheels are not buckled or physically damaged Replace if required Check that the wheel bearings 7 run freely without exc essive play Check that the castor wheel and fork nuts 2 are tight Check that the castor forks 1 are bent ordamaged Check the crown castor fork bearings 4 forwearand corect adjustment Check tyres for wear and correct inflation Both wheels should show the same degree of wear see side of tyre pressure rating For tyre fitment see rear tyre section 7 3 Disassembly Wd Remove castorsocket cap with flat bladed screw driver hold the lower fork stem nut 2 secure with 19mm spannerand remove the upper fork stem nut 2 Gently tap the threaded end to the fork stem 3 with a mallet taking care not to damage the threads Remove the castor fork assemblies Lever out the top fork bearing 4 carefully using the fork stem asa lever Take care notto damage the threads Remove the lower fork bearing 4 using a drift and a mallet tapping gently to avoid damaging the bearing To remove the castor wheels undo the axle nut 6 with a 13mm spanner using a second spannerat the otherend of the ax
6. Left red LED flashing Battery charge is low Charge batteriesas soon as possible Right to Left LED chase Shark is being brought out oflock mode To unlock shark press the hom button twice within 10 seconds Left to right LED chase altemating with stea dy display Shark is in programming inhibit or charge mode The steady LED s indicate the curent state of battery charge Right green LED is Speed Limit Mode fla shing All LED s flashing slowly Out of neutral at power Release the joystick up condition detected back to neutral All LED s flashing quickly FAULT mode See table below 15 4 Shark Diagnostics Display The Flash code from the Shark information gauge is shown below The number of flashes are indicated with all LED s on forthe relevant number of flashes followed by a pause then Flash again Hash Code Description Notes 1 User Fa ult Possible stall timeout or user error Release the joystick and try again Battery fault Check the batteries and cabling Try charging the batteries Batteries may require replacing Left Motor Fault M2 Check the left motor connections and cabling Right Motor Fault M1 Check the right motor connections and cabling Left Park Brake Fault Check the left park brake connections and cabling Right Park Brake Fault Check the right park brake connections and cabling
7. Shark Control Unit Fault Check the Shark communications bus wiring Replace the control unit Shark Power Module Fault Check Shark connections and wiring Replace the power module Shark Communications Fault Check Shark connections and wiring Replace the Shark control unit 10 11 Unknown Fault Incompatible Control Unit Check all connections and wiring Consult a service agent Wrong type of control unit connected Ensure the branded power module matchesthat of the 31 For further details and in depth information refer to the Shark Installation G uide GBK80047 control unit 15 5 Hand Held Programmer HPP Diagnostics 32 User Fa ult 00 Possible stall timeout or user emor Release the joystick and try again Battery fa ult 00 Batteries are too low to drive with or voltage istoo high or low Left Motor Fa ult 00 Left motor short circ uit M2 01 Left motor open circuit VA Not 02 Left motor connection fault short to B 00 amp 01 change 03 Motorterminal connected to B motor 02 08 change 04 Left motor voltage consistency fault power probably fa ult with power module module electronics 05 Left motor bridge fault probably fault with powermodule electronics 06 Too many hardware curent limit events 07 Current measurement offset out of range 08 Hardware curent limit fault Right M
