Invacare ® Orion SERVICE MANUAL
Contents
1. 25 SERVICE MANUAL Reassembly of the shock absorber takes place in reverse order Check function trial run 26 Invacare Orion Invacare Orion SERVICE MANUAL 7 9 A d EI W Replacing front axle ATTENTION Risk of accident Accidental rolling can lead to accidents Secure the scooter against rolling away Note When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence Note The front axle can only be replaced on the 3 wheel version The 4 wheel version does not have a replaceable axle Requirements Open spanner 17 mm Open spanner 19 mm Supporting wooden block Remove the seat Remove motor cover Separate battery cable Place a supporting wooden block under the front part of the frame so that the front wheel is no longer touching the floor Loosen axle bolts 1 simultaneously on both sides Pull front axle slowly out Replace front axle Reassembly of the axle takes place in reverse order Check function trial run 2 SERVICE MANUAL Invacare Orion 7 6 Replacing steering column fork 3 wheel LN ATTENTION Risk of accident Accidental rolling can lead to accidents Secure the scooter against rolling away Note i When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reasse2. 7 18 A A VW Replacing the electronic module ATTENTION Risk of accident When parking the scooter on the scooters support wheels it is no longer slowed by the engine brake The scooter can roll away out of control Place the scooter rear frame on a supporting wooden block before you remove the wheels ATTENTION Burn and scald hazard if power cable is short circuited Turn off the power completely before removing any power supply components of the electric vehicle Therefore take out the batteries Avoid a bridging of the contacts during measurements on live electrical components WARNING Any changes to the drive program can affect the driving characteristics and the tipping stability of the mobility aid Changes to the drive program may only be carried out by trained Invacare specialist dealers Invacare can only give a warranty for safe mobility aid driving behaviour especially tipping Stability for unaltered standard drive programs ATTENTION Risk of accident Accidental rolling can lead to accidents Secure the scooter against rolling away Note The electronic system is supplied with a standard drive program If you have carried out customer specific modifications to the drive program you will have to make these changes again after installing the new electronic module Note When disassembling note the position of small parts such as screws and washers Put small parts dow
3. 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 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 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 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 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 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 SERVICE MANUAL Invacare Orion 1 5 Images in this manual The detailed images in this manual are given digits to identify various components Component num
4. Push freewheel mode error SERVICE MANUAL Comments Ensure that the disconnection lever is pressed in There is a defect in the braking coil or in the cabling Check the magnetic brake and cabling for open or short circuited circuitry Contact your Invacare dealer Drive lever is not in neutral when the keyswitch was turned Put the drive lever in neutral turn the power off and then turn on again lt may be necessary to recalibrate the drive lever Contact your Invacare dealer The drive lever electronic could be faulty or incorrectly connected Check the cabling for open or short circuited circuitry Potentiometer is not correctly adjusted Put the potentiometer into the centre position The motor or its cabling is defective Check the cabling for open or short circuited circuitry Contact your Invacare dealer The Scooter has exceeded the permissible maximum speed during pushing or freewheeling Switch the electronic system off and on again 19 SERVICE MANUAL Invacare Orion 20 Repair Work General warning information on installation work CAUTION Risk of damage to the vehicle Collisions can be caused if shim rings are removed from the drive wheels during installation work 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 Install all shim rings in
