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TDX SP2 NB Service Manual

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1. 5 8 Allen key 5 16 Allen key Phillips screwdriver size 2 1 4 socket spanner 5 16 socket spanner torque wrench 5 25 Nm or similar M8 washer two long wooden blocks min 14 x 14x 30 cm Loctite 242 if the gas cylinder is repaired Lift the wheelchair up on one side and place a 14 cm high wooden block under the battery case so that the wheels are off the ground and can rotate freely Use proper lifting techniques Repeat the same procedure on the other side of the wheelchair Remove both the stability lock system protective caps The protective caps on the stability lock system will either be held using a screw or a cable tie depending on the wheelchair s date of manufacture Remove the batteries as described in chapters 8 5 1 and 8 5 2 8 5 3 Remove the drive wheel as described in chapter 8 10 1 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL e Rotate the top walking beam 5 so that you can reach the screw 4 on the gas cylinder through the drillhole 3 in the battery case e Remove the nut 6 with a 1 4 socket spanner Use a 5 16 Allen key to counter the bolt while doing so e Push the bolt 4 towards the battery case so that the gas cylinder 1 is separated from the walking beam e Push the gas cylinder against the battery case e Raise the rear axle so that the gas cylinder is activated and then retract the cylinder e Push the gas cylinder to the rear and pull it off the batte
2. Ensure that the rear springs 7 are compressed Block method e Raise the suspension arms 6 and place wooden blocks underneath them until the springs are pressed together enough so that the nylon stopper 4 can be removed Clamp method e Undo both bolts 3 with a 5 32 Allen key and remove the bolts including the nylon spacer 2 e Make sure the suspension arms 6 are lowered as much as possible Remove the rubber caps 5 e Press the springs together with a joiner s clamp or similar suitable clamp until the nylon stopper 4 can be removed Undo both nuts on the nylon stopper with a 5 16 socket spanner and remove the nuts the washers and the nylon stopper It may be necessary to use a blade screwdriver to loosen the nylon stopper Remove the wooden blocks or joiner s clamps carefully so that the springs are released Remove the springs Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 12 2 Refitting the rear springs Note ij Invacare recommends always replacing both springs simultaneously in order to ensure that the wheelchair works perfectly A WARNING Danger of crushing The mobility device is very heavy Injury hazard to hands and feet e Use proper lifting techniques 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 wW
3. Refitting the tyres e Refit the tyres onto the wheel rim in reverse order Note If the old inner tube is to be repaired and re used and has become wet during repair you can make replacement easier by sprinkling the inner tube with a little talcum powder e When putting the rim rings back together ensure that drillholes and threads for the bolts are exactly over each other e Tighten the Allen screws 2 to 18 Nm e Inflate the inner tube to the specified air pressure Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 10 2 2 Replacing puncture protected tyres Note Pneumatic tyres have black valve caps Puncture protected tyres have red valve caps Requirements e 7 8 Allen key e Two long wooden blocks min 14 x 14 x 30 cm e Torque spanner 5 25 Nm or similar e Repair kit for tyre repair or a new inner tube e Tyre pump or compressor e Talcum powder Removing the tyres e Remove the wheel as described in chapter 8 10 1 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 CAUTION Material damage hazard The valve can become blocked by the puncture protection gel and be unusable e During the following work you should always hold the valve up so that the
4. e Secure the rim rings with joiner s clamps Secure the rim rings against unexpected discharge with three joiner s clamps When doing so ensure that you do not scratch the rims Undo the five 7 8 Allen screws 2 on the inside of the wheel Now loosen the joiner s clamps carefully and alternately until you can remove the rim rings without danger Remove the inner 3 and outer 1 ring of the rim from the tyre 4 Replace any defective or worn parts Refitting the tyres Refit the tyres to the rim in the reverse sequence When fitting the rim rings together ensure that the drillholes and threads for the bolts are placed exactly above each other Place the joiner s clamps in position Tighten the joiner s clamps alternately in small stages until the rim rings are precisely aligned Tighten the Allen screws 2 to 18 Nm 101 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 10 3 Replacing the drive wheel hub Standard motor A CAUTION Possible material damage to mobility device 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 removed and not replaced again collisions can be caused Always replace the adjusting washers exactly as they were before you started dismantling wW Requirements iv e socket spann
5. 3 mm Allen key 10 mm open spanner T25 Torx wrench T40 Torx wrench Side cutting pliers Cable ties Remove legrests Tilt the seat tilting completely to the rear if possible Switch the electronics OFF on the remote Remove the backrest cushion Loosen and remove the screws which secure the middle seat plate A with a 3 mm Allen key Remove the middle seat plate B Loosen and remove the screws on both sides which secure the lateral seat plates C with a 3 mm Allen key Remove the lateral seat plates D or Remove the seat cushion Loosen and remove the screws on both sides which secure the sling seat A with a T25 Torx wrench Remove the sling seat B 161 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series e Remove the seat frame by removing the screws 1 with a T40 Torx wrench e Disconnect the actuator cable and microswitch cable from the cable harness 162 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL Loosen and remove the screws 2 incl the washers with a 10 mm open spanner Lift the module of the seat angle adjustment 1 from the adapter A or B and replace it Depending on the chassis type Adapter A Chassis TDXSP TDXSP2 total width of 650 mm Adapter B Chassis TDX SP total width of 620 mm Chassis TDX SP2 total width of 610 mm Reassembly takes place in the reverse order Note a Make sure that all screws washers and nut
6. 8 20 4 Replacing the backrest actuator cee ceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeseneeeeeeeeeaees 164 8 20 5 Replacing the seat support without lifter or tilt modules eee eter ee teeeeees 165 Backrest MOdullite 2c cc0s0ccccectececessceceetee sececeteccesettetecectuetecsenaecesessuuecesetoeteceseaueecseneceeessaeecesenss 168 8 21 1 Replacing the standard backrosStr acena ai aS R E A 168 8 21 2 Replacing the backrest mounting bracket sssssesssssrssssrrsssrrssrirnssrinnnsinnssrnnnssrnnns 169 8 21 3 Replacing the backrest mounting bracket for SB 53 cecceecceseeceseeteeeeseeeeeeeeeeeees 170 Adjusting the seat width backrest width Modulite cccccseseeseeeeceeeeeeeneeneeeeeeeees 171 8 22 1 Adjusting the Seat width 00 0 eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeteaeeeeeseaeeeeeeaeeeeesaeeeeeeeneeeeeeeeeaees 171 8 22 2 Adjusting the backrest width assie erasa ene a SEEE A EENES Ra AAEE E 173 8 223 Adjusting the Flex3 backrest eee seeeceeeeceeeeeseeeeeeeeeeeeeeeeaeeeeeeaaeeeeeeaaeeeseeeeneeseeneneees 175 Centre mounted legrest electric amp MaNUal ccssecccessseeeeesseeeeenseeeeeenseeeeeeeseeceneeseeeenes 176 8 23 1 Replacing the manually operated centre mounted legrest ccccceceeeeeeeeeeeeeeeees 176 8 23 2 Replacing the electrically operated centre mounted legrest ccceeeeeeeeeeeeetees 179 8 23 3 Replacing the electrically operated centre mounted legrest LN
7. Drive motor s Replace motor s See chapter defective 8 15 1 8 15 2 Replace carbon See chapter brushes 8 15 6 8 15 7 Wheelchair None Drive motors Change See chapter 8 4 pulls to left or running programming to right asymmetrically synchronise motors Error None Bad connections Check all See chapter 8 5 7 message connecting does not go cables out Motor brake Measure internal See chapters 7 2 defective resistance of and 8 15 1 8 15 2 brakes replace motor if defective Motors stop None Voltage decline Stop journey and and start allow electronic to irregularly cool down Motor runs None High motor Stop journey and but loses loading causes allow electronic to power electronic module cool down to decrease voltage 25 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series PROBLEM OTHER POSSIBLE SOLUTION DOCUMENTATION SYMPTOMS CAUSE Motors stop None High motor Leave wheelchair and do not loading causes switched on and start again electronic module allow electronic to decrease module to work voltage Charge batteries overnight with wheelchair switched on None Fuse burnt out Check cabling See chapters 8 5 7 and replace fuse and 8 5 5 8 5 6 None Motor defective Check carbon See chapter brushes and 8 15 6 8 15 7 replace if necessary Measure internal See chapters 7 1 resistance of and 8 15 1 8 15 2 motor replace motor if defective None Electronic module Replacing the See chapter 8 3 2 defect
8. Insert and tighten the screws 5 again Adjust the straps of the sling backrest to the new width or install the adjusted Flex 3 backrest Install the backrest cushion Perform a function check of the chair Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 22 3 Adjusting the Flex3 backrest wW Requirements id e Phillips screwdriver e 5mm Allen key e Remove the front lateral plates 2 and 4 from the backrest 1 by loosening and removing the five hexagon socket head screws 3 e Remove both Phillips screws A on the middle plate LL e Shift the position of the rear plate halves three settings are possible using the drill holes Before pulling the Flex3 backrest apart a 1 will be visible in the small rectangular cut out After pulling the Flex3 backrest apart a 2 will be visible in the small rectangular cut out e Re insert the two screws A into the middle plate e Fasten the front lateral plates 2 and 4 again 175 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 23 8 23 1 176 Centre mounted legrest electric amp manual Replacing the manually operated centre mounted legrest WARNING Danger of crushing The legrest is very heavy Danger of injury to hands and feet Pay attention to the heavy weight Requirements e 5mm Allen key e 6mm Allen key e Side cutting pliers e Cable ties Uninstalling the manually operated centre mounted
9. Stellen Sie sicher dass BEIDE Antriebsrader angehoben werden und den Boden nicht ber hren k nnen Secure the area Lift the wheelchair up on one side and place a 14 cm high wooden block underneath it so that the drive wheel is suspended freely Use proper lifting techniques Repeat the same procedure on the other side of the wheelchair Allow the motors to run in the forward direction for an hour Allow the motors to cool down for 30 minutes Allow the motors to run in the reverse direction for an hour Lift the wheelchair off the wooden blocks 131 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 15 7 Replacing the carbon brushes Standard motor i A W 132 a Note Always replace all the carbon brushes on both motors WARNING Danger of crushing The mobility device is very heavy Injury hazard to hands and feet e Use proper lifting techniques Requirements 5 8 Allen key 7 8 Allen key 5 16 Allen key blade screwdriver Phillips screwdriver size 2 1 2 socket spanner 1 4 socket spanner 5 16 socket spanner torque wrench 5 25 Nm or similar two long wooden blocks min 14 x 14 x 30 cm Removing the carbon brushes e Switch the wheelchair off e Remove the drive wheels as described in chapter 8 10 1 e Remove the bottom walking beams as described in chapter 8 13 e Remove the top walking beams as described in chapter 8 14 a 0 i a ROARS
10. The system allows normal usage of the wheelchair after component replacement only if the profile is selected afterwards Profile selection with remote REM A or REM B e Plug the plug into the remote or the ACS2 controller e LEDs 1 and 4 blink e Use the bottom rocker switch 5 to select where the required controller profile is saved LED 1 remote LED 4 ACS2 control system e The relevant LED illuminates permanently the other LED is off e Press the Horn 2 and 3 buttons on the speed selection and hold them down for 3 seconds to confirm the selection e The system will switch itself off and restart automatically During the process the selected profile will be saved both in the remote and in the electronic module Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 3 5 2 Profile selection with remote REM 550 e Plug the plug into the remote or the ACS2 controller e The display 2 shows that you need to select a profile e Use the bottom rocker switch 3 to select where the required controller profile is saved remote II electronic module e The display will show which profile you have selected e Press the Horn 4 and 1 buttons on the speed selection and hold them down for 3 seconds to confirm the selection e The system will switch itself off and restart automatically During the process the selected profile will be saved both in the remote and in the electronic
11. e Switch the vehicle s power system off ON OFF key e Engage the drive motors e Secure the vehicle against rolling away by placing wedges under the wheels ATTENTION Danger of crushing The motor gearbox unit is extremely heavy Injury hazards to hands e Please note the high weight Requirements 5 8 Allen key 7 8 Allen key 5 16 Allen key Phillips screwdriver size 2 1 2 socket spanner 1 4 socket spanner 5 16 socket spanner torque wrench 5 25 Nm or similar torque wrench 10 80 Nm or similar two long wooden blocks min 14 x 14 x 30 cm Removing the motor transmission unit e Remove the drive wheel as described in chapter 8 10 1 e Remove the wheel hub as described in chapter 8 10 3 e Remove the bottom walking beam as described in chapter 8 13 e Remove the top walking beam as described in chapter 8 14 e Loosen and remove the three nuts 2 with a 5 16 socket spanner Remove the washers 3 e Take note of the optional wheel lock 6 if fitted Invacare TDX SP Series TDX SP2 Series A SERVICE MANUAL ATTENTION Danger of crushing The motor gearbox unit is extremely heavy Injury hazards to hands e Please note the high weight e Pull the motor transmission unit 4 off the bolt Refitting the motor transmission unit e Replace the defective parts e Refit the motor transmission unit in reverse order e Tighten the motor bolts 5 to 30 Nm
12. electric amp manual wW Requirements e e 1 64 Allen key e 1 4 Allen ke A manual legrest can be seen in the illustration The method of fixation to the seat is almost identical with both legrests Uninstalling the footplate e f possible raise the lifter to the highest position e f possible tip the wheelchair with the tilt module as far backwards as it will go e Switch the electronic control system off e Use the 1 64 Allen key to loosen and remove both screws 3 e Replace the foot plate 1 Installing the footplate e Assemble the parts in reverse order e Tighten the hexagon socket head screws 3 till they are tight enough that the footplate can barely be moved In the area denoted by the 2 there is an adjustment screw that can only be reached when the footplate is swivelled upwards e Use the 1 64 Allen key to adjust the angle of the footplate to the needs of the user with this screw 185 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 24 Stability lock system 8 24 1 A Wd 186 Removing the gas cylinder WARNING Danger of crushing The mobility device is very heavy Injury hazard to hands and feet Use proper lifting techniques Injury hazard caused by uncontrolled movement of the mobility device Switch the power supply off ON OFF key Engage the drive Before raising the vehicle secure the wheels by blocking them with wedges Requirements
13. lt i t A e A G a A 4 e Disengage the motor 1 by setting the engaging lever to Push Undo all four plastic caps 3 with a blade screwdriver and remove the caps Pull the carbon brushes 4 a little out of the brush holder Note the fixing position and location of the carbon brushes Note If the carbon brushes were checked but not replaced you must know their exact fitting position Used carbon brushes need to the refitted exactly in the same position from which they were taken in order to guarantee optimum contact to the collector Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL gt 9 Make a marking on the motor and the carbon brushes in order to guarantee correct refitting Remove the carbon brushes complete from the mounting 2 Check the carbon brushes and springs for the level of wear broken components or discolouration Refitting the carbon brushes Depending on the condition of the brushes and the spring either replace the brushes in exactly the same position from which they were taken or fit new brushes Replace the plastic caps and tighten them Refit the top walking beams as described in chapter 8 14 2 Refit the bottom walking beams as described in chapter 8 13 Refit the drive wheels as described in chapter 8 10 1 Note The following procedure is necessary to run the carbon brushes in after replacement and to therefore guarantee maximum performance WARNING Ris
14. 121 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 15 2 A W 122 Replacing the motor transmission unit SSD motor WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Use proper lifting techniques Danger of injury due to uncontrolled movement of the wheelchair e Switch the vehicle s power system off ON OFF key e Engage the drive motors e Secure the vehicle against rolling away by placing wedges under the wheels ATTENTION Danger of crushing The motor gearbox unit is extremely heavy Injury hazards to hands e Please note the high weight Requirements 6 mm Allenkey 5 8 Allen key 7 8 Allen key 5 16 Allen key Phillips screwdriver size 2 13 mm socket spanner 1 2 socket spanner 1 4 socket spanner 5 16 socket spanner torque wrench 5 25 Nm or similar torque wrench 10 80 Nm or similar two long wooden blocks min 14 x 14 x 30 cm Uninstalling the motor gear box unit e Remove the rear battery box cover as described in chapter 8 1 2 TDX SP or chapter 8 2 2 TDX SP2 e Disconnect the motor plug from the power module e Open the cable ties so you can freely access the motor cable e Remove the drive wheel as described in chapter 8 10 1 e Remove the wheel hub as described in chapter 8 10 4 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL Use a 1 2 socket wrench to
15. 3 for visible damage and crushing locations e Replace any damaged cables Note The following figure shows checking of the cables using the ACS electronic module as an example The position of the plugs is different for other electronic modules The procedure for checking is otherwise identical The position of the plugs is described in chapter 4 2 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL e Check all cables for visible damage and crushing locations Replace any damaged cables e Pull each plug 1 carefully The plug should not come out of the socket e f one of the plugs is loose press it back into the socket with light pressure The plug must engage e Checked to ensure that the plug is now firmly in its socket If not repeat the previous operation e Refit the parts in reverse order e Check all vehicle functions 67 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 5 8 Cable routing 68 W i Requirements e Phillips screwdriver size 2 e oblique pliers e cable ties e Remove the rear panel as described in chapter 8 1 2 or 8 2 2 e When routing cables in the rear section please ensure that the rear wheel stabilisers are movable e Fix the cable with cable ties at the locations marked A e Make sure the cable has enough play so that all movable parts can move freely without stretching clamping or abrading the cable e Route the cable in the same
16. 8 22 2 Adjusting the backrest width W The backrest width is adjusted by performing the following tasks e Adjust the backrest tube e Adjust the backrest Sling backrest as described in chapter 8 19 1 Flex3 backrest as described in chapter 8 22 3 e Replace the backrest cushion these are available in various widths When modifying the backrest width the seat width must also be correspondingly adapted Please see chapter 8 22 1 Requirements e 3 mm Allen key e 5mm Allen key e 13 mm Open ended spanner The screw position for the backrest width refer to the table Ge V GE Screw position Seat width A 530 mm B 480 mm C 430 mm D 380 mm 173 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 174 Remove the backrest cushion Loosen the straps of the sling backrest or remove the Flex3 backrest Loosen and remove both screws 5 of the actuator fixation bracket Remove the cover of the actuator fixation bracket Loosen and remove the screws and nuts 2 4 on the upper and lower actuator fixation bracket on both sides Adjust the backrest fixation 6 for the new backrest width according to the table on page 173 Insert the screws 2 through the cover of the actuator fixation bracket and the corresponding holes of the backrest fixation to the actuator fixation Fasten these with the nuts 4 Reposition the cover of the actuator fixation bracket