8. 5 Ifthe seat clamp 7 islocked unlock both right and left hand side and fold wheelchairframe 6 Remove the Hanger Bracket 4 Use a 10mm open ended spanner and 5mm Hex Wrench to completely remove the 2 socket head screws in the side frames and the bottom section of the seat clamp 7 Use a 4mm Hex Wrench and a 10mm open ended spannerto remove the front seat saddle 6 Slide hanger bracket out from the side frame 7 Use a flat blade screw driverto carefully lever out the plastic frame fittings 12 8 Locate X Brace 8 and seat stays 11 9 Using a 4mm Hex Wrench and 10mm open ended spanner remove the bolts which clamp the U brackets 14 seat stay 11 and side frames 13 and 3 Remove the U bracket 14 10 Locate the Large Bolts at the bottom of each side of the X Brace 8 Remove the bolts using 2 x 17mm open ended spanners 11 Remove the X Brace 8 from the side frames 3 and 13 12 The X Brace 8 may be further disassembled e Push the bearings out from the short bottom tubes of the X Brace e The Seat Stays 11 may be removed by using 2 x 10mm open ended spanners and removing the bolt and spacer which supports them e The X Brace centre pivot may be disassembled by using 2 x 13mm open ended spannersand removing the bolt and spacers e Remove the Seat Clamp 7 by using a 10mm open ended spanner and 5mm Hex Wrench 13 The battery rails 9 can be removed by using 2 x 13mm open ended spanner at the rear
9. Check forany physical damage to the outercase of J oystick Remote 1 and Power Module 5 2 Inspect the rubber gaiter around the joystick knob 8 for any cracks splits or perishing This would enable water or moisture to access the unit This may cause damage to the controller 23 3 Check speed control knob is secure and its action is free and easy in rotation 4 Check the wire hamess from the joystick remote 1 is free from damage 12 3 Disassembly Caution AN e Before any work is canied out on the control system ensure the Shark Power Module 4 is unplugged from the Batteries and the Batteries are disconnected Wd J oystick Remote i 1 Unplug the shark remote 1 from shark power module 4 2 Depending on the type of control am 3 fitted to the wheelchair remove the screws 2 using either a 5mm Hex Wrench or 8mm Open Ended Spanner Remove J oystick Remote 3 Remove the J oystick Knob 8 by fimly pulling upwards if required V A Power Module 1 Unplug the remaining connectors from the power Module 2 Remove screws 7 using a 3mm Hex Wrench and a 7mm Open Ended Spanner in one position The Power Module is now free 3 To remove the power module bracket 5 from the wheelchair seat stays see section 9 remove screw 6 using a 5mm Hex Wrench 10mm open ended spanner 12 4 Assembly 1 To re assemble reverse the above steps ensuring that all fixing holesare aligned Take care not to over tighten th
10. fault 04 EEPROM fault 05 Watchdog fault 06 Stack fault 07 Software fault 08 Power up testing fault 09 Relay fault or Pre charge fault OA Bridge fault or Disable all fault 33 OB Electronics fault OC Calibration settings fault 9 Shark 00 Loss of communications between Communications remote and power module Fault 01 Limp mode due to unreliable communications 10 Unknown Fault 00 Catch all fault output 11 Incompatible 00 Wrong type of control unit connected Control Unit For further details and in depth information referto the Shark Installation Guide GBK80047 16 Servicing Requirements INVACARE recommendsthat routine servicing be canied out at six monthly intervals The routine service Consists of the following 16 1 Motors v e Inspect plugs for physical damage e Inspect insulation forcracksand splits e Checkand clean brake Resistance Approx 50 80 Ohms e Inspect and clean brushesand commutator e Checkaction and operation of clutch mechanism 16 2 Controller and joystick Remote e Check for physical damage to outer casings e Inspect joystick shroud and gaiterforcracks and splits e Checkall switch operations and LED s e Check joystick lead and plug ends for signs of cracks wearor physical damage e Check diagnostics to assure no faults present on systems Check information gauge if flashing referto section 15 diagnostics 16 3 Fram