5. SERVICE MANUAL ee terf rs ljare LS Invacare AB ira we i eweg Fagerstagatan 9 S 163 91 Spanga Sverige Tillverkare Invacare Deutschland GmbH KleiststraBe 49 D 32457 Porta Westfalica Deutschland Eastern European Distributor european Organisation EDO countries KleiststraPe 49 D 32457 Porta Westfalica Deutschland Kundtj nst Fax Kundtj nst WWW M LNDAL Lh Fax LANDSKRONA KE Fax OSKARSHAMN TI Fax Fax WWW 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 2 85 40 46 0 418 1 80 89 linvacare invacare com 46 0 491 1 01 40 46 0 491 1 01 80 oinvacare invacare com 49 0 5731 75 45 40 49 0 5731 75 45 41 edo invacare com www invacare de Invacare Orion Invacare Orion SERVICE MANUAL 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 OVERVIEW ELECTRONIC MODULES 5 SERVICE
6. brake takes place in reverse order Adjust braking force on wheel using brake lever setting screw Check braking function while pushing 32 Invacare Orion SERVICE MANUAL 7 8 Replacing brake cable LN ATTENTION Risk of accident Accidental rolling can lead to accidents Secure the scooter against rolling away Note i When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence Note You do NOT need to remove the wheel to replace the brake cable Vi Requirements n Open spanner 10 mm Phillips screwdriver Decrease the brake tension on the wheel using the setting screw 1 Disconnect the brake cable at the wheel 2 Disconnect brake cable at steering wheel brake lever Route the brake cable through the cladding Loosen brake lever screw 3 at wheel Replace brake cable Reassembly of the brake cable takes place in reverse order Check braking function while pushing 33 SERVICE MANUAL Invacare Orion 7 9 Replacing steering linkage steering rod LN ATTENTION Risk of accident Accidental rolling can lead to accidents Secure the scooter against rolling away Note i When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence Vi Requirements ES Open spanner 10 mm Open
7. cable Remove direction indicator screw 1 Disconnect direction indicator cable 2 from wiring harness Plug is located behind rear steering column cladding see chapter entitled Replacing steering column Replace direction indicator Reassembly of the direction indicators takes place in reverse order Check functions Remove steering column cladding and steering column see chapter entitled Replacing steering column Remove chassis bolts and fold chassis upwards Remove direction indicator screw 1 on chassis Disconnect direction indicator cable 2 from wiring harness Remove screws 3 on indicator glass Remove indicator glass Loosen screws 4 on orange coloured cap 5 and remove cap Replace lightbulb Reassembly of the direction indicators takes place in reverse order Check functions Invacare Orion SERVICE MANUAL 7 16 A Q Replacing centre brake light ATTENTION Burn and scald hazard if power cable is short circuited Turn off the power completely before removing any power supply components of the electric vehicle Therefore take out the batteries Avoid a bridging of the contacts during measurements on live electrical components Note When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence Requirements Phillips screwdriver Remove the seat Remove motor
8. exactly the same positions they were in before dismantling Replacing the drive motor ATTENTION Risk of accident When parking the scooter on the scooters support wheels it is no longer slowed by the engine brake The scooter can roll away out of control Place the scooter rear frame on a supporting wooden block before you remove the wheels ATTENTION Risk of accident Accidental rolling can lead to accidents Secure the scooter against rolling away Note When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence Note The plugs on the electronic module cannot be wrongly connected because all plugs have a different size and only fit in one socket Requirements Open spanner 10 mm Open spanner 17 mm oblique pliers Rubber hammer Phillips screwdriver Supporting wooden block Invacare Orion SERVICE MANUAL Secure the scooter against rolling away Place supporting wooden block under the frames at battery holder height Remove the seat Remove motor cover Disconnect both battery plugs 1 From the operating manual Unscrew the rear wheel fixing bolts Remove rear wheels Disconnect plugs from electronic module Rhino1 DS72KB01 DS112KB02 Rhino 2 DS90 DS120 21 SERVICE MANUAL Remove both screws 2 from the wheel cover 1 Remove wheel cover 1 Remove both screws 1 from