17. A B S a A Seat depth B Center of gravity of the seat seat position Standard seat The Seat depth is adjusted by moving the seat back Modulite seat The seat depth is adjusted by shifting the position of the backrest See User Manual Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 10 2 Adjusting the center of gravity of the seat The center of gravity of the seat can be adjusted by mounting the seat frame farther towards the front or the rear on the seat A CAUTION The seating system of the electric wheelchair is delivered ex works with an optimally adjusted center of gravity Any change in this adjustment setting can negatively influence the stability of the electric wheelchair e You must perform an individual risk analysis every time you change the center of gravity of the seating position in order to ensure the safety and stability of the electric wheelchair A B B A Seat depth B Center of gravity of the seat seat position 205 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series Note The user weight and seat depth have strong influences on the choice of the Center of gravity of the seat If the user is heavy and the seat depth is greater the focus should be the farther back ali n For best possible driving characteristics of rear wheel drive wheelchairs the weight to be distributed 30 40 front and 60 70 rear A WARNING Danger of damage
18. Allen key and a 1 2 socket wrench to loosen the screw 1 e Remove the nuts including the washers but leave the screw inserted in the screw hole do not pull it completely out e Pull the actuator 2 toward the side off of the screws 1 and 3 e Replace the actuator Installing the electrically operated legrest e Assemble the parts in reverse order e Test all functions of the wheelchair 183 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 23 6 Replacing the calf plate on the centre mounted legrest electric amp manual wW Requirements si e 1 64 Allen key A manual legrest can be seen in the illustration The method of fixation to the seat is almost identical with both legrests Uninstalling the calf plate e f possible raise the lifter to the highest position e f possible tip the wheelchair with the tilt module as far backwards as it will go e Switch the electronic control system off e Use the 1 64 Allen key to loosen and remove both screws 2 e Remove the calf plate 1 Installing the calf plate e Assemble the parts in reverse order e Using the different adjustment holes 3 in the calf plate and in the calf plate brackets the calf plates can be mounted at different heights and widths This must be adjusted to fit the needs of the user 184 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 23 7 Replacing the foot plate on the centre mounted legrest
19. Invacare TDX SP Series TDX SP2 Series 8 21 3 Replacing the backrest mounting bracket for SB 53 Wd 170 Requirements e 5mm Allen key Dismantling the backrest unit at rl Remove the backrest cushion Loosen the fixation levers 2 of the corresponding backrest tube 1 depending on the version There are two versions 2 for the manual backrest 3 for the electrically adjustable backrest Remove the backrest tube O Loosen and remove the two hexagon socket head screws 4 to the sliding block 5 on the left and right side of the chair Refitting the backrest unit Replace the parts in the reverse order To conclude you should always carry out a trial run to test the vehicle functions Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 22 8 22 1 Adjusting the seat width backrest width Modulite Adjusting the seat width You can only adjust the seat width for the adjustable seat plate or for the adjustable sling seat The sling seat is available in two widths for a seat width of 38 43 cm and for a seat width of 48 53 cm When modifying the seat width the backrest width must also be correspondingly adapted See chapter 8 22 2 Requirements e 3mm Allen key 5 mm Allen key 13 mm open ended spanner T25 Torx wrench T40 Torx wrench Remove the backrest cushion D Cc Remove the backrest from the backrest mounting bracket Se
20. Requirements 5 6 Allen key 5 32 Allen key Phillips screwdriver size 2 blade screwdriver 1 4 socket spanner 5 16 socket spanner torque wrench 0 20 Nm or similar oblique pliers cable ties M8 washer two long wooden blocks min 14 x 14 x 30 cm 113 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 114 Put the springs 7 into position between the suspension arm 6 and the stop 1 Ensure that the rear springs are compressed Block method e Raise the suspension arms and replace the wooden blocks underneath them until the springs are compressed Clamp method e Press the springs together with a joiner s clamp or similar suitable clamp until the nylon spacer 2 can be fitted into the recesses provided in the suspension 6 e Fit the two bolts 3 including the nylon spacer 2 e Tighten the bolts to 8 5 Nm Fit the two nylon stoppers 4 Fit the washer and nuts to secure the nylon stoppers Tighten the nuts to 8 5 Nm Remove the wooden blocks or joiner s clamps carefully so that the springs are released Reinsert all the necessary plugs and fix the cables with cable ties as previously see also chapter 8 5 8 Refit the rear panel as described in chapter 8 1 2 Lift the wheelchair off the wooden blocks Check all the wheelchair functions If necessary carry out adjustments to the setting screw on the stability lock system as described in chapter 8 24 5 Fit both the stability lo
21. TDX SP Series TDX SP2 Series 8 18 3 Replacing the tilt actuator 148 Note This chapter only deals with the replacement of the tilt actuator If you wish to replace the complete tilt module please proceed as described in chapter 8 18 1 2 or 8 18 2 WARNING Danger of crushing The seat is very heavy Injury hazard to hands if the seat is unintentionally folded down e Use proper lifting techniques e Ensure that the seat is properly secured before you start removing the actuator Requirements e retaining ring pliers e oblique pliers e cable binder Note Make a careful note of the seat settings Mark the fitting positions alignments cable routing etc and take photos with a digital camera if necessary Every change to the seat settings influences the centre of gravity of the mobility device If the seat settings are changed the stability lock system settings must be checked and readjusted if necessary as described in chapter 8 24 5 Removing the tilt actuator e Run the lifter up to the top position if possible e f possible tilt the seat with the tilt module as far as possible to the rear e Switch the controller off The actuator module for the lifter and the tilt actuators is fitted to the front edge of the seat support e Remove the two knurled screws 1 including washers e Remove the cover 2 e Pull the plug out of the actuator module e Open the cable holder on the undersi
22. To conclude carry out an extensive driving and function test with the wheelchair 8 8 Lighting unit 8 8 1 Replacing the front bulb conventional lighting system wW Requirements ane e Phillips screwdriver size 2 e Undo the concealed Philips screw on the rear of the headlight indicator combination e Remove the transparent plastic cover e Replace the defective bulb e Close the cover and tighten the Philips screw finger tight 71 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 8 2 Replacing the front headlight complete conventional lighting system wW Requirements 1 e Phillips screwdriver size 2 e oblique pliers e cable ties Removing the front headlight e Remove the rear panel as described in chapter 8 1 2 e Carefully note the location of the cable and the connection locations of the various plugs Either mark each plug and socket or take a photograph with a digital camera e On the illustration you can see the battery plug 1 the lighting PCB 2 for the electronic module 3 the optional cross connector 4 and the optional actuator module 5 e Loosen the cable leading to the lighting PCB from the front headlight affected e Remove all cable ties and pull the cable out of the wheelchair 72 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL e Undo and remove the two Phillips screws which hold the front headlight e Replace the headlight unit Refittin
23. and mounting belts for damage Replace if necessary Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL Component Batteries Check batteries for Replace batteries if See chapters damage necessary 8 5 2 8 5 3 and a 5 4 Check battery voltage Charge batteries Check battery voltage Charge batteries operating manual Check contacts and Clean contacts and Please refer to the terminals terminals safety information in chapter 8 5 2 8 5 3 and 8 5 4 for handling batteries Remote Remote status display Evaluate error blink See chapter 6 electronic blinking code module Fixings Tighten fixings replace if necessary Cables and connecting Tighten cables and plugs connecting plugs replace if necessary Drive lever function Replace drive lever if necessary Replace remote if necessary Power supply Tighten cables and connecting plugs replace if necessary Drive program Check drive electronic Update software if See chapter 8 4 program version newer version available 23 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 24 Operational faults The various electronic modules can be fitted in connection with differing remotes in the wheelchair Rectification of operational faults is dependent on the electronic module fitted The electronic modules used are described in chapter 4 2 Note The tables for rectification of operational faults listed in the following chapters
24. and spacers A 7 mm Screw length Note When installing the plates pay attention to the right screw length A 7 mm Longer screws can damage the batteries e Remove the legrests e Jack up the wheelchair using several wooden blocks Use proper lifting techniques e Calculate the required screw length in accordance with the above formula e Select five M8 Allen key countersunk screws in accordance with DIN 7991 material quality at least 8 8 to suit the calculated length e Fit the spacers 3 and the safety plate 2 over the drillholes e Fit the Allen screws 1 with a high strength screw blocker system such as Loctite 270 e Fit the remaining parts in the reverse order e To conclude check all fittings for secure connection Dismatling the DAHL docking station e Dismantle the remaining parts in the reverse order Further accessories Note The installation instructions for additional accessories are available at your Invacare specialist supplier or directly from Invacare Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 10 Adjusting the seating position In order to adapt the mobility device optimally to the requirements of the user we recommend that you ask your authorised Invacare the dealer toadjust the seat depth individually Adapting the seat to the user s seating position depends on which seat has been fitted and should be carried out
25. any wheelchair components such as adjusting motors actuators or motors to the electronic modules you should first ensure that you know exactly which electronic module has been fitted Please refer to the following table for an overview ACS2 REM 24 ACS2 PMA90L REMA REM B REM 550 ACS2 ACT actuator The actuator module module is optional Shark 2 remote Shark with lighting The lighting PCB is PCB optional ACT actuator The actuator module module is optional Lighting PCB The lighting PCB is optional 17 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series G Trac sensor The G Trac sensor is optional Operating hours counter The operating hours counter is optional Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 4 2 1 ACS2 electronic module Connections Battery 24V Bus cable to remote or ACT ee 3 ja 2 3 Bus cable to remote or ACT oa ff 4 Motor M1 i Fi S Fy z 5 Light i 6 Motor M2 t b Rubber stoppers for free slots sN r i 2 amp 3 Order number 1552876 FFE gt S Faj H r mi 4 2 2 ACS2 PMA9OL electronic module Connections Battery 24V Cable to G Trac sensor GYRO Bus cable to remote or ACT 1 2 Ty Z T z 3 ii alia lt N 4 Motor M1 i Q Q E g pa E g ra 5 Light ASA j 6 i Motor M2 sS 6 oo 4 2 3 Shark electronic module 4 2 3 1 4 2 4 Shark with DCI 12 pol
26. axle easier e Tighten the nuts 4 to 60 Nm 103 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 11 8 11 1 A 104 Rear wheel suspension Removing the rear wheel suspension WARNING Danger of crushing The mobility device is very heavy Injury hazard to hands and feet e Use proper lifting techniques 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 Requirements 5 16 Allen key 5 32 Allen key Phillips screwdriver size 2 torque wrench 0 20 Nm or similar torque wrench 20 80 Nm or similar oblique pliers cable ties e two long wooden blocks min 14 x 14 x 30 cm e Lift the wheelchair up on one side and place a 14 cm high wooden block under the battery case so that the wheels are off the ground and can rotate freely Use proper lifting techniques e Repeat the same procedure on the other side of the wheelchair e Remove the rear panel as described in chapter 8 1 2 e Ensure you note the cable routing carefully If necessary take photos with a digital camera e Remove all cables and cable ties which are fixed to the wheel suspension or which could get in the way during work Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL e Undo the two bolts 3 with a 5 32 Allen key and remove the bolts including the
27. drive program may only be carried out by trained Invacare specialist dealers e Invacare can only give a warranty for safe wheelchair driving behaviour especially tipping stability for unaltered standard drive programs Note All electronic modules are delivered 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 Requirements e 5 16 Allen key e Phillips screwdriver size 2 e socket spanner 8 mm e To adapt the drive program programming software or hand programming device and system installation manual available from Invacare Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL Removing the electronic module e Remove the rear panel as described in chapter 8 1 2 e Carefully note the location of the cable and the connection locations of the various plugs Either mark each plug and socket or take a photograph with a digital camera e On the illustration you can see the battery plug 1 the optional lighting PCB 2 for the electronic module 3 and the optional actuator module 5 e You can also see the optional cross connector between the rear wheel suspension 4 2 i r o ANN fo 1 Y lt 0 a gt NS eJ e Dismantle the cross connector if fitted Undo and remove the four Allen screws 1 with a 5 16 Allen key e Remove the cross con
28. due to collisions of the legrests with other parts of the wheelchair e Set the legrests to the smallest angle before adjusting the seat center of gravity e Pay attention with adjusting the seat center of gravity that the legrests do not touch any other parts of the wheelchair This ensures that the legrests can not collide with other parts of the wheelchair 206 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 10 2 1 Standard seat Depending on the seat that is installed you can attach the seat at different points on the seat frame and thus set the seat depth 10 2 2 Modulite seat The Modulite seat is available in two versions e Adjustable seats plate and strap Adjustment of the center of gravity via the lateral profiles as described in chapter 10 2 2 1 e Simple seat Adjustment of the center of gravity via the oblong holes of the seat adaptor TDX SP TDX SP chapter 10 2 2 2 TDX SP2 TDX SP2 chapter 10 2 2 3 10 2 2 1 Adjustable seats 4 Requirements ale e 6mm Allen key Remove the seat plate or sling seat 1 see chapter 8 22 1 Loosen the socket head screws 2 in the front and rear left and right DO NOT remove Shift the position of the seat Re tighten the screws e Install the seat plate or the sling seat again 207 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 10 2 2 2 Simple seat TDX SP TDX SP wW Requirements ELS e 6mm Allen ke
29. in the following sequence 1 Adjusting the lower leg length and seat depth see chapter 10 1 2 Adjusting the center of gravity of the seat frame see chapter 10 2 3 Checking that the swivel castors can move freely 4 Repetition of steps 2 to 3 if necessary WARNING Danger of injury hazard after tilting of mobility caused by blocked steering wheels Always check the seat depth settings for both forward and reverse movement Make sure that steering wheels can rotate freely and have not contact to any fixed mobility device component CAUTION 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 wheelchairs 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 WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet Pay attention to the hand and feet Use proper lifting techniques 203 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 10 1 Adjusting the lower leg length and seat depth 10 1 1 Adjusting the lower leg length Invacare offers a range of legrests which can be adjusted individually See operation manual 10 1 2 Adjusting the seat depth 204
30. mobility device must be completely switched off before removal of voltage carrying components To do this remove the batteries e Avoid short circuiting the contacts when carrying out measurements on voltage carrying components Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL A A CAUTION Danger of burns from hot surfaces on the motor e 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 e Use only undamaged tools in good condition e Some moving parts are mounted in sockets with PTFE coating Teflon Never grease these sockets Never use normal nuts instead of self locking nuts Always use correctly dimensioned washers and spacers When reassembling always replace any cable ties which were cut during dismantling After completing your work before renewed start up of the mobility device check all connections for tight fitting e After completing your work before renewed start up of the mobility device check all parts for correct locking e Only operate the vehicle with the approved tyre pressures see technical data e Check all electrical components for correct function Please note that incorrect polarity can result in damage to the electronics e Always carry out a trial run at the end of your work CAUTION Danger of injury and damage to property if the maxim
31. module 55 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 4 56 Wd 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 This also applies to the customer specific options of the seat setting for ACS2 remotes which are activated ex works WARNING Every alteration to the drive program can influence vehicle handling and the tipping stability of the wheelchair Alterations to the drive program must only be carried out by trained Invacare dealers Invacare 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
32. nylon washer 2 e Undo and remove the two bolts 4 with a 5 16 Allen key and remove the bolts including the bushes 5 If only one of the two bolts can be removed proceed as described in chapter 8 11 2 as an alternative e Take the complete rear wheel suspension off e Now you can replace individual parts such as the suspension arms 1 or the pivot bar 4 e Please see chapter 8 11 3 to replace the wheel suspension at a later time 105 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 11 2 Removing the rear wheel suspension alternative method wW Requirements Aai e more wooden blocks or e joiner s clamps e Carry out the following steps if only one of the two bolts 4 can be undone e Ensure that the rear springs are compressed Block method e Raise the suspension arms and replace the wooden blocks underneath them until the springs are compressed Clamp method e Lower the suspension arms downwards as far as possible e Remove the rubber caps 9 e Press the springs together with a joiner s clamp or similar clamp 106 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL e Remove the pivot bar 4 by putting it sideways out of the guides together with the remaining bolt and the socket e Please see chapter 8 11 4 to replace the wheel suspension at a later time 107 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 11 3 Refitting the rear wheel suspensi
33. of the seat frame rita e Completely remove both knurled head screws 1 including the washers e Remove the cover 2 e Pull the plug of the legrest actuator out of the actuator module 177 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series e Use the 6 mm Allen key to loosen and remove the two hexagon socket head screws 2 on both sides of the wheelchair e Completely remove both hexagon socket head screws including the washers e Pull the entire legrest forwards out of the seat e Loosen both hexagon socket head screws which attach the adapter brackets 1 to the legrest e Remove both adapter brackets Installing the electrically operated legrest e Assemble the parts in reverse order e Test all functions of the wheelchair 178 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 23 3 Replacing the electrically operated centre mounted legrest LNX Modulite seat A WARNING Danger of crushing The legrest is very heavy Danger of injury to hands and feet Pay attention to the heavy weight wW Requirements dai e 4mm Allen key e 10mm ring spanner or jaw spanner Uninstalling the electrically operated centre mounted legrest LNX e f possible raise the lifter to the highest position e f possible tip the wheelchair with the tilt module as far backwards as it will go e Switch the electronic control system off e Pull the plug of the legrest actuator out of the actua
34. on battery charger POSSIBLE CAUSE Charging device not connected to mains supply SOLUTION Ensure that the battery charger has been plugged in No mains supply Check the mains supply with a voltmeter Defective mains supply cable Check the mains supply cable Replace damaged cables or send the battery charger to Invacare Service for repair LEDs are burnt out Send the battery charger to Invacare Service for repair An internal fuse might be burnt out Send the battery charger to Invacare Service for repair Batteries do not charge Fuse on wheelchair has burnt out Check wheelchair fuses See chapter 8 5 5 8 5 6 Battery charger not connected to wheelchair Ensure that the battery charger has been connected to the wheelchair No mains supply Check the mains supply with a voltmeter Defective mains supply cable Battery charger could be defective Check the mains supply cable Replace damaged cables or send the battery charger to Invacare Service for repair Use a battery charger which you know is working properly to charge the batteries Send the defective battery charger to Invacare Service for repair Battery voltage is too low to operate wheelchair Replace the batteries See chapter 8 5 2 8 5 3 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 7 Test procedures 7 1 Testing the motor wW Requiremen