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12. 9 located in the gearbox shaft 15 8 4 Assembly 1 Re fitthe Wheel Hub 8 to the gearbox shaft ensuring alignment of the keyway N of the wheel centre to the key 9 fitted to gearbox shaft Gently tap the wheel i centre with a mallet until the threadscan be seen inside the shaft 2 Fitthe motor shaft bolt 7 using a 5mm Hex Torque Wrench ensuring that the washer 5 hasbeen fitted to the gearbox shaft Note vA e Torque rating of rear wheel bolt 35 40Nm 3 Locate tyre 1 and tube 2 to the face of the inside Rim 3 that has the hole forthe valve to st in sightly inflate the tube 4 Locate the other half of the Wheel Rim 3 in postion insert Socket Cap Screws 4 in position and proceed to tighten the screws Ensure the inner tube is not trapped between the Wheel Rim halves 5 Tighten securely Socket Head Cap Screws 4 using a 5mm Hex Wrench 6 Inflate to the correct pressure as indicated on the Tyre Side Wall 7 Position Wheel on Wheel Hub locate and tighten the four Wheel Bolts 6 using a 5mm Torque Hex Wrench Note S e Torque rating of rear wheel bolt 35 40Nm 16 9 1 9 2 1 Anti Tipper 2 Anti Tipper Soc ket 3 Side Frame LH 4 Hanger Bracket Fittings 5 Control Module Bracket 6 Seat Saddle 7 Seat Clamp 8 X Brace Seat Frame Tools Required e 8mm Open Ended Spanner x2 e 10mm Open Ended Spanner x 2 e 13mm Open Ended Spanner x 2 e 17mm Open Ended Spanner x 2 Inspection 13
13. Note e All plugsare fitted with mechanical latches which prevent release of the connecting plugs during operation e To release the connecting plugs the latches must be pressed in e When reassembling ensure that the latches are corectly engaged Before operation after completion of work Caution Check all fixings for tight fit Only operate wheelchair with correct tyre pressure Check electrical components forcorect functioning incorect polarity of cablescan result in damage to the electronics Asa last check alwayscany out a trial run Tools Required The following list givesthe basic tools required to perform the maintenance procedures as illustrated in this manual 1 Open Ended Spanner 7mm 2 Open End Spanner 8mm 2 Open End Spanner 10mm 1 Open End Spanner 11mm 2 Open End Spanner 13mm 2 Open Ended Spanner 17mm 1 Combination Spanner 19mm 1 Socket Wrench Shallow 19mm 1 Cross Point Screwdriver No 2 1 Cross Point Screwdriver No 1 1 Flat Bladed Screwdriver No 1 1 Nylon Mallet 1 Torque Wrench 1 Hex Wrench 3mm 1 Hex Wrench 4mm 1 Hex Wrench 5mm 1 Knife 1 Pressure Gauge 1 Pump 1 Drift 1 Vice 1 Valve Remover 1 Multimeter 1 Soldering Iron 1 Pin Hammer 1 Punch 1 Pair Pliers 1 Battery Discharge Tester 1 HHP Programmer 1 Shark Programming Adapter 1 Safety Goggles 4 Amrests Armrest Top Parts 1 Armpad
14. and a 13mm open spannerat the front positions Completely withdraw the rearbolt to remove the reartie down clamp 10 and spacers 14 The rear seat saddles 6 can be removed using a 10mm open ended spanner and 4mm Hex Wrench Assembly To re assemble reverse the above steps ensuring that all fixing holesin are aligned Take care not to over tighten the fixing screws Motor 10 1 10 2 v Parts 1 Ma NURUWUN Electro gnetic Brake Brush Connector Motor Complete Commutator Motor End Can Tools Required No 1 Cross Point Screwdriver Flat Headed Screwdriver Soldering Iron Multimeter 3mm Hex Wrench Inspection 1 Check motor assembly fordamage Set multimeterto continuity test Test continuity of motor leads 3 and electro magnetic brake leads 3 Brake resistance should read 50ohms 80 ohms 3 Check all joints forbad connection cracked ordry solder joints and oxidation Check that all the brushes 2 can move freely in the brush guides with no obstruction thiscan be easily done by pulling on the free brush feeder wire 5 Check that all the brushes 2 are not chipped cracked orwom 6 Check that the brush 2 spring is positioned to the centre of the brush body to apply even force Also check the brush spring tensions Check the condition of the brush 2 feeder wire and check that the termination screws are secure Visually inspect the commutator 5 for carbon deposits and remove w
15. attery Wiring Diagram Circuit Breaker Rear Battery Box Connector Grey Connector red C Front Battery Box Mechanical Brakes Parts 1 Clamp 2 Screws 3 Anti Rotation Screw 4 Handgrip 5 Brake Shoe 6 Brake fixing Rail Tools Required e 5mm Hex Wrench e 4mm Hex Wrench Inspection 1 Checkthat the brake mechanism hasno excessive looseness isnot wom or damaged 27 2 Check that the brake shoe ispostioned corectly to provide maximum surface area contact on the tyre tread and gives the positive brake hold Note v e The distance between the brake shoe and tyre should be 30 35mm 14 3 Disassembly 1 Loosen and remove the Anti Rotation screw 3 with a 4mm Hex Wrench Wd 2 Remove the Brake and Clamp 1 by loosening the clamp screws 2 with a 5mm Hex Wrench 3 Remove the Brake from the clamp and side frame 4 Use a 5mm Hex Wrench to remove the brake shoe 5 from the brake assembly 5 Use a 4mm Hex Wrench to remove the brake assembly from the brake fixing rail 6 6 To remove the handgrip 4 pull upwards fimly 14 4 Assembly 1 To re assemble reverse steps1 to 6above 2 Ensure the brakesgive a positive hold on the tyre If the handgrip 4 hasbeen removed refit it with a suitable adhesive 15 Fault Diagnostics 15 1 General Drive Faults Wheelchair will not start Drive motors disengaged Enqaae Motors Section 11 2 No display on Batteries joystick remote de