9. 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 Switch the power supply off ON OFF key Engage the drive Before raising the vehicle secure the wheels by blocking them with wedges ATTENTION Fire and burn hazard due to electrical short circuit The mobility device must be completely switched off before removal of voltage carrying components To do this remove the batteries Avoid short circuiting the contacts when carrying out measurements on voltage carrying components 11 SERVICE MANUAL Invacare Orion CAUTION Danger of burns from hot surfaces on the motor Allow the motors to cool down before commencing work on them ATTENTION Injury hazard and danger of damage to vehicle due to improper or incomplete maintenance work Use only undamaged tools in good condition 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 which were cut during dismantling After completing your work before renewed start up of the mobility device check all connections for tight fitting After completing your work before renewed start up of the mobility device check all p
10. screwdriver Remove the seat Remove motor cover Separate battery cable Remove screws 1 below operating console Remove operating console and fold upwards Remove screws 3 on drive lever 2 and remove drive lever 38 Invacare Orion Disconnect plug from operating console circuit board Replace operating console Reconnect plug with circuit board on new operating console Reassembly of the operating console takes place in reverse order Check all functions trial run SERVICE MANUAL 39 SERVICE MANUAL Invacare Orion N _ N Replacing bend speed reducer ATTENTION Risk of accident Accidental rolling can lead to accidents Secure the scooter against rolling away Note When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence Requirements Phillips screwdriver Open spanner 32 mm V 40 Remove the seat Remove motor cover Separate battery cable Remove front and rear steering column cladding steering column and housing See chapter entitled Replacing steering column Replacing sensors 5 without mounting Loosen screws Replace sensor Replacing sensors 5 with mounting Loosen fork bolt 1 Replace sensors 5 with mounting Replacing regulating unit 4 Loosen screws Remove sensor 5 Loosen screws 3 Replace regulatin
11. 0 34 0 972 49 32 20 contactsp invacare com www invacare es 33 0 247 62 64 66 33 0 247 42 12 24 contactfr invacare com www invacare fr Invacare Orion Invacare Orion Be Bu Tee j fs Ge B i ha LEE Invacare Ltd Pencoed Technology Park Pencoed Bridgend CF35 5HZ United Kingdom 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 Lda Rua Estrada Velha 949 P 4465 784 Le a do Balio Portugal Customer services Fax Customer services WWW Fax WWW Fax WWW Kundeservice Fax Kundeservice WWW Fax WWW 44 0 1656 77 62 22 44 0 1656 77 62 20 uk invacare com www invacare co uk 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 ireland invacare com www invacare ie 47 0 22 57 95 00 47 0 22 57 95 01 norway invacare com island invacare com www invacare no 31 0 318 69 57 57 31 0 318 69 57 58 nederland invacare com csede invacare com www invacare nl 351 225 10 59 46 351 225 10 59 47 351 225 10 57 39 portugal invacare com www invacare pt SERVICE MANUAL
12. Invacare Orion SERVICE MANUAL LE Edition 28 03 12 SERVICE MANUAL These instructions contain information about Testing work Repair Instructions This manual is part of the instructions for use Service addresses o AY Invacare Austria GmbH 5 L Herzog Odilostrasse 101 A 5310 Mondsee Austria Invacare n v i Autobaan 22 Belgium ou vn Invacare AG CH Dee Bim BenkenstraBe 260 CH 4108 Witterswil Switzerland zc AlemannenstraBe 10 88316 Isny Deutschland eae Invacare A S Sdr Ringvej 37 DK 2605 Br ndby U Danmark Invacare SA CA KA ge C Areny s n Poligon Industrial de Celra E 17460 Celra Girona ESPANA Route de St Roch F 37230 Fondettes France L S B 8210 Loppem Brugge gs gt Invacare Aquatec GmbH dh cP Invacare Poirier SAS KN a Fax WWW Fax WWW Fax WWW Fax WWW Kundeservice Fax Kundeservice WWW Fax WWW Fax WWW 43 6232 5 53 50 43 6232 5 53 54 info invacare austria com www invacare at 32 0 50 83 10 10 32 0 50 83 10 11 belgium invacare com www invacare be 41 0 61487 70 80 41 0 61487 70 81 switzerland invacare com www invacare ch 49 0 7562 70 00 49 0 7562 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 0
13. NING The signal word WARNING refers to possibly occurring hazards which can lead to death or serious injuries if they are not avoided 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 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 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 Invacare Orion SERVICE MANUAL 1 4 9 E je ES E P V 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 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 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