35. or inner tube types e Pneumatic tyres have black valve caps e Puncture protected tyres have red valve caps e puncture proof tyres have no valves Please proceed in accordance with the appropriate chapter e Replacing pneumatic tyres see chapter 8 10 2 1 e Replacing puncture protected tyres see chapter 8 10 2 2 e Replacing puncture proof tyres see chapter 8 10 2 3 8 10 2 1 Replacing pneumatic tyres Note GD Pneumatic tyres have black valve caps Puncture protected tyres have red valve caps wW Requirements 7 8 Allen key two long wooden blocks min 14 x 14 x 30 cm torque wrench 5 25 Nm or similar Repair kit for tyre repair or a new inner tube Tyre pump or compressor Talcum powder 97 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series A 98 Removing the tyres e Remove the wheel as described in chapter 8 10 1 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 Remove the valve cover 4 e Press the release pin in the valve inwards and evacuate all the air from the tyre e Loosen the five 7 8 Allen screws 2 on the inside of the wheel e Remove the inside 3 and outside ring 1 on the wheel rim from the tyres 5 e Replace any defective or worn parts
36. puncture protection gel cannot enter the valve e Remove the valve cover 4 e Press the release pin in the valve inwards and evacuate all the air from the tyre e Undo the five 7 8 Allen screws 2 on the inside of the wheel e Remove the inner 3 and outer 1 ring of the rim from the tyre 5 e Replace any defective or worn parts 99 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 100 Refitting the tyres e Refit the tyres to the rim in the reverse sequence Note If the old inner tube is to be repaired and re used and has become wet during repair you can make replacement easier by sprinkling the inner tube with a little talcum powder e When fitting the rim rings together ensure that the drillholes and threads for the bolts are placed exactly above each other e Tighten the Allen screws 2 to 18 Nm e Inflate the inner tube to the specified air pressure Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 10 2 3 Replacing puncture proof tyres wW Requirements Iv e 7 8 Allen key e Two long wooden blocks min 14 x 14 x 30 cm e Three joiner s clamps with plastic caps e Torque spanner 5 25 Nm or similar Talcum powder Removing the tyres Remove the wheel as described in chapter 8 10 1 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 secure the rim rings
37. socket spanner 13 mm Removing the rear light e Remove the rear panel as described in chapter 8 2 2 e Carefully note the location of the cable and the connection locations of the various plugs Either mark each plug and socket or take a photograph with a digital camera e On the illustration you can see the battery plug 1 the lighting PCB 2 for the electronic module 3 the optional cross connector 4 and the optional actuator module 5 e Loosen the cable leading to the lighting PCB from the rear light affected e Remove all cable ties and pull the cable out of the wheelchair e Loosen the butterfly nut 2 The plastic housing is held by a butterfly nut which is undone from below e Remove the plastic cover 1 87 88 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series e Open the connector plug 3 for the rear light which needs to be replaced e The rear lights are only clamped in by the plastic housing If required replace the red rear light 2 or the indicator 1 The cables are labelled appropriately Dismantling the rear light e Refit the parts in reverse order e Tighten all the screws finger tight again e Check all vehicle functions Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 8 13 Replacing the rear bulbholder conventional lighting system until 08 2014 wW Requirements IV e Phillips screwdriver size 2 e socket spanner 8 mm e socket span
38. socket wrench to loosen the battery terminal screw 3 Remove the battery terminal screw together with both washers and the cable lug 5 from the battery terminal 4 Negative terminal Repeat the steps of the procedure for the positive terminal on the negative terminal of the battery Replace the batteries and or the battery cables Installing batteries battery cables Assemble the parts in reverse order Connect the negative terminal first then the positive terminal Make sure the battery box sockets and plugs are correctly installed A schematic showing the correct positions can be found in the battery box cover Carefully reposition the battery terminal caps and secure them with a cable tie to prevent them from possibly slipping out of place Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 5 4 Correct handling of damaged batteries A 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 immediatel
39. the rear cover panel Refit the parts in reverse order Now tighten all the screws finger tight again Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 1 3 Opening the top cover panel wW Requirements aed e Phillips screwdriver size 2 Dismantling the top cover panel e Remove the seat e Undo the four Phillips screws 3 on the top cover panel 2 e Remove the top cover panel Refitting the top cover panel e Refit the parts in reverse order e Now tighten all the screws finger tight again 39 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 1 4 Replacing the splash guard 40 W Requirements 5 6 Allen key 7 8 Allen key two long wooden blocks min 14 x 14 x 30 cm torque wrench 0 20 Nm or similar torque wrench 5 25 Nm or similar Removing the splash guard Remove the drive wheel as described in chapter 8 10 1 Undo and remove the three 5 6 Allen screws 1 Remove the splash guard 2 from the walking beam 3 Refitting the splash guard Refit the parts in reverse order Tighten the splash guard screws to 4 5 Nm Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 2 Covers TDX SP2 TDX SP2 8 2 1 Opening the front panel wW Requirements wy e 6mm Allen key Note ij If the front cover panel is fitted with tommy bolts and not with Allen screws you do not require any tools Dismantling the f
40. used for programming necessary programming cables see the user manual of the Wizard software Note When an electrical adjustment option is retrofitted such as electrical legrests then this option needs to be activated in the driving program as well if you have an ACS2 remote For more information refer to the user manual of the Wizard software and the installation instructions for the electronic modules Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 5 8 5 1 A gt Gore p gt Batteries cables amp battery charger Making the batteries accessible 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 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 WARNING BURN HAZA
41. vehicle and go for a test drive 167 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 21 Backrest Modulite 8 21 1 Replacing the standard backrest 4 Requirements aed e 5mm Allen key Dismantling the backrest unit e Remove the backrest cushion e Loosen the fixation lever 2 of the backrest tube e Remove the backrest tube Use the Allen key to loosen and remove the hexagon socket head screws 3 including the nuts and washers on the left and right side of the chair Refitting the backrest unit e Replace the parts in the reverse order e To conclude you should always carry out a trial run to test the vehicle functions 168 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 21 2 Replacing the backrest mounting bracket wW Requirements IU e 5mm Allen key Dismantling the backrest unit e Remove the backrest cushion e Loosen the fixation levers 2 of the corresponding backrest tube 1 depending on the version There are two versions 2 for the manual backrest 3 for the electrically adjustable backrest e Remove the backrest tube e Loosen and remove the two hexagon socket head screws 4 to the sliding block 5 on the left and right side of the chair Refitting the backrest unit e Replace the parts in the reverse order e To conclude you should always carry out a trial run to test the vehicle functions 169 SERVICE MANUAL
42. 1 2 amp 3 Order number 1552876 4 to 7 Order number 1555700 The ACI connection is used for actuator limitation or speed reduction Lighting PCB The lighting PCB connections are printed directly on the circuit board Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 5 Service plan 1x annually A CAUTION Danger of injury and damage to property if the maximum speed reduction on a wheelchair with a lifter does not function correctly The wheelchair s control unit must reduce the maximum possible speed as soon as the lifter is raised e Test the maximum speed reduction for correct function after any maintenance work or modifications to the wheelchair Component Check Remedy Notes P Safety belt Damage to safety belt Replace belt if See chapter 9 1 damaged Belt lock function Replace belt if See chapter 9 1 damaged Armrests Damage to armrests Replace covering if damaged Armrest fixings Tighten screws Side panels Damage to side panels Replace side panels damaged Side panel fixings Tighten screws Seat angle Tight seating of SL Replace SL fuses if adjustment fuses necessary Power backrest Damage to backrest Replace parts if if fitted Seams damaged Fixing Tighten screws Check cable Replace cable motor if necessary Check function Frames Check fixings welded Tighten screws chassis seams and battery Replace components battery mounting if necessary mounting DA
43. 14 89 8 8 14 Replacing the rear bulbholder conventional lighting system until 08 2014 90 8 8 15 Replacing the rear bulbholder TDX SP2 conventional lighting system 06 91 Wheel forks Tromtrean coccinea cscce cetacean OSANA EANA RANAR SAAE aes Se guscoseaauceesee 92 8 9 1 Replacing the wheel fOrkK eccccceeecccceeeeeceeeeeeeceeeeeeaeeeeseaaeeeseaeeeeneeaeeeseseaeeeeneeaeeneees 92 8 9 2 lt Adjusting the wheeltork res cry reier akenei aTa a ouen E REAR NAE TANT AE BAEAN SEERNES 94 8 9 3 Replacing the wheels on double sided wheel forks cc cseeseececeeeeeeeeeeneeeeeeeeeeeees 95 Drive Wheels a iaeia anere AAAA EEE EAE NETERA aAA N AARE ENEE EESAN EREE A AAAS 96 8 10 1 Replacing the drive Wheel 00 0 cecccceeecceceeeeeceeeeeeeceeeeseeeeeesseaeeeseseeeeeeeaaeeeseseaeeeeneeaeenees 96 8 10 2 Replacing the tyre or inner tube o oo ee ce ceeecceeeeeceeeeeeeceeeeeeeaeeeeseaeeeeneeaeensneeaeeeeneeaeeeeees 97 8 10 2 1 Replacing PNEUMATIC LYS 2 eee cece cence eeeeteeeeeeeaeeeeeeaaeeeeeeaaeeeeesaeeeeeeaeeeeeeaeeeeees 97 8 10 2 2 Replacing puncture protected tyres eee eeceeeceeeeeeeceeeeeeeeeeeeaeeeeeeaaeeeeeeaeeeeeenaeeeeees 99 8 10 2 3 Replacing puncture proof tyreS ec eeeeeceeeeeeeeeeeeeeeeeeeseeeeeeeseeeeeeseeeeeeeseneaeeeeeeeaees 101 8 10 3 Replacing the drive wheel hub Standard MOtor ccccccceceeceeseeseeeeeseeeeeneeeeeeeeeees 102 8 10 4 Replacing the drive
44. 4 socket spanner 5 16 socket spanner torque wrench 0 20 Nm or similar torque wrench 5 25 Nm or similar torque wrench 10 80 Nm or similar two long wooden blocks min 14 x 14 x 30 cm Removing the motor transmission clutch e Remove the motor transmission unit as described in chapter 8 15 1 e Loosen the two Allen screws 1 with a 6 mm Allen key and remove them including the washers 2 A WARNING Material damage hazard if the coupling is improperly handled e Please proceed carefully so that you do not damage the motor gearbox coupling e Pull the motor 3 and transmission unit 4 carefully apart e Remove the clutch individual parts 5 e Replace the clutch if necessary 126 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL Refitting the motor transmission clutch e Place the new clutch 2 on the motor axle 3 Note the position of the groove e Push the motor carefully into the transmission Observe the position of the groove in the transmission axle 4 If necessary rotate the transmission axle into the right position e Refit the two M6 Allen screws 1 including washers 2 Tighten the Allen screws to 8 5 Nm e Refit the motor transmission unit as described in chapter 8 15 1 127 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 15 5 Replacing the motor transmission clutch SSD Motor A 128 CAUTION Danger of crushing The motor
45. 47 42 12 24 F 37230 Fondettes contactfr invacare com France WWW www invacare fr Invacare Ltd GB nab Pencoed Technology Park Customer services 44 0 1656 77 62 22 Fax Customer services 44 0 1656 77 62 20 Pencoed uk invacare com Bridgend CF35 5HZ WWW www invacare co uk United Kingdom CID Invacare Mecc San s r l 39 0445 38 00 59 Via dei Pini 62 Fax 39 0445 38 00 34 36016 Thiene VI italia invacare com Italia WWW www invacare it Invacare TDX SP Series TDX SP2 Series D Invacare Ireland Ltd Unit 5 Seatown Business Campus Seatown Rd Swords County Dublin Ireland Fax WWW 353 18 10 70 84 353 18 10 70 85 ireland invacare com www invacare ie SERVICE MANUAL ND Invacare AS Grensesvingen 9 Kundeservice Fax Kundeservice 47 0 22 57 95 00 47 0 22 57 95 01 Postboks 6230 norway invacare com Etterstad island invacare com N 0603 Oslo WWW www invacare no Norge NL Invacare B V ss 31 0 318 69 57 57 Celsiusstraat 46 Fax 31 0 318 69 57 58 NL 6716 BZ Ede nederland invacare com Nederland csede invacare com WWW www invacare nl CP Invacare Lda 351 225 10 59 46 i Rua Estrada Velha 949 3 351 225 10 59 47 P 4465 784 Le a do Balio Fax 351 225 10 57 39 Portugal portugal invacare com WWW www invacare pt terf rs ljare Invacare AB Kundtj nst Fax Kundtj nst 46 0 8 761 70 90 4
46. 5 Service plan 1x annually 21 6 Operational faults 24 6 1 Drive fault diagnosis ssnseeunnnenuunnennnnnennnnnennnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnn nnmnnn nnmnnn nnmnnn nnmnnn nnmnnn nnn nana 25 6 2 REM remotes Error codes and diagnostic codes cccssecceceseeeeeeeeneeseeeeneeeeeennenseeenneeseeeenes 29 6 3 Shark 2 remote Error codes and diagnostic codes ssssssusssunennnnnunnnnnnnnnnnnnnnnnnnnnnnnnnnn nnna 31 6 4 Diagnosis of charging device faults cccceceeeceeeeeeeeeeeeeeeseeeeeeeseeesneesesesneeseeeseeseeeseaeeeeeenes 32 7 Test procedures 33 7 1 Testing the MOOV ascisiniee iisas eaa Nara an aA aa RATAA AEE AAAA RARE aA SAAE ARREA 33 7 2 Testing the electro mechanical parking brake ccssseeccsseeeeeeeseeeeeenseeneeenseeneeeeseenenenseeeenes 34 8 Repair work 36 8 1 Covers TDX SP TDX SPR secca hers aa rete er cee te 36 8 1 1 Opening the front panel c ccceccccceeeeeeececeeeeeeaeeeeaaeceeneeceaeeecaaeeseaaeseeeessaeeesaeeeeneeenaees 36 8 1 2 Opening the rear Cover panel cceeceeseeceeeeeceeeeeeeaeceeeeeceeeeeeaaeeeeaeeseeeeeseaeeesaeeeeneeenaees 37 8 1 2 1 Rear cover without an operating hours COUNTEL ec cceeeeeeeeeeeenneeeeeeaeeeeeeaaeeeeeeaas 37 8 1 2 2 Rear cover with an operating hours Counter 20 cee eeteeeeeeneeeeeeenaeeeeeeaaeeeeeeaaeeeeeeaas 38 8 1 3 Opening the top Cover Panel cccceceesceceeeeceeeeeeaeceeeeeceaeeeeaaeeeeaeeseeeeeseaeeesaeeeeneeenaees 39 8 1 4 Rep
47. 6 0 8 761 81 08 FIN Fagerstagatan 9 sweden invacare com S 163 91 Spanga finland invacare com Sverige WWW www invacare se Tillverkare M LNDAL Invacare Deutschland GmbH 46 0 31 86 36 00 Kleiststra e 49 Fax 46 0 31 86 36 06 D 32457 Porta Westfalica ginvacare invacare com Deutschland LANDSKRONA 46 0 418 2 85 40 Fax 46 0 418 1 80 89 linvacare invacare com OSKARSHAMN 4 46 0 491 1 01 40 Fax 46 0 491 101 80 oinvacare invacare com Eastern European Distributor 49 0 5731 75 45 40 european Organisation EDO Fax 49 0 5731 75 45 41 countries KieiststraBe 49 edo invacare com D 32457 Porta Westfalica WWW www invacare de Deutschland SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series Contents Chapter Page 1 introduction 8 1 1 General information aea aeaa a r a aa aaa aar aa ae E aaa aa a araa ea aED araa Sa a aeda raaa aea naaa daan daiis 8 1 2 Notes o iranspOri seeiis rrkennnek eranen nep eonan nran andes tetennereeuees tecqeeeeerceendseseeteneersueechisteivenes 8 1 3 Definition and representation of information and safety information in this manual 9 1 4 Hazard symbols and symbols USC ccceecceceeeeeeeeeeeeeseeeeneeseeesneeseeesneeseeeeneeseeesneesesesneseeeenes 10 1 5 IMAGES in this manual 0 eee eeeeeeee cece eee ee eeeeee seen enee see enee seer enee see neeeseeeeneeseeesneeseeesneeseeseneeseeeenes 11 2 Safety and fitting instructions 12 2 1 Before any ins
48. 8 Remove the electronic module as described in chapter 8 3 2 Remove the bottom walking beams as described in chapter 8 13 Remove the top walking beams as described in chapter 8 14 Remove the gas cylinder as described in chapter 8 24 1 Remove rear wheel suspension as described in chapter 8 11 Remove the front and rear bulbholders depending on version as in chapter 8 8 Remove the rubber bumper as described in chapter 8 16 Replace the battery case Refitting the battery case Refit the rubber bumper as described in chapter 8 16 Refit the front and rear bulbholders depending on version as in chapter 8 8 Refit rear wheel suspension as described in chapter 8 11 3 Refit the gas cylinder as described in chapter 8 24 3 Refit the top walking beams as described in chapter 8 14 2 Refit the bottom walking beams as described in chapter 8 13 Refit the electronic module as described in chapter 8 3 2 Refit the front and rear lights including bracket depending on version as in chapter 8 8 Refit the battery support as described in chapter 8 6 Replace the batteries in their correct location as described in chapters 8 5 2 8 5 3 and 8 5 1 Refit the the covers as described in chapter 8 1 or 8 2 Refit the seat including seat support as described in chapter 8 18 and 8 20 Modulite Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL e Adjust the setting screw on the stability lock system as described in chapter 8 24 5 e
49. HL Docking Check screws Tighten screws Station Stability lock Check gas cylinder Repair or replace if See chapter 8 24 system damaged Replace gas cylinder every 2 years Check adjustment See chapter 8 24 5 21 SERVICE MANUAL Component Wheel suspension and wheels Invacare TDX SP Series TDX SP2 Series Check Check drive wheels for tight fit and side play Adjust replace wheel hubs See chapters 8 10 1 and Check steering wheels 8 10 3 8 10 4 Replace wheels wheel fork or wheel See chapter 8 9 bearings Repair or replace if See chapter 8 10 2 damaged Check suspension Repair or replace if See chapter 8 12 damaged Check straight running Replace wheels See chapter 8 9 wheel fork or wheel bearings for tight fit float and side play Tyres Drive units clutch mechanism Legrests Power legrests if fitted Motors Check motors See chapter 7 Check functions in drive Check carbon and push modes brushes replace if Check clutch necessary mechanism Replace motor if necessary Tighten screws nuts adjust or replace if necessary See chapter 8 15 Check welded seams interlocking screws footplates Check cable Check contacts check functions Tighten replace if necessary Replace cable if necessary Lighting if Check cable Replace lamp or See chapter 8 8 fitted Check function cable if necessary Battery mounting 22 Check battery support
50. If this does not rectify the fault determine the cause using the blink codes from the following table BLINK CODE POSSIBLE CAUSE SOLUTION DOCUMENTATION 1 x blink Module defective Replace defective module See chapter 8 3 2 2 x blink Accessory error e g short Check accessory See chapter 8 5 7 circuit in adjusting motor connections check accessory Lifter too high or too low If the lifter is raised lower it See operating manual seat not at driving height slowly until the status display stops blinking If the lifter is too low raise it slowly until the status display stops blinking Only drive when the seat is at driving height 3 x blink Fault on left hand motor Check connection plug See chapters 8 5 7 M2 Connection check motor and 7 1 loose defective or motor defective 4 x blink Fault on right hand motor Check connection plug See chapters 8 5 7 M1 Connection check motor and 7 1 loose defective or motor defective 5 x blink Fault brake fault on left Check connection plug See chapters 8 5 7 hand motor M2 check motor and 7 1 Connection loose defective or motor defective 6 x blink Fault brake fault on right Check connection plug See chapters 8 5 7 hand motor M19 check motor and 7 1 Connection loose defective or motor defective 7 x blink Completely discharge Pre charge battery See operating manual battery 8 x blink Battery voltag
51. Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL Edition 1532486 Vers 011 06 10 2014 SERVICE MANUAL These instructions contain information about Testing work Repair Instructions This manual is part of the instructions for use Service addresses Invacare TDX SP Series TDX SP2 Series CA Invacare Austria GmbH 43 6232 5 53 50 Herzog Odilostrasse 101 Fax 43 6232 5 53 54 A 5310 Mondsee info invacare austria com Austria WWW www invacare at CB Invacare n v 2 32 0 50 83 10 10 Autobaan 22 Fax 32 0 50 83 10 11 CED B 8210 Loppem Brugge belgium invacare com Belgium WWW www invacare be CH Invacare AG 41 0 61487 70 80 BenkenstraBe 260 Fax 41 0 61487 70 81 CH 4108 Witterswil switzerland invacare com Switzerland WWW www invacare ch D Invacare Aquatec GmbH 49 0 7562 70 00 Alemannenstra e 10 Fax 49 0 7562 7 00 66 88316 Isny info invacare aquatec com Deutschland WWW www invacare aquatec de ni Invacare A S Sdr Ringvej 37 Kundeservice Fax Kundeservice 45 0 36 90 00 00 45 0 36 90 00 01 DK 2605 Br ndby denmark invacare com Danmark www www invacare dk CE Invacare SA 34 0 972 49 32 00 c Areny s n Fax 34 0 972 49 32 20 Pol gon Industrial de Celr contactsp invacare com E 17460 Celra Girona www www invacare es ESPANA CF Invacare Poirier SAS 33 0 247 62 64 66 Route de St Roch Fax 33 0 2