16. e and Chassis e Inspect all fixtures and fittings for tightness and integrity e Check front and rear wheel axle bolts are tight 0o00 lt S OF 0000 8 00000 e Ensure that all upholstery screws are present and tight Check surface of screw head for sharp edges Clean seat and back 34 upholstery 16 4 Batteries v e Check batteries for any signs of physical damage e Check teminalsforcracks or blackness OO Note W e Should batteries become suspect use battery discharge tester by Astra Tech Model DC 39 to test capacity and runtime 16 5 Battery Charger e Check for physical damage of casing e Checkall LED s are operational DOD S e Fortesting the battery charger see section 13 Batteries and Charger INVACARE INTERNATIONAL Belgium amp Luxemburg Autobaan 14 B 8210 Loppem Danmark Sdr Ringvej 39 DK 2605 Br ndby Deutschland Osterreich Switzerland amp East Europe Dehmer StraBe 66 D 32549 Bad Oeynhausen Espana c Areny s n Pol gon Industrial de Celr E 17460 Celr Girona 35 France Les Roches F 37230 Fondettes Italia Via dei Pini 62 36016 Thiene VI Nederland Celsiusstraat 46 NL 6716 BZ Ede Norge Grensesvingen 9 N 0603 Oslo Portugal Rua Senhora de Campanh 105 P 4369 001 Porto Sverige amp Suomi Fagerstagatan 9 P O Box 66 S 163 91 Sp nga United Kingdom amp Eire South Road Bridgend Industrial Estate Bridgend CF31 3PY UK MIRAGE V 01 UK 01
17. e fixing screws V Note e When fitting the joystick remote screws 2 be sure not to use a torque in excess OI DIN gt gt gt gt 12 5 Power Module Connector Orientation Position A Motor Cable LH Motor Battery Cable Motor Cable RH Motor NOT USED Shark J oystick Remote Cable MU O W Allconnectors are polarized and may only be fitted in one possible position 13 Rattenec and Chamer Front Battery Box Rear Battery Box Battery Box Straps WNE Tools Required Pliers Flat Bla ded Screwdriver 10mm Open Ended Spanner 11mm Open ended Spanner Inspection Caution MUR Battery Box Connector Charger Fuse Breaker not Shown No 1 Cross Point Screwdriver Multimeter Battery Discharger Safety Goggles e Safety goggles should be wom at all times while working on batteries 25 26 e Shock Hazard take care not to allow any metallic items such astoolsor jewellery touch between the battery terminals 1 Check that the battery box case leads sockets and batteries are not damaged 2 Measure the battery voltages the values must be the same 0 2v If not replace the batteries 3 Forthe battery charger operate the battery voltage must be shown above 8v each If not the batteries must be removed and charged with an unregulated charger until the voltage reaches 9v Re connect the batteriesand charge through a complete charge cycle this may ormay not recov
18. er the batteries if not replace the batteries 4 Oncompletion of charge the battery voltage must read 14 20v at 20 C or combined 28 4v Disassembly 1 Unplug the battery leads 4 and remove the battery wire hamess see section 12 if still present Undo the battery straps 3 Unclip the battery box lids remove the battery caps and with a 10mm 11mm spanner undo the battery terminals Remove the batteries from the cases Assembly To re assemble reverse steps 1 to 3 and charge the battery fully Caution e Take care of the battery polarities Never cross polarities and always refit battery caps If any wires or insulation isdamaged ALWAYS replace before use Inspection Battery Charger 1 Check the charger case for physical damage 2 Check the input and output leadsand plugsfor damage cuts and wear 3 Check that the charging charge complete and poweron lampsare operating correctly 4 With an ammeterora multimeter set to amp range 10A test the charging current Note e Ammeters must be connected in series with the battery circ uit e The current reading should read approximately 7amp at charge start and 0 2 ampsat complete charge 5 With a voltmeter ora multimeter set to volts range 30v test the charging voltage at the battery supply red blue ve wires The reading should i Av dU i Note 13 6 e The battery chargerisa sealed unit Under no circumstances should it be opened B