14. PLAN 1X ANNUALLY 6 OPERATIONAL FAULTS 6 1 Operational faults 6 1 1 Drive fault diagnosis 6 2 Error Codes and Diagnostic Codes 7 REPAIR WORK 7 1 General warning information on installation work 7 2 Replacing the drive motor 7 3 Replacing wheel suspension 7 4 Replacing shock absorber 7 5 Replacing front axle 7 6 Replacing steering column fork 3 wheel Page 10 11 11 11 11 13 14 15 17 17 17 18 20 20 20 23 25 27 28 SERVICE MANUAL 7 7 Replacing brakes 7 8 Replacing brake cable 7 9 Replacing steering linkage steering rod 7 10 Replacing the seat suspension spring 7 11 Replacing operating console 7 12 Replacing bend speed reducer 7 13 Replacing the potentiometer 7 14 Replacing front headlight lamp 7 15 Replacing the front direction indicators 7 16 Replacing centre brake light 7 17 Replacing rear lights direction indicators 7 18 Replacing the electronic module 7 19 Updating software Invacare Orion 31 33 34 36 38 40 42 44 46 47 49 51 54 Invacare Orion SERVICE MANUAL 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
15. arts for correct locking Only operate the vehicle with the approved tyre pressures see technical data Check all electrical components for correct function Please note that incorrect polarity can result in damage to the electronic 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 Changes to the drive program may only be carried out by trained Invacare specialist dealers Invacare 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 Invacare Orion SERVICE MANUAL 3 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 3Nm 6 N
16. bers in text and operational instructions always relate to the image directly above Invacare Orion SERVICE MANUAL 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 Read and observe this repair manual and the associated operating manual Observe the minimum requirements for carrying out the 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 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 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 Always wear acid proot 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 Please note the
17. cover Disconnect both battery plugs 1 Disconnect the plug 4 47 SERVICE MANUAL Invacare Orion Remove the bolt 1 on the rear panelling Lift the rear panelling upwards Remove screws 1 on brake light Replace brake light Reassembly of the brake light takes place in reverse order Check functions trial run 48 Invacare Orion SERVICE MANUAL 7 17 A i V Replacing rear lights direction indicators ATTENTION Burn and scald hazard if power cable is short circuited Turn off the power completely before removing any power supply components of the electric vehicle Therefore take out the batteries Avoid a bridging of the contacts during measurements on live electrical componenits Note When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence Requirements Phillips screwdriver Remove the seat Remove motor cover Disconnect both battery plugs 1 Remove the bolt 1 on the rear panelling Lift the rear panelling upwards Remove screws 1 on rear light 49 SERVICE MANUAL Remove rear light Remove screws 1 on rear light glass Remove rear light glass 1 Replace lightbulb 2 Reassembiy of the rear light direction indicator takes place in reverse order Check function 50 Invacare Orion Invacare Orion SERVICE MANUAL
18. eck functions trial run Invacare Orion Invacare Orion SERVICE MANUAL Replacing brakes ATTENTION Risk of accident Accidental rolling can lead to accidents Secure the scooter against rolling away Note When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence Note The front axle can only be replaced on the 3 wheel version The 4 wheel version does not have a replaceable axle Requirements Open spanner 10 mm Open spanner 17 mm Open spanner 19 mm Supporting wooden block Remove the seat Remove motor cover Separate battery cable Place a supporting wooden block under the front part of the frame so that the front wheel is no longer touching the floor 3 wheel version Slacken brake cable see chapter entitled Replacing brake cable on page 33 Disconnect brake cable at wheel Loosen axle bolts 1 simultaneously on both sides Pull front axle slowly out 4 wheel version Slacken both brake cables Disconnect brake cable at affected wheel Loosen wheel bolt Pull wheel and brake off shaft 31 SERVICE MANUAL Invacare Orion Pull brake out of brake drum Replace brake lining or complete brake Reassemble wheel and brake Push wheel and brake onto shaft or push axle through Operate brake and hold tighten axle bolts at same time Reassembly of the