52. MANUAL e Remove the two knurled screws 1 including washers e Remove the cover 2 e Pull the plug out of the actuator module e Open the cable holder on the underside of the seat e Uncover the actuator cable so that you can pull it out of the lifter module later on together with the actuator A WARNING Danger of crushing The seat is very heavy Injury hazard to hands if the seat is unintentionally folded down e Use proper lifting techniques e Ensure that the seat is properly secured against unintentional folding or falling down before you start removing the actuator If you are unable to secure the seat you must remove it completely If you are working on a combined lifter tilt module the lifter actuator is located in the lower section of the module 2 e Remove the retaining ring 1 with the retaining ring pliers e Push the bolts 4 out of the guides When removing the front bolts take care with the bushes 3 e Remove the actuator from the lifter module Refitting the lifter actuator e Refit all parts in the reverse sequence e Carry out a performance test 151 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 18 4 2 Method 2 Removing the lifter actuator when the lifter is lowered 152 WARNING Danger of crushing The seat is very heavy Injury hazard to hands and feet Use proper lifting techniques Requirements retaining ring pliers oblique pliers cable
53. RD 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 Phillips screwdriver size 2 e 5 8 Allen key e socket spanner 11 mm Note When disassembling take care of small parts such as screws and washers Put all small parts down so that they can be reassembled in the right sequence 57 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 58 Remove the legrests TDX SP TDX SP Remove the front 4 and rear 1 cover panels as described in the chapters 8 1 1 and 8 1 2 TDX SP2 TDX SP2 Remove the front 4 and rear 1 cover panels as described in the chapters 8 2 1 und 8 2 2 Disconnect the battery plugs 2 Pull the battery carrier forwards as far as the stop Only on the TDX SP TDX SP2 Disconnect the plug in connection between the batteries before removing them Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 5 2 A Replacing batteri
54. Trac sensor 1 Disconnect the cable of the G Trac sensor from the electronic module Replace the G Trac sensor Installing the G Trac sensor Install the G Trac sensor in reverse order Re connect the cable connector to the electronic module The G Trac sensor must be installed with the cable pointing upwards Test all functions of the vehicle Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 3 4 Replacing the operating hours counter connecting cable wW Requirements i e 10 mm socket wrench of The operating hours counter is located on the rear cover 2 Removing the operating hours counter e Switch the electronic system of the wheelchair off e Remove the rear cover as described in chapter 8 1 2 2 or 8 2 2 2 e Loosen and remove the nut 5 including the locking washer 4 using a 10 mm socket wrench e Pull the mounting bracket 2 off of the threaded rod 3 e Remove the retaining frame 6 e Pull the operating hours counter forwards out of the rear cover e Disconnect the two plugs of the cable not shown in the illustration from the pins amp e Replace the operating hours counter and cable respectively 51 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series Installing an operating hours counter A CAUTION Property damage can result if the counter is wrongly connected If the plus and minus wires are connected the wrong way it will damage the electron
55. X Modulite seat 181 8 23 4 Replacing an electric legrest actuator oe cece ee eeeeeeeeeeeeeeeeteeeeeeeteeeeeeeseneaeeeeeneaees 182 8 23 5 Replacing an electric legrest ACtUALON oe ee ceceeeeeeeeeee ee eeeeeeeeeeeeeeeeseeeeeeeeeeeeeeeeeeaees 184 8 23 6 Replacing the calf plate on the centre mounted legrest electric amp manual 186 8 23 7 Replacing the foot plate on the centre mounted legrest electric amp manual 189 Stability lock System si sicccccsscic a Teer p rae reee a aa akae eaaa E rao era EEr aa aaa aaae eaaa iE 192 8 24 1 Removing the gas Cylinder eee eceeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeaeeeeeseaeeeeeseneeeeeseneaeeeeeeeaees 192 8 24 2 Repairing the gas Cylinder eee ceceeeeeeeeeeeeeeeeeeeeeeeeeeeeesaeeeeeeaeeeeeseeeeeeseeeaeeeeeeaaees 195 8 24 2 1 Replacing the guide block fixing or Clamping support eee eeeeeeeeeeeeeeeeteeeeees 195 8 24 2 2 Replacing the guide DUSN ee eeeeeeeeeeeeeeeeeneeeeeeeeeeeeesaeeeeesaeeeeeseeeeeeeseneeeeeeeeeaees 196 8 24 2 3 Replacing the gas Cylinder eee eceeeceeeeeeeeeeeeeeeeeneeeeesaeeeeeeeeeeeeseeeeeeeeeeeaeeeeeaeees 196 8 24 3 Refitting the gas CylINer eee iari eee eeeeeeceeeeeeneeeeeeeeeeeeeeeeeesecaaeeeseeaeeeeeeseneeeeeneneees 197 8 24 4 Replacing the setting SCrOW ccceceseceeeseeeeeeeeeeeeeeeeeeeeeeeeaeeeseceaeeeseeaneeseeeeeaeeeeseneees 199 8 24 5 Adjusting the Setting SCrOW eecceceeeeeeeeeeeeeeeeeneeeeeeaeeeeesea
56. able binder Note Make a careful note of the seat settings Mark the fitting positions alignments etc and take photos with a digital camera if necessary Every change to the seat settings influences the centre of gravity of the mobility device If the seat settings are changed the stability lock system settings must be checked and readjusted if necessary as described in chapter 8 24 5 Removing the lifter tilt module e Run the lifter up to the top position if possible e f possible tilt the seat with the tilt module as far as possible to the rear e Switch the controller off e Remove the batteries as described in chapters 8 5 1 and 8 5 2 The actuator module for the lifter and the tilt actuators is fitted to the front edge of the seat support oe Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL Remove the two knurled screws 1 including washers Remove the cover 2 Pull the plug out of the actuator module Open the cable holder on the underside of the seat Uncover all the cables so that you can lift the seat up WARNING Danger of crushing The seat is very heavy Injury hazard to hands and feet Use proper lifting techniques Undo the four bolts 1 which connect the seat to the lifter tilt module using a 4 mm Allen key and a 13 mm open spanner Lift the seat off the lifter tilt module Use proper lifting techniques 145 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Se
57. 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 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 1 4 8 e amp FP RP P PB 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 standardised safety shoes during all work Wear eye protection This symbol refers to the requirement for wearing eye protection for example when working with bat
58. ade screwdriver and remove the caps e Pull the carbon brushes 4 a little out of the brush holder Note the fixing position and location of the carbon brushes Note If the carbon brushes were checked but not replaced you must know their exact fitting position Used carbon brushes need to the refitted exactly in the same position from which they were taken in order to guarantee optimum contact to the collector Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL gt 9 Make a marking on the motor and the carbon brushes in order to guarantee correct refitting Remove the carbon brushes complete from the mounting 2 Check the carbon brushes and springs for the level of wear broken components or discolouration Refitting the carbon brushes Depending on the condition of the brushes and the spring either replace the brushes in exactly the same position from which they were taken or fit new brushes Replace the plastic caps and tighten them Refit the top walking beams as described in chapter 8 14 2 Refit the bottom walking beams as described in chapter 8 13 Refit the drive wheels as described in chapter 8 10 1 Note The following procedure is necessary to run the carbon brushes in after replacement and to therefore guarantee maximum performance WARNING Risk of accidents Hazards to workers surroundings and mobility device Do not leave the mobility device unattended during the following procedure
59. air off for a few minutes the batteries can often charge themselves up enough to enable a short journey You should however only use this solution in emergency situations because it results in excessive battery discharging Replace batteries See chapter 8 5 2 3 Fault on left hand Check motor cable and connecting See chapters 8 5 7 motor M2 plug and 7 1 Check motor 4 Fault on right Check motor cable and connecting See chapters 8 5 7 hand motor M1 plug and 7 1 Check motor 5 Fault at left hand Check cable and plug See chapters 8 5 7 M2 motor brake and 7 2 6 Fault right hand Check cable and plug See chapters 8 5 7 M1 motor brake and 7 2 7 Error in Shark Check bus cable in remote and See chapter 8 3 1 remote connecting plug Replace remote 8 Error in Shark Check all the cables and plugs inthe See chapters 8 5 7 electronic Shark system and 8 3 2 module Replace electronic module 9 Communication Check all cables and connecting plugs See chapters 8 5 7 error in Shark in the Shark system and 8 3 1 system Replace remote 10 Unknown error Check all cables and connecting See chapter 8 5 7 plugs 11 Incompatible The wrong remote has been See chapters 8 3 1 remote connected Ensure that electronic and 8 3 2 module code and the remote code match 31 SERVICE MANUAL 6 4 32 Invacare TDX SP Series TDX SP2 Series Diagnosis of charging device faults SYMPTOM No LEDs illuminating
60. akes place in the reverse order Connect the actuator cable to the cable harness To complete check all seat tilting function 159 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 20 2 Replacing the lifter actuator 2 Requirements Ad e Screwdriver flat width 6 mm e Large screwdriver e Flat screwdriver e Remove legrests e Run the lifter up to if possible e Switch the electronics OFF on the remote e Secure the seat e Pull the plug from the actuator e Bottom fixing bolt 2 secured with snap rings Remove a snap ring using a screwdriver and remove the bolt e Top fixing bolt 3 with slot Loosen the fixing bolt with a screwdriver Remove the bolt e Replace actuator e Reassembly of the actuator takes place in the reverse order e Connect the plug of the actuator cable to the actuator e To complete check all seat tilting function If the lifter cannot be raised a cover can be removed from the upper rear side of the module This way it is possible to reach the lower fixation bolt of the actuator 160 Invacare TDX SP Series TDX SP2 Series 8 20 3 Replacing the lifter seat angle adjustment module Note Replacement of the seat angle adjustment module is performed in the same manner SERVICE MANUAL ATTENTION Danger of crushing The seat is very heavy Danger of injury to hands and feet Use proper lifting techniques Requirements
61. and the tilt module are very heavy Injury hazard to hands and feet e Use proper lifting techniques y A Requirements Phillips screwdriver size 2 1 2 socket spanner 13 32 socket spanner 5 32 Allen key oblique pliers cable ties Note ij Make sure you have noted the seat settings Mark the fitting positions alignment etc If necessary take photos with a digital camera Any changes to the seat settings influence the centre of gravity of the wheelchair If changes are made to the seat settings the stability lock system settings must be checked and readjusted if necessary as described in chapter 8 24 5 Removing the tilt module e Remove the legrests e Remove the seat cushion e Activate the tilt module to tilt the seat a little towards the rear e Remove the rear panel as described in chapter 8 1 2 136 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL e Pull the tilt module plug 1 out of the actuator module e Unclip the cable Remove any cable ties which are fitted e Undo the six nuts 1 with a 13 32 socket spanner and remove the six 5 32 Allen screws A WARNING Danger of crushing The seat and the tilt module are very heavy Injury hazard to hands and feet e Use proper lifting techniques e Lift the seat up off the tilt module Use proper lifting techniques e Loosen the four bolts 2 with a 1 2 socket spanner e Lift the tilt module off the seat support Use pr
62. are only an excerpt from the original manufacturer s manuals You can obtain the original manuals from Invacare If you have problems with the wheelchair please proceed as follows e First assess the possible cause of the problem using the following table e Check the remote status display Evaluate the error code e Carry out the necessary checks and repairs as recommended in the following table Invacare TDX SP Series TDX SP2 Series 6 1 Drive fault diagnosis PROBLEM Wheelchair will not start OTHER SYMPTOMS The remote status display illuminates normally and displays blink code 5 6 Remote status display does not illuminate Remote status display blinking POSSIBLE CAUSE Drive motors disengaged Batteries defective Completely discharge battery SERVICE MANUAL SOLUTION Engage drive motors Replace batteries Pre charge batteries DOCUMENTATION See operating manual See chapter 8 5 2 8 5 3 See operating manual Power supply to remote interrupted Check master fuse See chapter 8 5 5 8 5 6 Check cables between the modules for loose connections and damage See chapter 8 5 7 Remote defective Various causes Replace remote Assess error code See chapter 8 3 1 See chapter 6 2 and 6 3 None Wheelchair Batteries Replace batteries See chapter judders in defective 8 5 2 8 5 3 drive mode unstable voltage
63. axle of the gearbox If necessary rotate the motor and gearbox to the correct position e Insert the carriage bolt through the locking ring Do not forget the spacer sleeve 2 e Install the washer and the self locking nut e Do not tighten the self locking nut completely as the motor orientation must be adjusted during installation Install the motor gearbox unit as described in chapter 8 15 2 129 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 15 6 Replacing the carbon brushes SSD motor 130 Note Always replace all the carbon brushes on both motors WARNING Danger of crushing The mobility device is very heavy Injury hazard to hands and feet e Use proper lifting techniques Requirements 5 mm Allen key 6mm Allen key 10 mm socket spanner 19 mm socket spanner Screwdriver two long wooden blocks min 14 x 14 x 30 cm Removing the carbon brushes e Switch the wheelchair off e Remove the drive wheels as described in chapter 8 10 1 PS tk 7 BA RS A GY lt S J 3 Bas v n AW f ss Sa p ovar el 7 i F S BN VN a x KL Wik lt KIN 4 D x y A va as HES e Disengage the motor 1 by setting the engaging lever to Push Note In the case of the SSD motor you can unto the bolt 5 with a 10 mm socket spanner and then turn the motor around so that you can access the rear carbon brushes more easily e Undo all four plastic caps 3 with a bl
64. binder long nosed pliers angled 6 mm Allen key Note Make a careful note of the seat settings Mark the fitting positions alignments cable routing etc and take photos with a digital camera if necessary Every change to the seat settings influences the centre of gravity of the mobility device If the seat settings are changed the stability lock system settings must be checked and readjusted if necessary as described in chapter 8 24 5 Switch the controller off The actuator module for the lifter and the tilt actuators is fitted to the front edge of the seat support a Remove the two knurled screws 1 including washers Remove the cover 2 Pull the plug out of the actuator module Open the cable holder on the underside of the seat Uncover all the actuator cables so that you can remove the seat Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL e Undo and remove the seat support Allen screws 1 on the left hand and right hand side of the mobility device WARNING Danger of crushing The seat is very heavy Injury hazard to hands and feet e Use proper lifting techniques e Tilt the seat to the rear and push the rear holders 2 out of their guides e Remove the seat e Remove the retaining ring 1 with the retaining ring pliers e Push the bolts 4 out of the guide Take care with the bushes 3 153 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series e Fold th
65. cables Dismantling the main fuse e Remove the battery compartment cover disconnect the battery plugs and pull the batteries out of the battery compartment as described in chapter 8 5 1 e The fuseholder 1 is located on top of the batteries e Open the fuseholder cover 64 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 5 6 e You will be able to see the strip fuses 2 once the fuse holder 1 is open e Ifthe strip fuse has blown you must first ascertain and rectify the cause of the fault e The main fuse may only be replaced once the fault has been rectified e Remove the strip fuse nuts 3 with an 8 mm socket spanner e Replace the strip fuse Fitting the main fuse e Refit all the parts again in reverse order e To conclude check all the wheelchair functions Replacing the main fuse TDX SP TDX SP2 Note To replace the fuse the battery cable with the fuse attached to it must be replaced e Replace the battery cables as described in chapter 8 5 3 65 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 5 7 Checking the cable W iV 66 Requirements e 5 8 Allen key e Phillips screwdriver size 2 e oblique pliers e cable ties e Remove the cover panels disconnect the battery plugs and pull the batteries out of the battery compartment as described in chapter 8 5 1 e Check the fuse cable 1 battery cable 2 and the battery plug
66. ck system protective caps The protective caps on the stability lock system will either be held using a screw or a cable tie depending on the wheelchair s date of manufacture Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 13 Bottom walking beam 1A fj Y i 7 Requirements 5 8 Allen key 5 16 Allen key Phillips screwdriver size 2 1 2 socket spanner torque wrench 5 25 Nm or similar two long wooden blocks min 14 x 14 x 30 cm Removing the bottom walking beam e Remove the drive wheel as described in chapter 8 10 1 e Remove the front castor housing as described in chapter 8 17 e Remove the nut 4 with a 1 2 socket spanner e Remove the washer 1 e Pull the bottom walking beam 3 off the axle e Take the spacer 2 off the axle Refitting the bottom walking beam e Refit the parts in reverse order e Tighten the nuts 4 to 18 Nm 115 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 14 Top walking beam 8 14 1 Removing the top walking beam wW Requirements s e 5 8 Allen key 7 8 Allen key 5 16 Allen key Phillips screwdriver size 2 1 2 socket spanner 1 4 socket spanner torque wrench 5 25 Nm or similar two long wooden blocks min 14 x 14 x 30 cm e Remove the batteries as described in chapters 8 5 1 and 8 5 2 8 5 3 e Ensure you note the cable routing carefully If necessary take photos with a digital camera e Remove the dr
67. cket spanner 1 4 socket spanner 5 16 socket spanner torque wrench 0 25 Nm or similar torque wrench 10 80 Nm or similar two long wooden blocks min 14 x 14 x 30 cm a gt ee ate OFT Fa mM 4 iT Ro a A RY D DONY PRE i Ve N f A A Uninstalling the sealing ring e Uninstall the motor gearbox unit as described in chapter 8 15 2 e Use the 10 mm socket wrench to loosen and remove the self securing nuts 2 including the washers e Remove the carriage bolt 2 which secures the sealing ring 3 e Carefully bend the sealing ring apart and remove it 124 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL Installing the sealing ring e Install the sealing ring so that the square hole for the carriage bolt is on the inside of the wheelchair e Insert the carriage bolt through the sealing ring e Install the washer and the self locking nut Do not tighten the self locking nut completely as the motor orientation must be adjusted during installation 125 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 15 4 Replacing the motor transmission clutch Standard Motor A CAUTION Danger of crushing The motor gearbox unit is very heavy Danger of injury to the hands e Pay attention to the heavy weight wW Requirements 5 8 Allen key 7 8 Allen key 5 16 Allen key 6 mm Allen key Phillips screwdriver size 2 1 2 socket spanner 1
68. de of the seat e Uncover the actuator cable so that you can pull it out of the tilt module later on together with the actuator Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL A WARNING Danger of crushing The seat is very heavy Injury hazard to hands if the seat is unintentionally folded down e Use proper lifting techniques e Ensure that the seat is properly secured against unintentional folding down before you start removing the actuator If you are unable to secure the seat you must remove it completely If you are working on a combined lifter tilt module the tilt actuator is located in the upper section of the module e Remove the retaining ring 1 with the retaining ring pliers e Push the bolts 4 out of the guides When removing the front bolts take care with the bushes 3 e Remove the actuator from the tilt module Refitting the tilt actuator e Refit all parts in the reverse sequence e Carry out a performance test 149 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 18 4 8 18 4 1 wW 150 Replacing the lifter actuator Note This chapter only deals with the replacement of the lifter actuator If you wish to replace the complete lifter module please proceed as described in chapter 8 18 2 Possible methods The lifter actuator is very easy to replace if the lifter has been raised completely Replacement is slightly more complicated if the lift