19. fective Replace Section 13 13 Flat Batteries Charge Section 13 Power supply Check battery interupted Fuse breaker LSection 13 2 28 Check cable at joystick Section 12 Charl rahla GI Wheelc hair runs too slowly Section 12 3 Section 12 3 Section 13 2 Replace Remote Power module defective Power module defective 15 2 General Trouble Shooting Symptom Check Action ON OFF button pressed to ON e Arethe battery cablesconnected 29 J oystic k lights do not light up wheelchairdoesnot move ON OFF lights up wheelchair does not move or behaves ematically Battery Charge indicator shows low battery Wheelchair moves slowly and doesnot respond well to joystick movement Batteries will not accept charge Shark Remote Information Gauge Isthe joystick cable connected Are the batteries disc onnected Are the batteriescompletely flat Isthe fuse circuit breakeropen Are one orboth motors disengaged freewheel mode Is the Shark remote in Lock Mode See user guide Are the batteries discharged to the critical level Possible charger fault Batteries are no longerserviceable gt Infomation fana Hom Butto k The following table gives the basic status of the Shark remote Refer to the Information 30 All LED s off Power is off All LED s on steady PowerisON Less LED simply a reduced battery charge
20. his instruction remove the batteries from the Vd gt wheelchair Remove the rear wheel from the gearbox See Section 8 Unplug the motor from the Power Module Loosen and remove the six Screws 3 which hold the motor gearbox to the side frames of the wheelchair using a 5mm Hex Wrench 21 2 Remove the motor gearbox and then locate and remove the remaining two screws 3 from gearbox lid 1 The lower housing of the gearbox 2 will now detach from gearboxtop 3 To dismantle the declutching leverupper 4 and lower 5 parts knock out the fixing pin using a pin hammerand punch separate the two halves 4 To detach the gearbox from the motor degrease the gearbox remove the four fixing screws with an 8mm spanner taking care not to deface ordamage any gearteeth Separate the gearbox and motor assembly 11 4 Assembly V 1 To reassemble reverse steps 2 to 5 ensuring correct motorto gearboxalignment isachieved 2 Replace both gaskets 6 and 7 and re pack the gearbox with Shell Albida Grease approx 200g Note e To aid assembly it may be necessary to hold the gearbox housing 2 orgearbox top 1 ina vice Take care notto damage the parts 22 12 Control System Parts 1 Shark J oystick Remote 5 Power Module Bracket 2 Screws 6 Screw 3 Control Am 7 Screw Tools Required 3mm Hex Wrench 5mm Hex Wrench 7mm Open Ended Spanner 8mm Open Ended Spanner 10mm Open Ended Spanner Inspection 1
21. ith a soft brush Note Ensure all the segments of the commutator are not bridged with conductive materia Is i e Carbon or Copper 10 3 Disassembly Caution A Disconnect the battery and the motor from the power module before proceeding with this instruction 19 Remove the motor end 6 via the two cross point screws using a No 1 cross point screw driver Remove the two three electro magnetic brake 1 fixing screws and remove the brake Remove the brush 2 feeder wire termination screws release the brush springs and remove the brushes 2 10 4 Assembly 20 1 To reassemble reverse the steps 1 to 3 taking care not to damage the brushes and ensuring correct alignment of the electro magnetic brake Should there be fitting scoring orwear then replace the Motor Unit 11 Gearbox 11 1 Tools Required asket Gearbox Top Gearbox Housing Screws Clutch Lever Upper Clutch Lever Lower Gearbox Top Motor Gearbox Gasket ya 5mm Hex Wrench 8mm Open Ended Spanner Pin Hammer Punch Pliers Vice 11 2 Inspection FPWN Check casing forcracksordamage or leakages Check Gearbox for noises gearsand bearings Check the declutching lever 4 and mechanism engagesand disengagesconectly Check that the output shaft of the gearboxisnot damaged orbent Remove the rear wheel and inspect the key 8 and keyway forwearand conect fitting 11 3 Disassembly Caution AN e Before proceeding with t