19. ents 2 open spanners 17 mm Secure the scooter against rolling away Remove the seat pi 1 Loosen the securing bolt of the seat support a lt a es on fe tube r AE E SE gt Invacare Orion Remove the bolt 7 nut and washers Remove the seat support tube 2 from the receptacle tube 1 Remove the concertina type cover 3 including the spring 5 and the plastic end pieces 4 and 6 Fit the plastic end pieces 4 and 6 to the new spring Grease the spring generously The spring should be covered completely Assemble the concertina type cover 3 Install the concertina type cover 3 including the spring 5 and the plastic end pieces 4 and 6 Insert the seat support tube 2 into the receptacle tube 1 and press down gently Reposition the bolt 7 nut and washers Firmly tighten the seat support bolt Reposition the seat SERVICE MANUAL 37 SERVICE MANUAL Invacare Orion 7 11 Replacing operating console A ATTENTION Burn and scald hazard if power cable is short circuited Turn off the power completely before removing any power supply components of the electric vehicle Therefore take out the batteries Avoid a bridging of the contacts during measurements on live electrical components Note The plugs on the operating console cannot be wrongly connected because all plugs have a different size and only fit in one socket Vi Requirements gen Phillips
20. g unit 4 Invacare Orion SERVICE MANUAL Adjusting Set steering to straight ahead Align sensor straight using regulating unit Take hold of the sensor and tighten the fork screw Check Turn the steering completely to the right and then the left When the steering is turned to its limit the 3 regulating unit switching knobs should be visible Reassembly takes place in the reverse order Check functions trial run 41 SERVICE MANUAL Invacare Orion 7 13 A A 42 Replacing the potentiometer ATTENTION Burn and scald hazard if power cable is short circuited Turn off the power completely before removing any power supply components of the electric vehicle Therefore take out the batteries Avoid a bridging of the contacts during measurements on live electrical components ATTENTION Risk of accident Wrong potentiometer setting can result in dangerous driving situations Set the new potentiometer to the middle position before inserting Requirements Phillips screwdriver Digital multimeter Allen key 2m Remove the seat Remove motor cover Disconnect battery cable 1 Remove screws 1 below operating console Remove operating console and fold upwards Remove screws 3 on drive lever 2 and remove drive lever Disconnect potentiometer plug 1 from the operating console Invacare Orion SERVICE MANUAL Remove screws 1 on potentiometer Replace pote
21. ge steering rod on page 34 Check function trial run 24 Invacare Orion SERVICE MANUAL Replacing shock absorber ATTENTION Risk of accident When parking the scooter on the scooters support wheels it is no longer slowed by the engine brake The scooter can roll away out of control Place the scooter rear frame on a supporting wooden block before you remove the wheels ATTENTION Risk of accident Accidental rolling can lead to accidents Secure the scooter against rolling away Note When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence Note The drive motor needs to be removed before you can replace the left hand shock absorber If the right hand shock absorber is to be replaced you do not need to remove the drive motor Requirements Open spanner 10 mm Open spanner 17 mm oblique pliers Rubber hammer Phillips screwdriver 2 Allen keys 5m Supporting wooden block Left hand shock absorber Remove drive motor see chapter entitled Replacing the drive motor on page 20 Right hand shock absorber Dismantle wheel see operating manual Dismantle wheel cover see chapter entitled Replacing the drive motor on page 20 Loosen the top bolt 1 on shock absorber Loosen the bottom bolt 2 on shock absorber Replace shock absorber Use setting screw 3 to set the spring hardness
22. he windshield 14 Requirements 13 mm open ended wrench 14 mm open ended wrench Remove the rear view mirror and the stoppers of the plastic cover on the handlebars Remove the threaded bolts of the rear view mirror holder Insert the threaded bolts 1 into the holes in the brackets 2 Place the spacer sleeves 3 on the threaded bolts Screw the threaded bolts instead of the mirror brackets into the holes provided for this purpose but don t tighten the bolts completely yet Make sure the brackets are turned so they point upwards and outwards towards the ends of the handlebars Loosen the wing nuts 1 Insert the non threaded ends of the windshield brackets 2 into the fixtures from below 55 SERVICE MANUAL 56 Insert the threads of the windshield mounting brackets 3 through the bracket holders 1 Secure the windshield mounting brackets with the self locking nuts 2 Adjust the windshield using the nuts 2 and 4 on both sides so that it is perpendicular to the direction of travel Adjust the windshield so that it is horizontal Tighten the wing nuts Now tighten the threaded bolts Install the rear view mirrors again Invacare Orion