69. e Connections 1 Cable to remote Be wy cams aa 2 DCI for actuators lighting 12 pole gar PRAA A z z 3 Right hand motor M1 TT beoe sre ee en eS 4 Battery 24V 5 Left hand motor M2 d A A d j ACT actuator module A range of adjusting motors also known as actuators can be fitted to the wheelchair These actuators are either connected directly to the electronic module or to a separate actuator module The actuator module is connected with the electronic module via a bus cable 19 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 4 2 4 1 4 2 4 2 4 2 5 20 ACT 2 actuator module Connections f 1 ACI Bus cable to remote or ACT Bus cable to remote or ACT gel PQ QT I Of Adjusting motor actuator Channel 2 oss Adjusting motor actuator Channel 1 Rubber stoppers for free slots 1 Order number 1555701 2 amp 3 Order number 1552876 4 amp 5 Order number 1555700 2 3 4 5 The ACI connection is used for actuator limitation or speed reduction ACT 4 actuator module Connections 1 ACI ge e e a a le 2 Bus cable to remote or electronic gt fa module A D G D SI gt a YA Mrz Oh 3 Bus cable to remote or electronic t module 4 Actuator Channel 4 1 6 5 6 7 Actuator Channel 3 Actuator Channel 2 Actuator Channel 1 Rubber stoppers for free slots 1 Order number 155570
70. e Se tnnnr iiher rii ei iiin aae eia 213 T02 et Adjustable S ats air uxt ccbheluestetanded echeavecessanaiaebhteanendelandugevbeansteviawd vebhbearcedstawey 213 10 2 2 2 Simple seat TDX SP TDX sp SM lea eats EREE E el ay acl 214 10 2 2 3 Simple seat TDX SP2 TDX SPO arsshccesctatcdacaciacs tress weAsdecaneraataccunsends 215 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 1 1 1 1 2 Introduction General information Service and maintenance work must be carried out taking this service manual into account It is imperative that you observe safety information Information about operation or about general maintenance and care work on the mobility aid should be taken from the operating manual You can find information about ordering spare parts in the spare parts catalogue Only use original Invacare spare parts The guarantee will become invalid if other spare parts are used We reserve the right to make any alterations on the grounds of technical improvements The mobility aid may only be maintained and overhauled by qualified personnel The minimum requirement for service technicians is suitable training such as in the cycle or orthopaedic mechanics fields or sufficiently long term job experience Experience in the use of electrical measuring equipment multimeters is also a requirement Special Invacare training is recommended Alterations to the mobility aid which occur as a result of incorrectly
71. e Use the 3 8 Allen key and a 1 2 socket wrench to loosen the screw 1 e Remove the nuts including the washers but leave the screw inserted in the screw hole do not pull it completely out e Pull the actuator 2 toward the side off of the screws 1 and 3 e Replace the actuator Installing the electrically operated legrest e Assemble the parts in reverse order e Test all functions of the wheelchair 181 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 23 5 Replacing an electric legrest actuator A WARNING Danger of crushing The legrest is very heavy Danger of injury to hands and feet Pay attention to the heavy weight 1 A Requirements sl e 1 2 socket wrench e 3 8 Allen key e Side cutting pliers e Cable ties Uninstalling the electrically operated legrest e f possible raise the lifter to the highest position e f possible tip the wheelchair with the tilt module as far backwards as it will go e Switch the electronic control system off The actuator module for the lifter and the tilt actuator are mounted to the front edge of the seat frame e Completely remove both knurled head screws 1 including the washers e Remove the cover 2 e Pull the plug of the legrest actuator out of the actuator module 182 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL e Use the 3 8 Allen key and a 1 2 socket wrench to loosen the screw 3 e Use the 3 8
72. e chapter 8 21 Loosen and remove the screws which secure the middle seat plate A with a 3 mm Allen key Remove the middle seat plate B Loosen and remove the screws on both sides which secure the lateral seat plates C with a 3 mm Allen key Remove the lateral seat plates D or Remove the seat cushion Loosen and remove the screws on both sides which secure the sling seat A with a T25 Torx wrench Remove the sling seat B 171 SERVICE MANUAL 172 Loosen and remove the screws of the seat frame adjustment A with a T40 Torx wrench Loosen and remove the screws of the fixation of the legrest mounting brackets B Adjust the seat frame and the legrest fixation to the desired width according to the following illustrations and tables Invacare TDX SP Series TDX SP2 Series Seat frame Screw position Seat width A 530 mm gt B 480 mm lo ot C 430 mm Vad D 380 mm 7 Leg supports connection S Screw position Seat width PA te p A 380 mm PK f A B 430 mm HE La e C 480 mm Sz 7 Y ese EH D 530 mm tar Note When switching from 430 mm to Cy 480 mm and the other way around the fixation of the legrests must be replaced Reposition the screws and tighten them again Install the seat plate or the sling seat Reposition the seat cushion Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL
73. e tilt lever 1 forwards e Remove the retaining ring 1 on the front bolts 4 on the lifter actuator 2 using the retaining ring pliers e Pull the bolts out of the guide using the angled long nosed pliers until the bolt is almost contacting the tilt actuator 5 Take care with the bushes 3 154 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL e Lift the tilt actuator 5 slightly e Pull the lifter actuator bolts 4 under the tilt actuator and out of the guide 2 e Remove the retaining ring 1 on the rear bolts 3 on the lifter actuator 2 using the retaining ring pliers e Push the bolts out of the guides e Remove the actuator from the lifter module Refitting the lifter actuator e Refit all parts in the reverse sequence e Carry out a performance test 155 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 18 5 Seat support Note ij This chapter deals with replacing the seat support for a seat without lifter or tilt modules Please proceed as described in chapter 8 18 to replace lifter or tilt modules A WARNING Danger of crushing The seat is very heavy Injury hazard to hands and feet e Use proper lifting techniques wW Requirements 1M e Phillips screwdriver size 2 e 5 16 socket spanner e 5 8 Allen key e torque wrench 5 25 Nm or similar e protractor Note O Make sure you have noted the seat settings Mark the fitting positions a
74. e too high Switch lighting to low See charging unit battery voltage operating manual Check battery charger 9 or 10 x blink Faulty data transmission Remove electronic modules See chapter 8 3 2 between modules except for the power module and the remote Replace the modules one after another in order to ensure which was the one causing the fault 11 x blink Drive motors overloaded Switch remote on and off overheated wait if necessary 29 SERVICE MANUAL BLINK CODE POSSIBLE CAUSE Invacare TDX SP Series TDX SP2 Series SOLUTION DOCUMENTATION 12 x blink Compatibility problems between modules Remove incorrect module See chapter 8 3 2 30 Invacare TDX SP Series TDX SP2 Series 6 3 Shark 2 remote Error codes and diagnostic codes The drive electronic can automatically rectify some faults In this case the status display will stop SERVICE MANUAL blinking Switch the remote on and off again several times Wait around 5 seconds each time before switching the remote on again If this does not rectify the fault determine the cause using the following link codes BLINK CODE MEANING SOLUTION DOCUMENTATION 1 Operating error Set drive lever to neutral central position just release drive lever and switch on again 2 Battery error Check battery and mains cable See chapter 8 5 7 Charge batteries see operating manual If you switch the wheelch
75. eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeeeneaeeeteeeaees 116 8 14 2 Refitting the top Walking DCAM ceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeteneeeeeseneeeeeteeeaeeeseenaees 118 DAVE UNIT enginea ee ea ta cation eee ed ieee elt eee aa lea els 120 8 15 1 Replacing the motor transmission unit Standard Motor c cceeeeceeseeeeeteeeeeeeeees 120 8 15 2 Replacing the motor transmission unit SSD motor ceeeeeeeeceeeeeeeeeeeeeeeeeeeeeeees 122 8 15 3 Replacing or rotating the motor gearbox unit sealing ring SSD motor 0 124 8 15 4 Replacing the motor transmission clutch Standard Motor cccccceseeeeseeeeeeeeeeee 126 8 15 5 Replacing the motor transmission clutch SSD Motor cccccsceeeeeeeseeeeeseeeeeeeeees 128 8 15 6 Replacing the carbon brushes SSD motor cccceeeeeeceeeeeeeeeeeeeeeeeeeeeseaeeeeeeseeneeeaas 130 8 15 7 Replacing the carbon brushes Standard Motor cccececeeseeceeeeeeeeeeeeeeeeeseeeeeneeeaas 132 Replacing the rubber DUMP el ccccseecceeeeeeeeeeeeeeeeeeseeeeeenseeeseeeseeeseeeseaeeeenseaeeeenseeeseenseeneeenss 134 Castor NOUSING Tronto den etch tesa ceestceettectece ates edaeencntecaceustdusensstvecaceseoeeersseessactetueeererte 135 SO at SYStSMM E E ad beadbz codcueboadreatessbotecncactesdenes scnsdacdocedenedduadtaaseesqnedsuasensee 136 8 18 1 Replacing tilt module lifter module eee eee ee eeeeee ee eeee eter eeeeeeeeeeeeeeeteeeeeeeeeeeees 136 8 18 1 1 Replacing t
76. eeeeeseaeeeeeseaeeeeeeeneaeeeeeeeaees 202 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 10 Installing accessories 203 9 1 Replacing the Safety belt cccccssseeeeesseeeeeenseeeeeenseeeeeenseeeeeensneeeeenseeeeeenseeeeeenseeeeeesseeeenenss 203 9 2 Replacing seat belts Modulite seat cccceeseeceeeeeeeeeeeseeeeeeeseeeeeenseeeeeenseaeeeenseeeeeesseeneeenss 204 9 2 1 Installation on the backrest mounting bracket simple backrest 204 9 2 2 Installation on the backrest mounting bracket adjustable seat 205 9 2 3 Installation on the seat frame profile adjustable Seat 0 eee ceeeeeeeeeeeeeeeeeeeeeeeeees 206 9 3 DAHL docking station TDX SP2 TDX SP2 wou usescssesssssssessssssssssssssesssssssesssssssensenscsensees 207 9 4 Further acCeSSOres nion naain aaae aaa AAEE AEREE AEA EAEEREN AAEREN 208 Adjusting the seating position 209 10 1 Adjusting the lower leg length and Seat depth ss sssssnunnennunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnan 210 10 1 1 Adjusting the lower leg length eee ee eeceeeeenneeeeeenaeeeeeeaaeeeseeaaeeeeeeaaeeeeeeaeeeeeeaeeeeneaas 210 10 1 2 Adjusting the set depth sis cccsscescsibeaccecessscegevscaysceesavacatibeateceesancegeetcareceunavela TOARRE EAEE 210 10 2 Adjusting the center of gravity of the S at cccccsseeeeceseeeeeeeseeeeeenseeeeeenneeeeeenseeeeeenseeeeeenes 211 102 1 Standatrd S6abhuproeiotor un i a e a a e a irei e a Masts 213 10 22 M d lit
77. eeeeseaeeesaeeneneeenaees 50 8 3 4 Replacing the operating hours counter connecting Cable cccesseeeseeeeeeeeeteees 51 8 3 5 Drive program selection after component replaceMent cccceeeeeteeeeeeeteeeeeetteeeeees 54 8 3 5 1 Profile selection with remote REM A or REM B eeeccceeeeseeeeeeenneeeeeenaeeeeeeaaeeeeeeaas 54 8 3 5 2 Profile selection with remote REM 550 cc eecseeeeesneeeeeeneeeeeeaaeeeeeeaeeeeeeaeeeeeeaas 55 Updating the driving program ccecsecccceeeeeceeeseeeeeeeeeeeseeeeneeseeesneeseeesneeseeesneeseeesneeseeeseeseeesnes 56 Batteries cables amp battery charger c ecccceeeeeceeeeeeeeeeeeneeseeeeneeseeesneeseeesneeseeesneeseeeenenseneenes 57 8 5 1 Making the batteries acceSSible 00 eececeeeeene ee etter ee eeeaeeeeeeaaeeeeeeaeeeeeeaeeeeeeaeeeeees 57 8 5 2 Replacing batteries TDX SP TDX SPQ ccccceceseeeecce cece eeeeaeeeeaeeseseeeceaeeeseaeeeeeeeeaees 59 8 5 3 Replacing batteries replacing battery cables TDX SP P TDX SP2 owe 61 8 5 4 Correct handling of damaged batterieS cccccsseceeeeeceeeeeeeaeeeeaeeseeeeeseaeeesaeeeeeeeseaees 63 8 5 5 Checking and replacing the main fuse TDX SP TDX SP 2 eeens 64 8 5 6 Replacing the main fuse TDX SP TDX SP2N eiieeii 65 8 5 7 Checking the Cables saena tes acedeun sees aeea sea toetavseicezayterdege lt edeagavact EA 66 85 8 Gable OUtIAG seis aa scqeey sede a a A A A R E AER TRA 68 Battery Caiet crinie
78. er e Refit the parts in reverse order e Check all vehicle functions 77 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 8 6 Replacing the front bulbholder TDX SP2 LED lighting system W iV 78 Requirements e Phillips screwdriver e 4mm Allen key e 6mm Allen key e socket spanner 13 mm e socket spanner 10 mm Dismantling the bulbholder e Remove the complete front headlight as described in chapter 8 8 3 e Loosen the two retaining screws 2 with a 13 mm socket spanner and remove the screws complete with washers e Remove the bulbholder 4 Moving the bulbholder 3 e Loosen the two screws 1 with a 4 mm Allem key und a 10 mm socket spanner e Move the bulbholder 3 into the desired position e Refit the two screws 1 including the washers and nuts Refitting the bulbholder e Refit the parts in reverse order e Check all vehicle functions Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 8 7 Replacing the front bulbholder LED lighting system wW Requirements Vv e 4mm Allen key e socket spanner 8 mm Dismantling the bulbholder e Loosen the Allen screw 1 with a4 mm Allem key and remove the front bulb from the holder e Loosen the two nuts 2 using an 8 mm spanner and remove the headlight with the mounting from the rubber bumpers e Remove the bulbholder 4 Refitting the bulbholder e Refit the parts in reverse order e Now t
79. er 20 mm Removing the drive wheel hub e Loosen and remove the nuts 4 with a 20 mm socket spanner e Remove the washer 3 e Take the wheel hub 5 off the axle 2 e Take the feather key 1 off the axle Refitting the drive wheel hub e Refit the drive wheel hub parts in reverse order e Use a thin film of lubricant to make pushing the wheel hub onto the axle easier e Tighten the nuts 4 to 60 Nm 102 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 10 4 Replacing the drive wheel hub SSD motor A CAUTION Possible material damage to mobility device 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 removed and not replaced again collisions can be caused Always replace the adjusting washers exactly as they were before you started dismantling wW Requirements 1M e socket spanner 19 mm Removing the drive wheel hub e Loosen and remove the nuts 7 with a 19 mm socket spanner e Remove the washer 6 e Remove the distance ring 5 e Take the wheel hub 4 off the axle 2 e Remove the shim ring 3 e Take the feather key 1 off the axle Refitting the drive wheel hub e Refit the drive wheel hub parts in reverse order e Use a thin film of lubricant to make pushing the wheel hub onto the
80. er 8 2 2 1 Dismantling the front cover panel Loosen the Phillips screw 1 on the rear frame cover panel 5 Remove the rear cover panel from the frame Loosen the thumb screw 9 of the rear cover panel 7 Carefully loosen the rear cover Pay attention to the cable of the operation hours counter Take note of the positions of the cables and sockets Mark the plugs and sockets or take a photo with a digital camera Detach the cable of the operating hours counter from the drive motor Remove the rear cover panel Refitting the rear cover panel Refit the parts in reverse order Tighten all the screws finger tight again 43 44 SERVICE MANUAL 8 2 3 Opening the top cover panel Invacare TDX SP Series TDX SP2 Series Requirements e Phillips screwdriver size 2 Wd Dismantling the top cover panel e Remove the seat e Remove the top cover panel Refitting the top cover panel e Refit the parts in reverse order e Tighten all the screws finger tight again Undo the four Phillips screws 10 on the top cover panel 11 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 2 4 Replacing the splash guard Wd Requirements e 6mm Allen key two long wooden blocks min 14 x 14 x 30 cm torque wrench 0 20 Nm or similar torque wrench 5 25 Nm or similar J e J e Flat screwdriver Removing the splash guard e Remove the drive wheel as described in cha
81. er is in the lowered position and cannot be run up The work required for both methods is described below e f you wish to replace the lifter when it is in the raised position please proceed as described in chapter 8 18 4 1 e f you wish to replace the lifter when it is in the lowered position please proceed as described in chapter 8 18 4 2 Method 1 Removing the lifter actuator when the lifter is raised WARNING Danger of crushing The seat is very heavy Injury hazard to hands if the seat is unintentionally folded down e Use proper lifting techniques e Ensure that the seat is properly secured before you start removing the actuator Requirements e retaining ring pliers e oblique pliers e cable binder Note Make a careful note of the seat settings Mark the fitting positions alignments cable routing etc and take photos with a digital camera if necessary Every change to the seat settings influences the centre of gravity of the mobility device If the seat settings are changed the stability lock system settings must be checked and readjusted if necessary as described in chapter 8 24 5 e Run the lifter up to the top position if possible e f possible tilt the seat with the tilt module as far as possible to the rear e Switch the controller off The actuator module for the lifter and the tilt actuators is fitted to the front edge of the seat support Invacare TDX SP Series TDX SP2 Series SERVICE
82. es TDX SP TDX SP2 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 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 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 Req
83. et from the side through the guides the suspension arm bushes and the mounting e Refit the sockets and bolts you have removed e Tighten the bolts to 60 Nm 109 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 110 Ensure that the rear springs are compressed Block method e Lift the suspension arm and place wooden blocks or similar underneath it until the springs are pressed together and the nylon spacer 2 can be fitted into the recesses provided in the suspension 6 Clamp method e Remove the rubber caps 9 e Press the springs together with a joiner s clamp or similar suitable clamp until the nylon spacer 2 can be fitted into the recesses provided in the suspension 6 Fit the two bolts 3 including the nylon spacer 2 Tighten the bolts to 8 5 Nm Replace the two rubber caps 9 if necessary Reinsert all the necessary plugs and fix the cables with cable ties as previously see also chapter 8 5 8 Refit the rear panel as described in chapter 8 1 2 Lift the wheelchair off the wooden blocks Check all the wheelchair functions If necessary carry out adjustments to the setting screw on the stability lock system as described in chapter 8 24 5 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 12 Rear springs 8 12 1 A V a Removing the rear springs Note Invacare recommends always replacing both springs simultaneously in order to ensure that the wheelcha
84. fit the parts in reverse order e Tighten the bolt 6 and the nut 2 to 18 Nm 95 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 10 Drive wheels 8 10 1 Replacing the drive wheel A WARNING Danger of crushing The mobility device is very heavy Injury hazard to hands and feet e Use proper lifting techniques 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 wW Requirements iV e 7 8 Allen key e two long wooden blocks min 14 x 14 x 30 cm e torque wrench 5 25 Nm or similar Removing the drive wheel e Liftthe wheelchair up on one side and place a 14 cm high wooden block underneath it so that the drive wheel is off the ground and can rotate freely Use proper lifting techniques e f necessary repeat this procedure for the other side of the wheelchair e Remove the five 7 8 Allen screws 1 e Take the wheel 2 off the wheel hub Refitting the drive wheel e Refit the wheel in reverse order e Tighten the bolts to 18 Nm 96 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 10 2 Replacing the tyre or inner tube Note ij There are three different types of tyres or inner tubes and specific points must be observed for the replacement of each type It is easy to tell the difference between the tyre
85. g the front headlight e Refit the parts in reverse order Route the cables carefully and fix them with cable ties e Check all vehicle functions 73 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 8 3 Replacing the front headlight complete TDX SP2 LED lighting system wW Requirements dd e Allen key 4 mm e oblique pliers e cable ties Removing the front headlight e Remove the rear panel as described in chapter 8 2 2 e Carefully note the location of the cable and the connection locations of the various plugs Either mark each plug and socket or take a photograph with a digital camera e On the illustration you can see the battery plug 1 the lighting PCB 2 for the electronic module 3 the optional cross connector 4 and the optional actuator module 5 e Loosen the cable leading to the lighting PCB from the front headlight affected e Remove all cable ties and pull the cable out of the wheelchair 74 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL Loosen the Allen screw 1 with a 4 mm Allen key and remove the front bulb from the mounting Replace the headlight unit Refitting the front headlight Refit the parts in reverse order Route the cables carefully and fix them with cable ties In doing so please pay attention to chapter 8 5 8 Check all vehicle functions Now tighten all the screws finger tight again Check all vehicle functions Adjust the headli
86. gearbox unit is very heavy Danger of injury to the hands e Pay attention to the heavy weight Requirements 5 8 Allen key 7 8 Allen key 5 16 Allen key 6 mm Allen key Phillips screwdriver size 2 10 mm socket spanner 1 2 socket spanner 1 4 socket spanner 5 16 socket spanner torque wrench 0 20 Nm or similar torque wrench 5 25 Nm or similar torque wrench 10 80 Nm or similar two long wooden blocks min 14 x 14 x 30 cm Uninstalling the motor gearbox coupling e Uninstall the motor gearbox unit as described in chapter 8 15 2 e Use the 10 mm socket wrench to loosen and remove the self securing nut 3 e Remove the carriage bolt 6 which secures the sealing ring 5 e Carefully bend the sealing ring apart and remove it WARNING Material damage hazard if the coupling is improperly handled e Please proceed carefully so that you do not damage the motor gearbox coupling Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL e Pull the motor 4 and transmission unit 1 carefully apart e Remove the clutch individual parts 7 e Replace the clutch if necessary Refitting the motor transmission clutch e Place the new clutch 7 on the motor axle Pay attention to the position of the groove e Position the locking ring 5 on the motor 4 or the gearbox 1 e Carefully insert the motor into the gearbox Pay attention to the position of the groove in the