22. le bolt 5 to lock against rotation Remove the axle bolt and remove the wheel from the fork Remove the bearings 7 by hand 74 Assembly V 1 To reassemble the wheel reverse step 5 amp 6 but adjust tightness of nut until the wheel runs freely to a gradual halt Note VA e Ifthe wheel stopsabruptly loosen the castoraxle nut 13 14 e If the wheel wobbles side play tighten the castor a xle nut enough to allow free spinning without side play Insert the fork stem bearings 4 using a mallet and drift acrossthe bearing to prevent damage Start at the bottom and place the threaded end of the fork stem 3 through both bearings 4 and into the castor fork socket Locate fork stem nut 2 on the threaded end of the stem and tighten with a 19mm spanner just enough to allow the fork to swivel freely To check for correct tightness perform the following test e Tip chairbackwardsand rest the push handles on the floor remove the battery boxes first e Raise castor wheel towards ceiling then gently push downward to either side The wheel and fork should freely rotate down and hang straight towards the floor aftera pendulum type swing Note e Ifthe wheel stops angled to one side loosen the fork stem nut slightly e Ifthe wheel continuesto swing to both sides like a pendulum tighten the fork stem nut slightly e Check the bearings for excessive play by gently rocking the fork assembly Rear Wheel Parts
23. n of all liability on the side of INVACARE e We reserve the right to make any alterationson the grounds of technical improvements e Information about operation or about general maintenance and care work should be taken from the wheelchair Operating Manual Failure to comply with the above absolves INVACARE Ltd of liability Note Certain components will require removal to carry out maintenance With the exception of fasteners those components should be refitted Notes on transport e Ifthe wheelchair hasto be shipped back to the manufacturer for major repairs you should always use the original packaging for transport e You should also include asaccurate a fault description as possible Information Symbols SY Note This symbol identifies general information which indicates special points orsimplifications in dismantling reassembly CAUTION It is imperative that you observe any safety instructions identified AN with this symbol Wd This symbol identifies service work or tools required Contents Section Page 1 Layout of Modules Components and 4 Controls 2 Safety and Assembly Instructions 5 3 Tools Required 6 4 Anmrests 7 5 Legrests 9 6 Upholstery Seat and Back 11 7 Castor Wheel and Fork 12 8 Rear Wheel 14 9 Frame and Chassis 16 10 Motor Assembly 18 11 Gearbox Assembly 20 12 Control System 22 13 Batteries and charger 24 14 Mechanical Brakes 26 15 Fault Diagnostics 27 16 Servicing Requirements 32 1 Lay
24. otor Fault 00 Right motor short circuit M1 01 Right motor open circuit V Note 02 Right motor connection fault short to B 00 amp 01 change 03 Motorterminal connected to B motor 02 08 change 04 Right motor voltage consistency fault power probably fault with power module module electronics 05 Right motor bridge fault probably fault with power module electronics 06 Too many hardware curent limit events 07 Current measurement offset out of range 08 Hardware curent limit fault Left Park Bra ke 00 Left park bra ke drive time test failed Fault 01 Left park brake output enabled when chair idle 02 Left park brake output did not enable when entering drive 03 Left park brake fault during power up test 04 Left park brake feedback low during drive park brake short circ uit Right Park Brake 00 Right park bra ke drive time test failed Fault 01 Right park brake output enabled when chair idle 02 Right park brake output did not enable when entering drive 03 Right park bra ke fa ult during power up test 04 Right park brake feedback low during drive park brake short circ uit Shark Control Unit 00 Localremote fault electronics power Fault button fa ult etc 01 Joystick fault at remote 02 Speed pot fault at remote Power Module 00 PowerModule Fault Fault 01 RAM fault 02 ROM fault 03 CPU