23. ing out further development and improvements to drive programs for electric vehicles For this reason you should always check whether the drive program version number is up to date when carrying out any repairs or regular maintenance If a newer version is available the drive program must be updated The procedure for updating the drive program is described in the wizard software operating manual NOTE The electronic system is supplied with a standard drive program If you have carried out customer specific modifications to the drive program you will have to make these changes again after installing the new electronic module WARNING Any changes to the drive program can affect the driving characteristics and the tipping stability of the mobility aid Changes to the drive program may only be carried out by trained Invacare specialist dealers Invacare can only give a warranty for safe mobility aid driving behaviour especially tipping stability for unaltered standard drive programs Requirements Dynamic Wizard software Operating manual for Wizard software 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 Invacare Orion SERVICE MANUAL 8 Accessories 8 1 Installing t
24. m 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 Always tighten screws nuts etc to the stated tightening torque Only tighten screws or nuts which are not listed here fingertight 13 SERVICE MANUAL 4 Overview electronic modules Invacare Orion Different electronic modules can be installed in the scooter These are listed below zen Jee Electronic modules DEE Rhino1 DS72KB01 DS112KB02 Rhino2 DS90 DS120 max current 70A 110A max current 90 A 120A Invacare Orion SERVICE MANUAL 5 Service plan 1X annually Welded seams Tighten screws fixings and replace parts if upholstery damaged Seat suspension Grease the spring See Replacing generously the seat replace parts if suspension damaged spring on page 36 Check fixings Tighten screws welded seams and replace parts if battery mounting damaged Check battery fixing straps Check drive wheels Tighten hub nuts y neg for tight fit replace if necessary Check steering Adjust replace EEE wxe gl i N float and side play if damaged manual Frames chassis battery mounting suspension and wheels Check tracking and Tighten screws steering linkage Check tracking and steering Test brake function Adjust or replace Check shock Adjust or replace Check functions i
25. mbled in the right sequence Vi Requirements deg Open spanner 10 mm Open spanner 17 mm Open spanner 19 mm Open spanner 32 mm Phillips screwdriver Supporting wooden block Remove the seat Remove motor cover Disconnect battery cable 1 Place a supporting wooden block under the front part of the frame so that the front wheel is no longer touching the floor Remove drive lever screws 3 Remove drive lever 2 Unscrew the bolts 1 on the drive console Remove drive console 28 Invacare Orion SERVICE MANUAL Remove screws 1 on rear steering column cladding Remove steering column cladding Loosen screws on front basket holder Remove basket holder Remove spacer bushes Remove screws 3 on front steering column cladding Remove the front steering column cladding 29 SERVICE MANUAL 30 Release brake cable see chapter entitled Replacing brakes on page 31 Unscrew screw at clamp 1 Unscrew fixing bolt for steering column and remove Pull steering column out upwards Replacing fork 3 wheel Remove rubber mat in foot well Loosen screws in chassis below mat Remove chassis upwards Remove front wheel see chapter entitled Replacing front axle on page 27 Pull off clamp 1 Loosen fork bolt 2 Loosen knurled screw 3 Replace fork Reassembly takes place in the reverse order Operate brake and hold tighten axle bolts at same time Ch