87. ght roughly using the grid The user can carry out the final adjustment following the operating manual 75 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 8 4 Replacing the front bulbholder conventional lighting system wW Requirements i e Phillips screwdriver size 2 e socket spanner 13 mm EE Dismantling the bulbholder e Remove the complete front headlight as described in chapter 8 8 2 e Undo the two retaining screws 2 with a 13 mm socket spanner and remove the screws complete with washers e Remove the bulbholder 1 Refitting the bulbholder e Refit the parts in reverse order e Check all vehicle functions 76 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 8 5 Replacing the front bulbholder TDX SP2 TDX SP conventional lighting Wd system Requirements e Phillips screwdriver 4 mm Allen key 6 mm Allen key socket spanner 13 mm e e e e socket spanner 10 mm Dismantling the bulbholder e Remove the complete front headlight as described in chapter 8 8 2 e Loosen the two retaining screws 2 with a 13 mm socket spanner and remove the screws complete with washers e Remove the bulbholder 4 Moving the bulbholder 3 e Loosen the two screws 1 with a 4 mm Allem key und a 10 mm socket spanner e Move the bulbholder 3 into the desired position e Refit the two screws 1 including the washers and nuts Refitting the bulbhold
88. hand plastic cover 2 with a 10 mm socket spanner e Remove the plastic cover e Undo the cable and the plug from the angular sensor 1 Remove any cable ties which are fitted e Remove the cable ties holding the angular sensor e Replace the angular sensor Refitting the angular sensor e Refit the parts later in reverse order 140 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 18 1 2 Replacing the tilt module max lt 30 without a lifter il Note This chapter discusses how to replace a tilt module max gt 30 on a chair without a lifter Similar tasks are described In the following chapters e Replacing only the seat support chapter 8 18 5 Replacing a tilt module max gt 30 chapter 8 18 1 1 Replacing a combined lifter tilt module chapter 8 18 2 Replacing only the tilt actuator chapter 8 18 3 Replacing only the lifter actuator chapter 8 18 4 WARNING Danger of crushing The seat is very heavy Injury hazard to hands and feet e Use proper lifting techniques Requirements 1 2 socket spanner 13 mm jaw spanner 4 mm Allen key 6 mm Allen key oblique pliers cable binder Note Make a careful note of the seat settings Mark the fitting positions alignments etc and take photos with a digital camera if necessary Every change to the seat settings influences the centre of gravity of the mobility device If the seat settings are changed the
89. he tilt module max gt 30 without a lifter eect eeeeeeeees 136 8 18 1 2 Replacing the tilt module max lt 30 without a lifter eee eeeeeeeeeeeeees 141 8 18 2 Replacing the lifter tilt module 2 cece ee eeee ee ee eeee eter eeeeeeetaeeeeeeeaeeeeeseneaeeeeeeeaees 144 8 18 3 Replacing the tilt actuator oe cee eee eeee eter eeee Eaa REIA KEKEE ANER N REALES ERAN EAEN EREE 148 8 18 4 Replacing the lifter actuator oe eee eee eeeeee ee eeee eter te eeeeeeteaeeeeeeeaeeeeeseeeeeeeeeeaeeeeeeneees 150 8 18 4 1 Method 1 Removing the lifter actuator when the lifter is raised eee 150 8 18 4 2 Method 2 Removing the lifter actuator when the lifter is lowered 005 152 8 18 5 Seal SUPPOMi as tives atin Givi eas that ade thy etd eta tas 156 Backrest Unit ssori ceccsssscesscccce ce ctcceete naanin ei ia anaana aaar ina aaa aa ariaa Eaa aA 158 8 19 1 Adjusting backrest fOrmer ue eeeece cence ee eeeeeeeeeeeeeeeeteaeeeeeseaeeeeesaeeeeeeeeeeeeseeeeeeeeeeeaees 158 Seat system Modulite cccceeccesccesseeeesneeeeeeeeeeeeeescaesesneeeneeeeseaesesaesasneeeneeeeseeseseaeenseaeeeenaess 159 8 20 1 Replacing the tilt actuator oo eee eeee ee eeee ee ee eeeeee eee aeeeeeeeaeeeeeteaeeeeesaeeeeeseeeeeeeeneaees 159 8 20 2 Replacing the lifter actuator oe eee ee eeeeee teeta ee eeeeaeeeeeseaeeeeeseaeeeeeteaeeeeeseeeeeeeeeeeees 160 8 20 3 Replacing the lifter seat angle adjustment module eee ceeeeeeeeeeeeeeeteeeeeeeeeeeees 161
90. he tilt mounting Refitting the tilt module Refit the tilt module in the reverse sequence Tighten the connecting bolts between the tilt mounting and the battery case to 18 Nm When routing the cable ensure that it has been placed in the cable clamps so that it cannot be crushed or damaged in any way at any seat setting Refit the batteries including battery supports as described in chapters 8 5 2 8 5 3 and 8 5 1 A WARNING Danger of crushing The seat is very heavy Injury hazard to hands and feet e Use proper lifting techniques Refit the seat Adjust the stability lock system as described in chapter 8 24 5 143 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 18 2 Replacing the lifter tilt module A W 144 Note This chapter deals with replacing the seat support for a seat with lifter tilt module Similar work is described in the following chapters e Replacing a seat support only chapter 8 18 5 Replacing a tilt module max gt 30 chapter 8 18 1 1 Replacing a tilt module max lt 30 chapter 8 18 1 2 Replacing the tilt actuator only chapter 8 18 3 Replacing the lifter actuator only chapter 8 18 4 WARNING Danger of crushing The seat is very heavy Injury hazard to hands and feet e Use proper lifting techniques Requirements Crosshead screwdriver size 1 1 2 socket spanner 13 mm jaw spanner 6 mm wrench 4 mm Allen key oblique pliers c
91. ic components of the operating hours counter Make sure the cable is connected correctly e Connect the plug on the blue wire to the pin on the operating hours counter which is marked with a minus symbol e Connect the plug on the brown wire to the pin on the operating hours counter which is marked with a plus symbol The brown wire is additionally marked with a yellow sleeve with a plus symbol on it e Insert the cable from the outside through the cut out for the operating hours counter located in the rear cover e Position the operating hours counter in the cut out e Reposition the retaining frame 6 e Place the mounting bracket 2 on the threaded rod 3 so that the mounting bracket presses the retaining frame on the cover 52 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL e Place the locking washer 4 and the nut 5 on the threaded rod e Tighten the nut hand tight e Install the rear cover again as described in chapter 8 1 2 2 or 8 2 2 2 53 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 3 5 8 3 5 1 54 Drive program selection after component replacement The drive program is saved in the REM remote and also in the DX ACS or ACS2 electronic module If one of these two components is replaced the system must be told which of the components has not been replaced so that it knows which contains the current controller profile Note
92. ide bush into the battery case holder 5 e Hold the gas cylinder in position and lift the rear axle so that the gas cylinder ball joint is pressed 191 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series e Push the gas cylinder 1 from the front towards the rear into the holder until the bottom end is just in front of the hole 3 in the battery case 2 and you can insert the screw 4 e Rotate the top walking beam 5 so that you can insert the screw 4 through the drillhole 3 on the gas cylinder into the gas cylinder and walking beam e Push the bolt 4 through Fix the bolt with a 5 16 Allen key e Fit the nut 6 with a 1 4 socket spanner onto the bolt and tighten the nut to 8 5 Nm e Fit both the stability lock system protective caps e Fit the drive wheel as described in chapter 8 10 1 e Replace the batteries in their correct location as described in chapters 8 5 2 8 5 3 and 8 5 1 e Remove the wooden block from under the wheelchair 192 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 24 4 Replacing the setting screw A WARNING Danger of crushing The mobility device is very heavy Injury hazard to hands and feet e Use proper lifting techniques 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 Requireme
93. ies TDX SP2 Series SERVICE MANUAL 3 i V maj LE pje Note ij For the following operation use an M8 washer as a thickness gauge e Rotate the setting screw 3 until it has a space of 1 5 mm A between it and the gas cylinder 4 e Fit the lock nut 2 and tighten it using a 1 4 socket spanner e Refit the two protective caps again 195 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 24 5 Adjusting the setting screw wW Requirements Vv e 1 4 socket spanner e M8 washer Ay A A e Remove both the stability lock system protective caps The protective caps on the stability lock system will either be held using a screw or a cable tie depending on the wheelchair s date of manufacture e Ensure that the wheelchair is contacting the floor with all its wheels and castors e Loosen and remove the two locknuts 2 with a 1 4 socket spanner Note ci For the following operation use an M8 washer as a thickness gauge e Rotate the setting screw 3 until it has a space of 1 5 mm A between it and the gas cylinder 4 Tip use an M8 washer as a thickness gauge e Fit the lock nut 2 and tighten it using a 1 4 socket spanner e Refit the two protective caps again 196 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 9 Installing accessories 9 1 Replacing the safety belt wW Requirements i e open ended spanner 13 mm e 5mm Al
94. ighten all the screws finger tight again e Adjust the headlight roughly using the grid e Check all vehicle functions e Adjust the headlight roughly using the grid The user can carry out the final adjustment following the operating manual 79 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 8 8 Replacing the rear bulb conventional lighting system wW Requirements aed e Phillips screwdriver size 2 e Undo the Philips screw in the transparent cover over the rear light indicator combination e Remove the transparent plastic cover e Replace the defective bulb e Close the cover and tighten the Philips screw finger tight 80 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 8 9 Replacing the rear light complete conventional lighting system up to 08 2014 wW Requirements ad e Phillips screwdriver size 2 e socket spanner 8 mm Removing the rear light e Remove the rear panel as described in chapter 8 1 2 e Carefully note the location of the cable and the connection locations of the various plugs Either mark each plug and socket or take a photograph with a digital camera e On the illustration you can see the battery plug 1 the lighting PCB 2 for the electronic module 3 the optional cross connector 4 and the optional actuator module 5 e Loosen the cable leading to the lighting PCB from the rear light affected e Remove all cable ties and pull the cable out of the
95. ir works perfectly WARNING Danger of crushing The mobility device is very heavy Injury hazard to hands and feet e Use proper lifting techniques 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 Requirements 5 6 Allen key 5 32 Allen key Phillips screwdriver size 2 blade screwdriver 1 4 socket spanner 5 16 socket spanner torque wrench 0 20 Nm or similar oblique pliers cable ties M8 washer two long wooden blocks min 14 x 14 x 30 cm e Lift the wheelchair up on one side and place a 14 cm high wooden block under the battery case so that the wheels are off the ground and can rotate freely Use proper lifting techniques e Repeat the same procedure on the other side of the wheelchair e Remove the rear panel as described in chapter 8 1 2 e Ensure you note the cable routing carefully If necessary take photos with a digital camera e Remove all cables and cable ties which are fixed to the wheel suspension or which could get in the way during work e Remove both the stability lock system protective caps The protective caps on the stability lock system will either be held using a screw or a cable tie depending on the wheelchair s date of manufacture 111 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 112
96. it the parts in reverse order e Tighten the nuts 3 and 4 to 2 5 0 3 Nm e Check all vehicle functions Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 8 11 Replacing the rear light complete TDX SP2 conventional lighting system wW Requirements i e Phillips screwdriver size 2 e socket spanner 8 mm Removing the rear light e Remove the rear panel as described in chapter 8 1 2 e Carefully note the location of the cable and the connection locations of the various plugs Either mark each plug and socket or take a photograph with a digital camera e On the illustration you can see the battery plug 1 the lighting PCB 2 for the electronic module 3 the optional cross connector 4 and the optional actuator module 5 e Loosen the cable leading to the lighting PCB from the rear light affected e Remove all cable ties and pull the cable out of the wheelchair 85 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series e Remove the two protect caps 5 e Loosen and remove the two nuts 4 and 3 including the washers 2 and the protection caps 1 with an 8 mm socket spanner e Replace the rear light Dismantling the rear light e Refit the parts in reverse order e Check all vehicle functions 86 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 8 12 Replacing the rear light complete TDX SP2 LED lighting system wW Requirements i e 4mm Allen key e
97. ive Replace charging unit See charging unit operating manual 27 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series PROBLEM OTHER POSSIBLE SOLUTION DOCUMENTATION SYMPTOMS CAUSE Short None One of the Replace batteries See chapter charging batteries could be 8 5 2 8 5 3 period defective Wheelchair None Remote defective Replace remote See chapter 8 3 1 runs too slowly Batteries defective Replace batteries See chapter 8 5 2 8 5 3 Actuator does not react Remote shows blinking E or blink code 2 Status diode on lighting actuator module does not go out even if the remote has been switched off or disconnected None Lighting actuator module defective Replace lighting actuator module See chapter 8 3 2 Cable Safeguard cable See chapter 8 5 7 disconnected or connection damaged replace cable if necessary Electrical Check adjusting adjusting motor motor defective Remote defective Replace remote See chapter 8 3 1 1 Only applies to remote SD24 2 All remotes except SD24 28 Invacare TDX SP Series TDX SP2 Series 6 2 REM remotes Error codes and diagnostic codes SERVICE MANUAL The drive electronic can automatically rectify some faults In this case the status display will stop blinking Switch the remote on and off again several times Wait around 5 seconds each time before switching the remote on again
98. ive electronic module Motors lose None Bad connections Switch wheelchair See chapter 8 5 7 power during off wait 10 journey seconds switch wheelchair on again Check all cabling Motor judders None Carbon brushes Check carbon See chapter or runs worn brushes and 8 15 6 8 15 7 irregularly or replace if only one necessary motor runs Clutch es Replace clutch See chapter defective 8 15 4 8 15 5 Bearing defective Replacing the See chapter motor 8 15 1 8 15 2 Collector Measure internal See chapters 7 1 defective resistance of and 8 15 1 8 15 2 motor replace motor if defective Motors do not None Bad connections Check all cabling See chapter 8 5 7 26 run Fuse burnt out Check cabling and replace fuse See chapters 8 5 7 and 8 5 5 8 5 6 Batteries Replace batteries See chapter defective 8 5 2 8 5 3 Cabling to check cabling See chapter 8 5 7 electronic module or joystick defective Electronic module defective Replacing the electronic module See chapter 8 3 2 being charged cable defective and replace fuse Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL PROBLEM OTHER POSSIBLE SOLUTION DOCUMENTATION SYMPTOMS CAUSE Corroded Water salt or Check cabling See chapter 8 5 7 contacts urine has replace if penetrated necessary Motor makes None Clutch es Replace clutch See chapter clic
99. ive wheel as described in chapter 8 10 1 e Remove the front castor housing as described in chapter 8 24 e Remove the rubber bumper as described in chapter 8 16 e Pull the motor plug 1 out of the electronic module e Note carefully how the motor cable is routed e f necessary remove any existing cable ties which are fixing the motor cable 116 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 10 e Rotate the top walking beam 11 until the Allen screw 5 is in line with the opening 3 in the battery case 4 e Remove the nut 10 which secures the 5 16 Allen screw 5 using a 1 4 socket spanner e Push the Allen screw 5 towards the battery case until the gas cylinder is free of the top walking beam e Fix the gas cylinder in place with a cable tie or suitable adhesive tape e Remove the nut 8 with a 1 2 socket spanner e Remove the washer 9 e Remove the top walking beam including motor transmission unit from the axle e Remove the washer 1 from the axle 117 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 14 2 Refitting the top walking beam W 118 Requirements 5 8 Allen key 7 8 Allen key 5 16 Allen key Phillips screwdriver size 2 1 2 socket spanner 1 4 socket spanner torque wrench 5 25 Nm or similar two long wooden blocks min 14 x 14 x 30 cm Place the washer 1 on the battery case 4 rear axle Push the top wa
100. k of accidents Hazards to workers surroundings and mobility device Do not leave the mobility device unattended during the following procedure Make sure that BOTH drive wheels are off the ground before calibrating Secure the area Lift the wheelchair up on one side and place a 14 cm high wooden block underneath it so that the drive wheel is suspended freely Use proper lifting techniques Repeat the same procedure on the other side of the wheelchair Allow the motors to run in the forward direction for an hour Allow the motors to cool down for 30 minutes Allow the motors to run in the reverse direction for an hour Lift the wheelchair off the wooden blocks 133 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 16 Replacing the rubber bumper Note e Invacare recommends that you replace all the rubber bumpers as soon as one needs replacing wW Requirements dd e 5 16 socket spanner e 7 8 Allen key e two long wooden blocks min 14 x 14 x 30 cm e torque wrench 5 25 Nm or similar vail ie Removing the rubber bumper e Remove the drive wheel as described in chapter 8 10 1 e Undo and remove the 5 16 nut 3 e Remove the washer 2 e Remove the rubber bumper 1 Refitting the rubber bumper e Refit the parts in reverse order 134 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 17 Castor housing front wW Requirements d e 5 16 Allen key e torque wre
101. ke 34 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL A i CAUTION Material damage can be caused to the electronic module due to short circuits in the electro mechanical brake e NEVER connect an electro mechanical brake to an intact electronic module with a short circuit e Always replace short circuited brakes immediately Note A defective motor can damage the electronic module but not the other way around 35 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 Repair work A CAUTION Danger of injury and damage to property if the maximum speed reduction on a wheelchair with a lifter does not function correctly The wheelchair s control unit must reduce the maximum possible speed as soon as the lifter is raised e Test the maximum speed reduction for correct function after any maintenance work or modifications to the wheelchair 8 1 Covers TDX SP TDX SP 8 1 1 Opening the front panel wW Requirements iV e Phillips screwdriver size 2 e 5 8 Allen key Dismantling the front cover panel e Remove the legrests Remove the two bolts 5 on the front cover panel 4 with a 5 8 Allen key e Pull the front cover panel upwards and remove it Refitting the front cover panel e Refit the parts in reverse order e Now tighten all the screws finger tight again 36 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 1 2 Opening
102. king noise defective 8 15 4 8 15 5 Bearing defective Replacing the See chapter motor 8 15 1 8 15 2 Collector Measure internal See chapters 7 1 defective resistance of and 8 15 1 8 15 2 motor replace motor if defective Scraping None Clutch es Replace clutch See chapter noise or defective 8 15 4 8 15 5 ae d Bearing defective Replacing the See chapters oce motor 8 15 1 8 15 2 and 8 15 4 8 15 5 Transmission Replace See chapters defective transmission 8 15 1 8 15 2 and 8 15 4 8 15 5 Transmission None Transmission Replace See chapters makes defective transmission 8 15 1 8 15 2 and clicking noise 8 15 4 8 15 5 Drive wheel loose Tighten drive See chapter wheel secure 8 15 1 8 15 2 bolts with Loctite if necessary Transmission None Sealing ring on Replace See chapters losing oil drive shaft transmission if 8 15 1 8 15 2 and defective sealing ring 8 15 4 8 15 5 defective Check carbon See chapters brushes for oil 8 15 1 8 15 2 wetting replace 8 15 4 8 15 5 and motor if brushes 8 15 6 8 15 7 wet Irregular None Drive shaft Check drive shaft See chapters running movable or bent replace 8 15 1 8 15 2 and transmission if 8 15 4 8 15 5 defective Parts lost None Parts lost Reattach parts once found Batteries not None Fuse burnt out Check cabling See chapters 8 5 7 and 8 5 5 8 5 6 Batteries defective Replace batteries See chapter 8 5 2 8 5 3 LEDs blinking on charging unit Charging unit defect