25. out of Modules components and contols Main Frame Motor Gearbox Front Castor heel 1 2 3 W 4 Rear Drive Wheel 5 Legrest 6 Seat 7 Backrest 8 Amrest 9 Footplate 10 Shark Remote 11 Shark Power Module 12 Battery Boxes 13 Back Brace Anti Tipper Wheels Mechanical Brakes Batteries Removed Legrests Removed Armrests Removed Backrest removed Folded Chassis 2 Safety and assembly instructions These safety instructions are intended to prevent accidents at work and it is imperative that they are observed 2 1 A 2 2 2 3 Before any inspection or repair work Read and observe this repair manual and the associated operating manual Caution e Please note the heavy weight of some components Thisapplies especially to the removal of drive units and batteries e The wheelchair must be switched off before removal of voltage camying components e To do this disconnect the batteries or remove them e When making measurements on voltage canying components avoid short circuiting the contacts e Dangerof fire and combustion During dismanting reassembly Mark all current settings for the wheelchair seat armrests backrest etc and the cable connecting plugs associated before any removals This makes reassembly easier Caution e Prop up the wheelchair with appropriate supports before starting the disassembly or assembly e Neveruse standard nuts instead of self locking nuts
26. s Adjustable Footplate Parts 13 Adjustment Fixings 5 1 Tools Required No 2 Cross Point Screwdriver 5mm Hex Wrench 10mm open ended spanner Mallet 5 2 Inspection 1 Check that the footplate fits securely and operatescorectly 2 Check the operation of the footplate extension clamping and adjustment screw 5 3 Check the legrest fordamage 4 Check the hanger lock fordamage orexcessive wear 7 53 Disassembly Assembly 1 Operate the legrest release mechanism and remove from the wheelchair 2 Release the height adjustment screw 5 and slide the lower footplate tube from the hanger Use a mallet to gently tap the footplate if the tube will not move VA Hanger 1 Remove screws 5 and 6 using a 5mm Hex Wrench 2 Slide Hanger support assembly 2 overthe end of the hangertube 1 Gently tap with a mallet if it will not move 3 Remove screw 4 with a No 2 Cross Point screwdriver and side out hanger pivot 5 10 Note It is NOT possible to disassemble the Hanger support 2 V A Footplates Standard and Adjustable 1 Remove screw 11 using a 5mm Hex Wrench 2 Separate the footplate 10 from the lower legrest tube 9 3 Take care not to damage the spacers 12 or adjustment fixings 13 if fitted VA Hanger Locks 6 1 6 2 1 Remove fixing screw and nut 8 using a 10mm spanner 2 Remove Hanger 7 Lock from wheel chair To re assemble reverse the above stepstaking care not to over
27. tighten the fixing sc rews Upholstery Seatand Back Parts 1 Backpost 2 Push Bar 3 Hand wheel 4 Screw 5 Back Upholstery 6 Seat Upholstery 7 Screw Tools Required e No 2 Cross Point Screwdriver Inspection 11 6 3 W 12 1 Check that the upholstery 5 6 does not excessively sag is unevenly stretched wom ortom Pay particular attention to bucklesand straps inside tension adjustable back upholstery 2 Check that all stitches are in good condition 3 Check that all screwsand washers 4 7 are in good condition and are not burred Disassembly Assembly 1 Release the hand wheels 3 by rotating anti clockwise and remove push bar 2 Note e Remove backrest from the wheelchair at this point if not already removed 2 Remove screws 7 in orderto remove seat upholstery 6 Pay attention to the fixing postion fora Lapbelt if fitted 3 Remove screws 4 and slide off back upholstery If a tension adjustable back is fitted remove the back cushion first which isheld on by hook and loop fastening strip Note e Ifa reclinerback is fitted it may be necessary to remove the gas spring and lowersection of the back post to completely disassemble the upholstery To re assemble reverse the above steps ensuring that the fixing holesin the upholstery and tubesare aligned Take care not to over tighten the fixing screws Castor Wheels and Forks Y Gt Castor Fork Nut Fork stem Bearings
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