26. n Replace motor if drive and push necessary modes Tighten screws Check clutch nuts adjust or mechanism replace E Check function Replace lightbulbs connections Batteries Check batteries for Replace batteries See operating damage manual Check battery charge batteries See operating voltage manual Drive units coupling mechanism Check contacts and Clean contacts terminals and terminals 15 SERVICE MANUAL Component Drive electronic Drive program Speed reduction in bends Invacare Orion Status display flashing Fixing Cable connecting plug Drive lever function Power supply Check drive electronic program version Newer version available Check cable and connecting plug Check function Evaluate blinking code Tighten or replace fixing Replace cable connecting plug Replace drive lever Replace cable connecting plug or Update software Adjust or replace sensor on microswitch Invacare Orion SERVICE MANUAL 6 Operational Faults 6 1 Operational faults Please proceed as follows if you have any problems First assess the possible cause of the problem using the following table Check the drive console status display Evaluate the blink error code Carry out the necessary checks and repairs as recommended in the following table 6 1 1 Drive fault diagnosis PROBLEM OTHER POSSIBLE SOLUTION Documentation SYMPTOMS CAUSE Scooter will Status display Batteries po
27. n so that they can be reassembled in the right sequence Note The plugs on the electronic module cannot be wrongly connected because all plugs have a different size and only fit in one socket Requirements Open spanner 10 mm Open spanner 17 mm Rubber hammer Phillips screwdriver Supporting wooden block To adapt the drive program programming software or hand programming device and electronic system installation manual available from Invacare 51 SERVICE MANUAL Invacare Orion Secure the scooter against rolling away Place supporting wooden block under the frames at battery holder height Remove the seat Remove motor cover Disconnect both battery plugs 1 From the operating manual Unscrew the rear wheel fixing bolts Remove rear wheels Remove the drive unit see chapter entitled Replacing the drive motor on page 20 Remove screws 1 on electronic module Rhinot DS72KB01 DS112KB02 Rhino 2 DS90 DS120 I L 1 I 1 1 2lslvlstslstr 52 Invacare Orion Remove screws 1 on electronic module Replace electronic module 2 Reassembly of the drive and the electronic module takes place in reverse order Load drive program onto electronic module See electronic software description Check all functions trial run SERVICE MANUAL 53 SERVICE MANUAL Invacare Orion 7 19 Vid 54 Updating software Invacare is continuously carry
28. ntiometer Reconnect potentiometer plug 1 with operating console Setting the potentiometer to the middle position Loosen the bolts 1 on the drive lever mounting Twist the potentiometer shaft 2 until the same resistance approx 5kOhm is measured between the central connection cable 3 and both outputs 4 Retighten the bolts on the drive lever mounting Check settings and repeat the adjustment if necessary Reassembly of the operating console takes place in reverse order Check all functions trial run 43 SERVICE MANUAL Invacare Orion 7 14 Replacing front headlight lamp M Requirements ku Phillips screwdriver Remove the seat Remove motor cover Separate battery cable 3 wheel version Remove screw 1 on front headlight under front cladding 4 wheel version Remove screw 1 on front headlight under front cladding Remove headlight Disconnect cable from wiring harness Remove screws 1 on headlight glass Remove headlight glass Replace bulb s in headlight es Ke DD i j a EY diran N tee jedan ede 44 Invacare Orion SERVICE MANUAL Reassembly of the headlight takes place in reverse order Check function 45 SERVICE MANUAL Invacare Orion 7 15 Replacing the front direction indicators Vi 46 3 wheel version 4 wheel version Requirements Phillips screwdriver Remove the seat Remove motor cover Separate battery
29. 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 should always use the original packaging for transport Please attach a precise description of the fault SERVICE MANUAL Invacare Orion 1 3 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 The following lines in italics refer to actions which serve to avoid such hazards WAR
30. spanner 12 mm Open spanner 13 mm Phillips screwdriver Circlip pliers Supporting wooden block Remove the seat Remove motor cover Disconnect battery cable 1 Dismantle the steering column and the chassis See chapter entitled Replacing steering column fork 3 wheel on page 28 34 Invacare Orion Replacing steering link SERVICE MANUAL Remove circlip 1 on steering link 2 Replace steering link Adjust length of steering link using setting screws 3 Replacing steering rod Remove circlip 4 on steering rod 5 Replace steering rod Adjust tracking by 1 inwards using setting screw 6 See sketch i IW T s i F Ta i li j ka d i E Ezi l i VE U J ji i i d J d i A d i VW d he Wi j j ee L i A i Reassembly of the steering linkage and or steering rod takes place in reverse order Check function trial run 35 SERVICE MANUAL Invacare Orion We 36 Replacing the seat suspension spring ATTENTION Risk of accident Accidental rolling can lead to accidents Secure the scooter against rolling away Note When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence Note The following seat support tubes are available for the seat suspension tube 0 136 kg 478 5 mm SP1522456 503 5 mm SP1522457 528 5 mm SP1522458 Requirem