103. lacing the splash guard ice ad na doe deny atin Uae A a E rete ii a 40 8 2 Covers TDX SP2 TDX SP2 scceseesseeceseeeenseeeeeeseseeeseseeeensneeseaeseseeesnsnaeeneeeessaesaseaeenseaeeeees 41 8 2 1 Opening the front panel ccccceccceceseceeeeceeeeecaeeeeaaeeseneeceaeeecaaeseeaeeseeeeseaeeeeaaeseeneeesaees 41 8 2 2 Opening the rear cover panel ceeeceesceceeeeeeeeeeeesaeeeeeeeceaeeesaaeeseaeeseeeeesaeeesaeeseneeeeaees 42 8 2 2 1 Rear cover without an operating hours counter ssssessssrisseerssssrrssrrrrssrerrssreens 42 8 2 2 2 Rear cover with an operating hours Counter ssesesssssrssesrrssserrssrrrssrirnssrernssrnns 43 8 2 3 Opening the top Cover panel tssirini caisi e idi aana a a aiana ei 44 8 2 4 Replacing the splash guard 0 ccceeecceeeeeeeneceeeeeneeeeeeaeeeeeeaeeeeeeaaeeeeeeaaeeeeeeaeeeenenaeeeenes 45 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 3 8 4 8 5 8 6 8 8 8 9 8 10 8 11 8 12 8 13 Electronic module ccvsce sy etece crete eeereceectesestce eu eblceic Peat deeteecedateenateiverecdgeietedugeectenducresestgaearenecee 46 8 3 1 Replacing the remote ee cccceecccceeseccceeceeeeeeeeeeeceeeeeeeaeeeeeaaaeesseaeeeeaeaaaeeseseaeeeeneeaeenees 46 8 3 2 Replacing the electronic MOCUIC ee eeeeeceee een ceeeeene ee ee eaeeeeeeaaeeeeetaaeeeeetaeeeenenaeeeeee 46 8 3 3 Replacing the G Trac SCNSOM ccccceesceceeececeneeeesaeceeeeeseaeeesaaeeseaees
104. late A with a 3 mm Allen key SNK Remove the middle seat plate B Loosen and remove the screws on both sides which secure the lateral seat plates C with a 3 mm Allen key Remove the lateral seat plates D or Remove the seat cushion Loosen and remove the screws on both sides which secure the sling seat A with a T25 Torx wrench Remove the sling seat B 165 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series Uninstalling the seat support adjustable seat simple seat wW Requirements e 6mm Allen key e 13 mm ring spanner or jaw spanner The following figure shows the seat support with the adjustable seat plate e Loosen and remove the screws 2 incl washers and nuts with a 6 mm Allen key and a 13 mm jaw spanner e Pullthe seat frame 1 up and off e Loosen and remove the screws 4 incl washers and nuts with a 6 mm Allen key and a 13 mm jaw spanner e Remove the seat adapter 3 The dismantling of the seat support on the chassis is described in chapter 8 18 5 166 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL Installing the seat and seat support e Assemble all parts in reverse order ij Note Make sure that all screws washers and nuts are reassembled in the correct order and securely tightened during assembly e When installing the seat pay attention to its heavy weight e Tighten the screws to a torque of 25 Nm e Check all functions of the
105. le seat wW Requirements sia e 5mm Allen key e Loosen the screw 1 with a5 mm Allen key e Remove the screw 1 the washer 2 the seat belt the sliding bushing 3 and the sliding block 4 from the seat frame profile 5 e Replace the safety belt e Refit the parts in the reverse order 200 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 9 3 DAHL docking station TDX SP2 TDX SP2 A CAUTION Danger of crushing The mobility device is very heavy Injury hazard to hands and feet e Use proper lifting techniques Injury hazard caused by uncontrolled movement of the mobility device e Switch the power supply off ON OFF key e Engage the drive e Position the mobility device on it s side and secure the position so it does not turn over wW Requirements iM e 6mm Allen key e high strength screw blocker system e g Loctite 270 Refitting the DAHL docking station 201 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series O O 202 Note Depending on the vehicle several spacers 3 may be required in addition to the safety plate 2 Please refer to the documentation provided by DAHL see also www dahlengineering dk for information on whether and how many spacers are required Note The countersunk screw 1 material quality must be at least 8 8 If spacers have been fitted the screws length should be completed as follows A thickness of safety plate
106. legrest An electric legrest can be seen in the illustration The method of fixation to the seat is identical with both legrests e Uninstall the locking lever for the height adjustment of the legrest by loosening the grub screws with a 5 mm Allen key e Use the 6 mm Allen key to loosen and remove the two hexagon socket head screws 2 on both sides of the wheelchair e Completely remove both hexagon socket head screws including the washers e Pull the entire legrest forwards out of the seat e Loosen both hexagon socket head screws which attach the adapter brackets 1 to the legrest e Remove both adapter brackets Installing the manually operated centre mounted legrest e Assemble the parts in reverse order e Test all functions of the wheelchair Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 23 2 Replacing the electrically operated centre mounted legrest A WARNING Danger of crushing The legrest is very heavy Danger of injury to hands and feet Pay attention to the heavy weight 1 A Requirements di e 6mm Allen key e Side cutting pliers e Cable ties Uninstalling the electrically operated centre mounted legrest e f possible raise the lifter to the highest position e f possible tip the wheelchair with the tilt module as far backwards as it will go e Switch the electronic control system off The actuator module for the lifter and the tilt actuator are mounted to the front edge
107. len key Note ij A nut is fixed between the two washers 2 and 4 as a spacer so that the belt mounting can rotate freely e Remove the plastic cap 5 e Loosen the bolt 3 and the associated nut in the figure this is covered by the plastic cap with a 5 mm Allen key and a 13 mm socket spanner e Remove the nut e Remove the bolt including safety belt and flat washers 2 and 4 e Remove the flat washers 4 e Replace the safety belt 1 e Refit the parts in the reverse order 197 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 9 2 Replacing seat belts Modulite seat 9 2 1 Installation on the backrest mounting bracket simple backrest wW Requirements wer e Socket spanner 13 mm e 5mm Allen key e The seat belts are attached via the drill hole 1 at the top right e The installation of seat belts is described in chapter 9 1 198 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 9 2 2 Installation on the backrest mounting bracket adjustable seat wW Requirements sat e 5mm Allen key Loosen the screw 1 with a5 mm Allen key Remove the screw 1 the corresponding washer 2 and the seat belt and belt winder 3 from the backrest mounting bracket 4 Replace the safety belt Refit the parts in the reverse order 199 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 9 2 3 Installation on the seat frame profile adjustab
108. lignment etc If necessary take photos with a digital camera Any changes to the seat settings influence the centre of gravity of the wheelchair If changes are made to the seat settings the stability lock system settings must be checked and readjusted if necessary as described in chapter 8 24 5 Dismantling the seat support e Remove the seat Use proper lifting techniques e Remove the batteries as described in chapters 8 5 1 and 8 5 2 8 5 3 Undo the bolt 3 with a 5 16 socket spanner Hold the seat support 1 firmly while you remove the bolts 3 and the metal plates 2 156 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL Refitting the seat carrier Hold the seat support 1 firmly while you fit the bolts 3 and the metal plates 2 Screw the bolts in but do not tighten them Use the protractor to adjust the seat carrier to the required angle Tighten the bolts to 18 Nm Refit the batteries including battery carrier as described in chapters 8 5 2 8 5 3 and 8 5 1 Refit the seat Adjust the stability lock system as described in chapter 8 24 5 157 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 19 Backrest Unit 8 19 1 Adjusting backrest former The backrest former can be individually adapted to the user s back shape e Pull the front and rear faces of the backrest upholstery 1 apart and remove The backrest upholstery front and rear faces are held together using Velcro faste
109. lking beam 11 including motor transmission unit onto the axle Push the washer 9 onto the axle Fit the nut 8 onto the axle Tighten the nut 8 to 18 Nm Rotate the nut 8 back by 1 4 turn Raise the rear wheel suspension to free the gas cylinder 2 Position the gas cylinder so that the 5 16 x2 50 Allen screw 5 is in line with the opening 3 in the battery case 4 Rotate the top walking beam 11 until the drillhole for the Allen screw 5 is in line with the opening 3 in the battery case 4 Push the Allen screw 5 through the gas cylinder and the top walking beam Fit the 1 4 20 nut 10 onto the Allen screw 5 and tighten it to 8 5 Nm Refit the rubber bumper as described in chapter 8 16 Refit the front castor housing as described in chapter 8 17 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL e Refit the batteries as described in chapters 8 5 1 and 8 5 2 8 5 3 e Refit the rear panel as described in chapter 8 1 2 e Refit the front panel as described in chapter 8 1 1 e Fit the drive wheel as described in chapter 8 10 1 119 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 15 8 15 1 A W 120 Drive unit Replacing the motor transmission unit Standard motor WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Use proper lifting techniques Danger of injury due to uncontrolled movement of the wheelchair
110. loosen the four hexagon head screws 3 Remove the screws Pull the motor gear box unit 1 off of the Walking Beam 2 Take into account the heavy weight of the unit Installing the motor gearbox unit Replace the defective components Before installing a new motor gearbox unit make sure the sealing ring is correctly mounted The sealing ring securely attaches the motor and the gearbox The ring must be installed such that the self locking nut is located on the outside If the sealing ring is incorrectly installed rotate it around as described in chapter 8 15 3 Install the motor gearbox unit in reverse order DSF m Use the scale to align the motor to the centre axis 1 E FL 2 pole motors and 4 pole motors OL m Left 0 a f H Right 0 i L Q i f Make sure that the motor cable cannot be pinched or bent and AT that it is not exposed to chafing in any place To conclude you should always carry out a trial run to test the vehicle functions 123 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 15 3 Replacing or rotating the motor gearbox unit sealing ring SSD motor A CAUTION Danger of crushing The motor gearbox unit is very heavy Danger of injury to the hands e Pay attention to the heavy weight wW Requirements 6 mm Allen key 5 8 Allen key 7 8 Allen key 5 16 Allen key Phillips screwdriver size 2 10 mm socket spanner 1 2 so
111. manner underneath the seat and the control panel Invacare TDX SP Series TDX SP2 Series 8 6 Battery carrier wW Requirements dd e Phillips screwdriver size 2 e 5 8 Allen key e 5 32 Allen key SERVICE MANUAL Dismantling the battery carrier e Make the batteries accessible as described in chapter 8 5 1 e Remove the batteries as described in chapter 8 5 2 8 5 3 e Remove the two stop bolts 1 with a 5 32 Allen key e Pull the battery carrier 2 out of the battery case Refitting the battery carrier e Refit the parts in reverse order 69 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 7 70 14 17 Replacing the battery case Requirements 5 6 Allen key 5 32 Allen key Phillips screwdriver size 2 blade screwdriver 1 4 socket spanner 5 16 socket spanner torque wrench 0 20 Nm or similar torque wrench 5 25 Nm or similar torque wrench 20 80 Nm or similar oblique pliers cable ties M8 washer two long wooden blocks min 14 x 14 x 30 cm Removing the battery case Remove the seat including seat support as described in chapter 8 18 and 8 20 Modulite Remove the covers as described in chapter 8 1 or 8 2 Remove the batteries as described in chapters 8 5 1 and 8 5 2 8 5 3 Remove the battery support as described in chapter 8 6 Remove the front headlights and rear lights depending on version including bracket as described in chapter 8
112. nch 5 25 Nm or similar Removing the front castor housing e Remove the two Allen screws 1 with a 5 16 Allen key e Remove the two nylon washers 2 e Remove the castor housing 5 from the top walking beam 3 and the bottom walking beam 4 Refitting the front castor housing e Refit the parts in reverse order e Tighten the Allen screws to the following sequence tighten all the screws to 18 Nm turn the screws back by 1 8 turn 135 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 18 Seat system 8 18 1 Replacing tilt module lifter module Note ca Depending on which tilt module is installed either chapter 8 18 1 1 or 8 18 1 2 applies You can determine the type of tilt module by the maximum adjustment angle it allows e Max angle is larger than 30 See chapter 8 18 1 1 e Max angle is smaller than 30 See chapter 8 18 1 2 8 18 1 1 Replacing the tilt module max gt 30 without a lifter Note ij This chapter discusses how to replace a tilt module max gt 30 on a chair without a lifter Similar tasks are described In the following chapters e Replacing only the seat support chapter 8 18 5 Replacing a tilt module max lt 30 chapter 8 18 1 2 Replacing a combined lifter tilt module chapter 8 18 2 Replacing only the tilt actuator chapter 8 18 3 Replacing only the lifter actuator chapter 8 18 4 A WARNING Danger of crushing The seat
113. nector 3 47 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 48 Pull the plug 1 out of the actuator module Pull the plug 2 out of the light module Pull the plug 3 out of the electronic module Loosen both the 8 mm nuts 1 Remove the module carefully Replace the defective module Refitting the electronic module Refit the various modules in reverse order Refit the cross connector if this is fitted Plug all the plugs into their old positions If you have replaced a DX ACS or ACS2 Electronic module select the drive programmatically in chapter 8 3 3 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL e If anew software version is available update the drive program as described in chapter 8 4 e Adapt the drive program using the programming software if necessary e Toconclude check all the wheelchair functions 49 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 3 3 Replacing the G Trac sensor Wd 50 Requirements e 10mm socket wrench Uninstalling the G Trac sensor Switch the electronic of the wheelchair OFF Remove the rear cover as described in chapter 8 1 2 Take note of the positions of all cables and the sockets that they are connected to Mark the connectors and sockets or take a photograph with a digital camera Loosen and remove the self locking nut 3 including the washer 4 with the 10 mm socket wrench Remove the G
114. ner 13 mm Dismantling the bulbholder e Remove the complete rear light as described in chapter 8 8 8 e Undo the two retaining screws 2 with a 13 mm socket spanner and remove the screws complete with washers e Replace the bulbholder 1 Refitting the bulbholder e Refit the parts in reverse order e Check all vehicle functions 89 90 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 8 14 Replacing the rear bulbholder conventional lighting system until 08 2014 wW Requirements IV e Phillips screwdriver size 2 e socket spanner 8 mm e socket spanner 13 mm Dismantling the bulbholder e Remove the complete rear light as described in chapter 8 8 10 e Undo the two retaining screws 2 with a 13 mm socket spanner and remove the screws complete with washers e Replace the bulbholder 1 Refitting the bulbholder e Refit the parts in reverse order e Check all vehicle functions Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 8 15 Replacing the rear bulbholder TDX SP2 conventional lighting system wW Requirements iv e Phillips screwdriver size 2 e socket spanner 8 mm e 3 16 Allen key Dismantling the bulbholder e Remove the complete rear light as described in chapter 8 8 11 e Undo the two retaining screws 2 on the chassis with a 3 16 Allen key and remove the screws including the washers e Replace the bulbholder 1 Refitting
115. nings e Open the backrest belt 2 Velcro fastenings and adjust to the required length e Reattach the backrest upholstery and fix with Velcro fastenings 158 Invacare TDX SP Series TDX SP2 Series 8 20 8 20 1 W Seat system Modulite Replacing the tilt actuator SERVICE MANUAL Note Replacing the actuator for the seat angle adjustment in the lifter seat tilt adjustment module is also described Requirements Screwdriver flat width 6 mm 13 mm jaw spanner 2x Slotted screwdriver Remove legrests Switch the electronics OFF on the remote Disconnect the actuator cable from the cable harness Variant actuator tilt Bottom fixing bolt 3 with nut 4 Loose the nut with the open ended wrenches Remove the nut and bolt Top fixing bolt 2 secured with snap rings 1 Remove a snap ring using a screwdriver and remove the bolt Pull the actuator out Insert a new actuator Reassembly takes place in the reverse order Connect the actuator cable to the cable harness To complete check all seat tilting function Variant seat angle adjustment actuator in the lifter seat angle adjustment module Bottom fixing bolt 3 with slot Loosen the fixing bolt with a screwdriver Remove the bolt Top fixing bolt 2 secured with snap rings 1 Remove a snap ring using a screwdriver and remove the bolt Pull the actuator out Insert a new actuator Reassembly t
116. nts e 1 4 socket spanner e two long wooden blocks min 14 x 14 x 30 cm e M8 washer Note Invacare recommends always replacing both setting screws simultaneously in order to ensure that the wheelchair works perfectly Removing the setting screw e Lift the wheelchair up on one side and place a 14 cm high wooden block under the battery case so that the wheels are off the ground and can rotate freely Use proper lifting techniques e Repeat the same procedure on the other side of the wheelchair e Remove both the stability lock system protective caps The protective caps on the stability lock system will either be held using a screw or a cable tie depending on the wheelchair s date of manufacture e Undo the two bolts 2 with a 1 4 socket spanner and remove the bolts together with the nylon washers 3 193 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series e Undo and remove the lock nut 2 the setting screw 4 with a 1 4 socket spanner e Rotate the setting screw 4 towards the battery case until it can be removed from its holder 3 Refitting the setting screw e Screw the new setting screw 4 into the holder 3 e Screw the two bolts 2 together with their nylon washers 3 in again e Tighten the bolts using a 1 4 socket spanner e Remove the wooden block from under the wheelchair so that all wheels and castors are in contact with the floor 194 Invacare TDX SP Ser
117. on 108 Sg WV yi 9 8 a gt it N AD D Position the complete rear wheel suspension between the two mounting points 6 Fit the two sockets 5 and the two bolts 4 Tighten the bolts to 60 Nm Ensure that the rear springs are compressed Block method e Lift the suspension arm and place wooden blocks or similar underneath it until the springs are pressed together and the nylon spacer 2 can be fitted into the recesses provided in the suspension 6 Clamp method e Remove the rubber caps 9 e Press the springs together with a joiner s clamp or similar suitable clamp until the nylon spacer 2 can be fitted into the recesses provided in the suspension 6 Fit the two bolts 3 including the nylon spacer 2 Tighten the bolts to 8 5 Nm Replace the two rubber caps 9 if necessary Reinsert all the necessary plugs and fix the cables with cable ties as previously see also chapter 8 5 8 Refit the rear panel as described in chapter 8 1 2 Lift the wheelchair off the wooden blocks Check all the wheelchair functions If necessary carry out adjustments to the setting screw on the stability lock system as described in chapter 8 24 5 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 11 4 Refitting the rear wheel suspension alternative method e Position the mounting 5 centrally between the two suspension arms 1 e Push the pivot bar 4 including the remaining bolts and the sock
118. oper lifting techniques Refitting the tilt module e Refit the parts later in reverse order 137 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series Replacing the tilt module microswitch wW Requirements I e socket spanner 10 mm e 5mm Allen key e oblique pliers e cable ties Note i Either two microswitches or one microswitch and an angular sensor can be fitted The angular sensor see sub chapter Replacing the tilt module angular sensor Page 140 Removing the tilt module microswitch e Undo and remove the two cap nuts 1 on the right hand plastic cover 2 with a 10 mm socket spanner e Remove the plastic cover e Remove the two washers 5 e Loosen and remove the two nuts 4 with a 10 mm socket spanner 138 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL e Remove the servo motor including transmission e Undo the cable and plug for the microswitch Remove any cable ties which are fitted e Undo the Allen screws 3 with a 5 mm Allen key e Take the microswitch mounting off e Replace the microswitch Refitting the tilt module microswitch e Refit the parts later in reverse order 139 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series Replacing the tilt module angular sensor wW Requirements I e socket spanner 10 mm e oblique pliers e cable ties Removing the tilt module angular sensor e Undo and remove the two cap nuts 1 on the right
119. 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 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 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 1 3 bP BP DDD 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 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
120. ork 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