31. ssibly Replace See operating manual not start on operating defective batteries console does Batteries possibly Pre charge See operating manual over discharged batteries not illuminate Power supply to Check master See operating operating console fuse instructions for main fuse possibly position interrupted Check cable See Replacing the between electronic module on loose connections or damage Operating Replace See Replacing console possibly operating operating console on defective console page 38 Operating unit Various causes Assess error See Error Codes and status display code Diagnostic Codes on blinking page 18 17 SERVICE MANUAL Invacare Orion Scooter Drive motor s Replace See Replacing the judders in possibly defective Motor s drive motor on page 20 drive mode Drive lever Replacing the See Replacing the potentiometer potentiometer potentiometer on page possibly defective 42 Batteries None Batteries possibly Replace See operating manual not being defective batteries charged LEDs blinking Charging device Replace See charging unit on charging unit possibly defective charging unit operating manual Scooter Operating Replace See Replacing runs too console possibly operating operating console on slowly defective console page 38 Batteries possibly Replace See operating manual defective batteries 6 2 Error Codes and Diagnostic Codes Blink Fault Conseq
32. the drive holder 2 Remove drive holder 2 Remove screws 1 on disengaging lever 2 Remove disengaging lever 2 Lifted drive out of its holder and take it out of the frames to the side Replace drive unit Reassembly of the drive takes place in reverse order Check all functions trial run 22 Invacare Orion Invacare Orion SERVICE MANUAL 7 3 A d Replacing wheel suspension ATTENTION Risk of accident Accidental rolling can lead to accidents Secure the scooter against rolling away Note When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence Requirements Open spanner 10 mm Open spanner 12 mm Open spanner 13 mm Open spanner 32 mm Phillips screwdriver Supporting wooden block Remove the seat Remove motor cover Disconnect battery cable 1 3 wheel version Dismantle steering column and chassis see chapter entitled Replacing steering column fork 3 wheel on page 28 4 wheel version Dismantle steering link and steering rod see chapter entitled Replacing steering linkage steering rod on page 34 23 SERVICE MANUAL Invacare Orion Loosen wheel suspension screw 1 Loosen knurled screw 2 Replace wheel suspension Reassembly takes place in the reverse order Adjust tracking see chapter entitled Replacing steering linka
33. uence Comments code for the Scooter Battery must be Continues to The batteries are discharged Charge the charged drive battery as soon as possible Battery voltage too Stops driving The batteries are depleted Charge low batteries If you switch the Scooter off for a few minutes the battery can often recuperate to such a stage that a short journey is still possible Battery voltage too Stops driving The battery voltage is too high If the high battery charger is connected disconnect it from the Scooter The electronic system charges the batteries when running downhill and when braking This fault is caused when the battery voltage becomes too high during this process Switch the Scooter off and on again Power time Stops driving The maximum current was exceeded ERA E over too long a period probably because the motor was overloaded or has been working against an immovable resistance Switch the scooter off wait a few minutes and then switch on again The electronic system has determined a motor short circuit Check the wiring harness for short circuit and check the motor Contact your Invacare dealer Invacare Orion Blink code Fault Consequence for the Scooter NR Brake failure Stops driving No neutral position Stops driving when switching Scooter on 7 Fault in speed Stops driving potentiometer Motor voltage error Stops driving Miscellaneous Stops driving internal fault Stops driving
Download Pdf Manuals
Related Search