121. pection or repair WOFK eeececeeeeeceeeeneeseeeeeeeeeeenneeseeesneeseeesneeseeesneeseeesenseeeenes 12 2 2 Personal Safety CQUIPIMEN cccceseeeceeeseeeeeeeseeeeeeesneeeeeesneeeeessneeeeeesneeseessneeeeessneesesssneeeesesnee 12 2 3 General safety information and information about fitting removal csseeseeeeeees 12 3 Tightening torques 14 4 Layout of components and componentry 15 4 1 oa Er AEP EEE EEEE ETET ET EE E EEE 15 4 2 Electronic MOCUICS ccceceeececeeneeseeeeneeseeeeneeseeeeneeseeeeneeseeeeneeseeesneeseeesneesesesneeseeesneesesesneeseneenes 17 4 2 1 ACS2 electronic module ce eeecceecceceeeee cee eeeeaeeeeneeceaeeeceaeeeeaaesdeneeseaeeesaaesseaaeseeneeeaas 19 4 2 2 ACS2 PMASQOL electronic MOdUIC ccccceecceeeeeeeeeeeeeeee eae eeeaaeseeaeeceaeeesaeeeeaaeseeeeeeaas 19 4 23 Shark electr nic mod le ics seecs cessive tnt ivietgeecdeet ata eect ghesazeesrtavtal tet der sideee gh Taruia taia 19 4 2 3 1 Shark with DCIA2 poles asnon annaa taner EE aeia ark geht elite ane aaraa AUAA 19 4 2 4 ACT actuator MOGUIC iis 2ccssecehisesid sie seelccedteddaveeteadantvndecenes alateenedidenne anadodnes ceed 19 4 2 4 1 ACT 2 actuator MOUIC cccccceecceceeeeeeaeeeeeeeeeeeeeceaeeeeaaeseeaeeseeneeseaeeeeaaeeneaeeseeeeess 20 4 2 4 2 ACT 4 actuator MOUIC ccccceeeeeeceeeeeeeaeeeeeaeseeeeecaeeeceaeeeeaeeseeeeeseaeeesaeeneeeseeneess 20 42 52 LIGhting IRG R eter re cetesuneeNc a iat T 20
122. pter 8 10 1 e Undo and remove the three slotted screws 4 e Remove the splash guard 3 from the walking beam Refitting the splash guard e Refit the parts in reverse order e Tighten the splash guard screws to 4 5 Nm 45 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 3 8 3 1 i 8 3 2 46 W a Electronic module Replacing the remote Note Replacing the remote is very easy and is not described in detail However please note that when replacing an REM remote in connection with a DX ACS or ACS2 electronic module the subsequent selection of drive program should be carried out as described in chapter 8 3 3 Replacing the electronic module Note However please note that when replacing an REM remote in connection with a DX ACS or ACS2 electronic module the subsequent selection of drive program should be carried out as described in chapter 8 3 3 The various electronic modules can be fitted to the wheelchair with a range different remotes The possible electronic modules are described in chapter 4 2 Replacement is described below using the ACS2 electronic module with optional lighting PCB and optional actuator module as an example The procedure for other electronic modules is the same The only difference is the plug positions WARNING Any changes to the drive program can affect the driving characteristics and the tipping stability of the wheelchair e Changes to the
123. ra e aE NEA deen EAE E AART EEEE E VOE 69 Replacing the battery Case c scccceeeeeceeeeneeeeeeeneeeeeeeneeseeesneeseeesneeseeesneeseeesneeseeeseeeseeeenenseeeenes 70 Eaka E D oes cee eas aa er asic EE hee EA eet ese E D rected ceed ai Gt E T T A 71 8 8 1 Replacing the front bulb conventional lighting SySteM cece eeeeeeeeeeteeeeeeneeeeeees 71 8 8 2 Replacing the front headlight complete conventional lighting system s es 72 8 8 3 Replacing the front headlight complete TDX SP2 LED lighting system 74 8 8 4 Replacing the front bulbholder conventional lighting system 76 8 8 5 Replacing the front bulbholder TDX SP2 TDX SP conventional lighting system 77 8 8 6 Replacing the front bulbholder TDX SP2 LED lighting system s 78 8 8 7 Replacing the front bulbholder LED lighting System ceeeeeeeeeneeeeeenteeeeeeneeeeees 79 8 8 8 Replacing the rear bulb conventional lighting system ceeceeeseeeeeeetteeeeeeneeeeeees 80 8 8 9 Replacing the rear light complete conventional lighting system up to 08 2014 81 8 8 10 Replacing the rear light complete conventional lighting system starting 08 2014 83 8 8 11 Replacing the rear light complete TDX SP2 conventional lighting system 85 8 8 12 Replacing the rear light complete TDX SP2 LED lighting system c eee 87 8 8 13 Replacing the rear bulbholder conventional lighting system until 08 20
124. ries e Open the lifter energy chain lift the cover 1 up pull the tab 2 out of the cover repeat this part by part e Remove the two cable ties which fix the cable to the ends of the energy chain e Pull the cable out of the energy chain 1 N e Use the Phillips screwdriver to loosen the screws 1 e Remove the power supply chain 2 e Use the Phillips screwdriver to loosen the screws 4 e Additionally the sensor 5 is secured with nuts Loosen the nuts by holding against a 6 mm wrench e Remove the magnet 3 e Remove the sensor 5 e Undo the four bolts 2 on both sides of the seat using a V2 socket spanner e Lift the lifter tilt module off the battery case 146 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL Refitting the lifter tilt module e Refit the lifter tilt module in the reverse sequence e Tighten the connecting bolts between the lifter tilt module and the battery case to 18 Nm e When routing the cable ensure that it has been placed in the cable clamps so that it cannot be crushed or damaged in any way at any seat setting e Refit the batteries including battery supports as described in chapters 8 5 2 and 8 5 1 A WARNING Danger of crushing The seat is very heavy Injury hazard to hands and feet e Use proper lifting techniques e Refit the seat e Adjust the stability lock system as described in chapter 8 24 5 147 SERVICE MANUAL Invacare
125. ront cover panel e Remove the legrests e Remove both screws 1 n the ont cover panel 2 e Pull the front cover panel upwards and remove it Refitting the front cover panel e Refit the parts in reverse order e Tighten all the screws finger tight again 41 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 2 2 Opening the rear cover panel 8 2 2 1 Rear cover without an operating hours counter wW Requirements a e Phillips screwdriver size 2 Note ED This chapter explains how to open the rear cover if no operating hours counter is installed The procedure for opening the rear cover with an operating hours counter installed is described in chapter 8 2 2 2 Dismantling the front cover panel e Loosen the Phillips screw 1 on the rear frame cover panel 5 e Remove the rear cover panel from the frame e Loosen the thumb screw 9 of the rear cover panel 7 e Remove the rear cover panel Refitting the rear cover panel e Refit the parts in reverse order e Tighten all the screws finger tight again 42 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 2 2 2 Rear cover with an operating hours counter wW Requirements d e Phillips screwdriver size 2 Note e This chapter explains how to open the rear cover if an operating hours counter is installed The procedure for opening the rear cover with no operating hours counter installed is described in Cc hapt
126. ry case 187 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series e Undo the two Allen screws 9 with a 1 4 Allen key e Remove the bolts together with the washers 3 and the plates 2 and 4 e Remove the gas cylinder from the mounting 5 A e Remove the guide bush 1 if you wish to replace it or the gas cylinder itself e Remove the guide bush fixing 3 and or the clamping support 4 188 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 24 2 Repairing the gas cylinder When a gas cylinder has been removed it can be completely replaced or to have a range of maintenance work carried out on it as described in the following sub chapters 1 Replacing the guide block fixing 3 and or the clamping support 4 See chapter 8 24 2 1 2 Replacing the guide bush 1 See chapter 8 24 2 2 3 Replacing the gas cylinder See chapter 8 24 2 3 All the sub chapters relate to the following graphic 8 24 2 1 Replacing the guide block fixing or clamping support Removing e Remove the guide bush 1 from the gas cylinder piston 2 e Remove the guide block fixing 3 from the gas cylinder piston e Remove the clamping support 4 from the gas cylinder piston Refitting e Refit the replaced clamping support and guide block fixing in reverse order e Apply alittle Loctite 242 to the end of the gas cylinder piston in the area marked A on the graphic It is imperative that you do NOT appl
127. s and feet e Use proper lifting techniques Requirements e Phillips screwdriver size 2 e 5 8 socket spanner Note The front and rear wheels are adjusted in the same manner The following illustrations only show the front castor e f necessary remove the Philips screw 1 and the cover cap 2 e Tilt the wheelchair to the rear Use proper lifting techniques e Rotate the wheel forks 5 upwards e Let go of the wheel forks so that they can swing downwards again e Adjust the nut 4 with a 5 8 socket spanner so that the wheel forks are not too loose but can still rotate freely The wheel forks should oscillate to the opposite side a maximum of once and then come to rest facing downwards e Place the wheelchair on all four wheels again e Test the wheelchair s manoeuvrability e Repeat the adjustment steps if necessary until the castors are correctly adjusted e Replace the cap 2 and tighten the Philips screw 1 finger tight Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 9 3 Replacing the wheels on double sided wheel forks wW Requirements Y e 7 16 socket spanner e 7 16 jaw spanner e torque wrench 5 25 Nm or similar Removing the wheel e Loosen the nut 2 with a 7 16 socket spanner e Remove the bolt 6 with a 7 16 socket spanner e Remove the two washers 3 and 5 e Remove the wheel 4 e Replace any defective parts Refitting the wheel e Re
128. s are reassembled in the correct order and securely tightened during assembly When installing the seat pay attention to its heavy weight To complete check all seat tilting function 163 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 20 4 Replacing the backrest actuator Dismantling the backrest actuator e Pull the cable off directly where it is connected to the actuator 1 e Detach the bracket of the actuator at the top and bottom to do this slide the bolts 3 to the side using the lever 4 and tilt the actuator 1 out of the backrest clamp 2 e Replace actuator Refitting the backrest actuator e Assemble the parts in the reverse order 164 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 20 5 Replacing the seat support without lifter or tilt modules O A Note This chapter deals with replacing the seat support for a seat without lifter or tilt modules Please proceed as described in chapter 8 20 3 to replace lifter or tilt modules WARNING Danger of crushing The seat is very heavy Injury hazard to hands and feet Pay attention to the hand and feet Use proper lifting techniques Requirements 3 mm Allen key 10 mm open spanner T25 Torx wrench T40 Torx wrench Side cutting pliers Cable ties Remove legrests Switch the electronics OFF on the remote Remove the backrest cushion 5 C Loosen and remove the screws which secure the middle seat p
129. s are short circuited e Take special care that the battery terminals are NOT short circuited with a tool or metallic components of the wheelchair e Make sure that the battery terminal caps are fitted to the battery terminals at all times if you are not working on them CAUTION Danger of crushing The batteries are very heavy There is a danger that you may injure your hands e Take into account the heavy weight of the batteries e Handle the batteries carefully WARNING Risk of chemical burns Danger of injury by leaking acid e Wear acid resistant protective gloves when handling batteries e Wear protective goggles when handling batteries How to deal with a battery acid leak e Remove clothes that have been soiled or soaked with acid immediately e Immediately wash the affected area of skin that has come into contact with battery acid with lots of water After contact with eyes e Immediately rinse eyes under running water for several minutes Consult an eye doctor immediately afterwards Requirements e 11mm socket wrench e Side cutting pliers e Cable ties 61 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 62 Uninstalling batteries battery cables Remove the batteries as described in chapter 8 5 1 Positive terminal Remove the cable ties 1 with side cutting pliers Lift the battery terminal cap 2 off and move it up the cable and out of the way Use an 11 mm
130. stability lock system settings must be checked and readjusted if necessary as described in chapter 8 24 5 Removing the tilt module e f possible tilt the seat with the tilt module as far as possible to the rear e Switch the controller off e Remove the batteries as described in chapters 8 5 1 and 8 5 2 8 5 3 The actuator module for the lifter and the tilt actuators is fitted to the front edge of the seat support a e Remove the two knurled screws 1 including washers e Remove the cover 2 141 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series e Pull the plug out of the actuator module e Open the cable holder on the underside of the seat e Uncover all the cables so that you can lift the seat up WARNING Danger of crushing The seat is very heavy Injury hazard to hands and feet e Use proper lifting techniques e Undo the four bolts 1 which connect the seat to the tilt module using a 4 mm Allen key and a 13 mm open spanner e Lift the seat off the lifter tilt module Use proper lifting techniques 142 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL Undo the two Allen screws 3 on both sides of the seat with a 6 mm Allen key Remove the screws and the washers Lift the tilt module 1 off the battery case If one of the tilt mountings 2 needs to be replaced undo the four bolts 4 on the appropriate side of the seat using a V2 socket spanner remove t
131. teries 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 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 1 5 Images in this manual The detailed images in this manual are given digits to identify various components Component numbers in text and operational instructions always relate to the image directly above 11 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 2 1 O 2 3 A A 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 w
132. the bulbholder e Refit the parts in reverse order e Check all vehicle functions 91 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 9 Wheel forks front rear 8 9 1 Replacing the wheel fork wW Requirements da e Phillips screwdriver size 2 e 5 8 socket spanner Removing the wheel forks 1 1 e Undo the Philips screw 2 e Take the cover cap 2 off the castor housing 3 e Loosen the nut 1 with a 5 8 socket spanner e Remove the washer 2 e Pull the wheel fork 8 and the spacer 7 away downwards e f necessary you should also remove the ball bearings 3 and 6 in addition to the tolerance rings 4 and 5 92 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL Refitting the wheel fork e f you removed them replace the tolerance rings 4 and 5 and the ball bearings 3 and 6 e Place the spacer 7 on the wheel fork 8 e Insert the wheel fork from underneath e Fit the washer 2 from above e Fit the nut 1 and tighten it with a 5 8 socket spanner loosely so that the wheel forks can just turn e Adjust the castor as described in chapter 8 9 2 e Place the cover cap 1 on the castor housing 3 e Tighten the Philips screw 2 finger tight 93 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 9 2 Adjusting the wheel fork 94 WARNING Danger of crushing The mobility device is very heavy Injury hazard to hand
133. the rear cover panel 8 1 2 1 Rear cover without an operating hours counter wW Requirements I e Phillips screwdriver size 2 Note i This chapter explains how to open the rear cover if no operating hours counter is installed The procedure for opening the rear cover with an operating hours counter installed is described in chapter 8 1 2 2 Dismantling the front cover panel e Undo the three Phillips screws 1 on the rear cover panel 7 e Remove the rear cover panel Refitting the rear cover panel e Refit the parts in reverse order e Now tighten all the screws finger tight again 37 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 1 2 2 Rear cover with an operating hours counter W 38 Requirements e Phillips screwdriver size 2 Note This chapter explains how to open the rear cover if an operating hours counter is installed The procedure for opening the rear cover with no operating hours counter installed is described in Cc hapter 8 1 2 1 Dismantling the front cover panel Undo the three Phillips screws 1 on the rear cover panel 7 Carefully loosen the rear cover Pay attention to the cable of the operation hours counter Take note of the positions of the cables and sockets Mark the plugs and sockets or take a photo with a digital camera Detach the cable of the operating hours counter from the drive motor Remove the rear cover panel Refitting
134. tor module Loosen the screws 3 with a 6 mm Allen key Pull the entire legrest 2 forwards out of the seat frame profile Loosen and remove the screws 1 including the nuts and washers with a 4 mm Allen key and a 10 mm ring spanner or jaw spanner e Replace the legrest 2 179 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series Installing the electrically operated centre mounted legrest LNX e Assemble the parts in reverse order e Test all functions of the wheelchair 8 23 4 Replacing an electric legrest actuator A WARNING Danger of crushing The legrest is very heavy Danger of injury to hands and feet Pay attention to the heavy weight 1 4 Requirements iii e 1 2 socket wrench e 3 8 Allen key e Side cutting pliers e Cable ties Uninstalling the electrically operated legrest e f possible raise the lifter to the highest position e f possible tip the wheelchair with the tilt module as far backwards as it will go e Switch the electronic control system off The actuator module for the lifter and the tilt actuator are mounted to the front edge of the seat frame e Completely remove both knurled head screws 1 including the washers e Remove the cover 2 e Pull the plug of the legrest actuator out of the actuator module 180 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL e Use the 3 8 Allen key and a 1 2 socket wrench to loosen the screw 3
135. ts I e Phillips screwdriver size 2 e digital multimeter with resistance measurement e Remove the rear panel as described in chapter 8 1 2 e Pull the motor plug 3 out of the electronic module e Connect the digital multimeter to the motor plug contacts 3 and measure the resistance between the contacts Note i A resistance of between 0 5 and 5 ohms indicates a motor ready for operation A resistance of between 15 ohms and infinity indicates a defective motor High resistances are normally caused by bad connections or worn carbon brushes 33 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 7 2 Testing the electro mechanical parking brake Note e This test should only be carried out on wheelchairs with conventional motor transmission units wW Requirements i e Phillips screwdriver size 2 e digital multimeter with resistance measurement e Remove the rear panel as described in chapter 8 1 2 e Pull the motor plug 3 out of the electronic module e Connect the digital multimeter to the adjacent central motor plug contacts 3 and measure the resistance between the contacts e If there is a defect replace the motor and send it to Invacare Service for inspection or repair Note A resistance of between 40 and 80 ohms indicates an intact brake A resistance of 0 ohms or a very high resistance mega ohms or infinity indicates a short circuit a bad connection or a defective bra
136. uirements e Phillips screwdriver size 2 e 5 8 Allen key e socket spanner 11 mm 59 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 60 Removing the batteries e Make the batteries accessible as described in chapter 8 5 1 e Remove the terminal caps e Remove the terminal bolts 3 with an 11 mm socket spanner First remove the negative terminal bolt After this you can remove the positive terminal bolt e Remove the connection cable 4 and the connection cable with the main fuse 4 e Open the battery strap 5 e Lift the batteries 6 out of the battery carrier 1 Refitting the batteries e Refit the batteries in reverse order e Ensure that the battery cage sockets plugs have been correctly refitted A polarity diagram is located in the battery case cover Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 5 3 Replacing batteries replacing battery cables TDX SP TDX SP2 i A gt Gor gt W Note To replace the fuse the battery cable with the fuse attached to it must be replaced CAUTION Danger of injury and danger of damage to property if the batteries are handled incorrectly e The installation of new batteries may only be performed by authorised technicians e Pay attention to the warning notes on the batteries e Only use the battery type defined in the technical specifications CAUTION Risk of fire and burns if battery terminal
137. um speed reduction on a wheelchair with a lifter does not function correctly The wheelchair s control unit must reduce the maximum possible speed as soon as the lifter is raised e Test the maximum speed reduction for correct function after any maintenance work or modifications to the wheelchair Note Mark all current settings for the wheelchair seat armrests backrest etc and the associated cable connecting plugs before dismantling This makes reassembly easier All plugs are fitted with mechanical safety devices which prevent release of the connecting plugs during operation To release the connecting plugs the safety devices must be pressed in When reassembling ensure that these safety devices are correctly engaged WARNING Any changes to the drive program can affect the driving characteristics and the tipping stability of the vehicle e Changes to the drive program may only be carried out by trained Invacare specialist dealers e Invacare supplies all wheelchairs with a standard drive program ex works Invacare can only give a warranty for safe vehicle driving behaviour especially tipping stability for this standard drive program 13 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 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 dr
138. wheel hub SSD Motor cccceeecceeeeeeeeeeeeeeeeeteeeeeseaeeeeeeeeeeeeeeaas 103 Rear wheel SUSPENSION ccceceeeeeeeeeeeeeeeeneeseeeeeeeeeeesuee sees sneeseeeseeeseeeseeeeeeeseaeseenseeeeeenseeeeeenas 104 8 11 1 Removing the rear wheel SUSPENSION 0 ee cece cece ee eeee eter eeeeeeeeteaeeeeeseeeeeeseneaeeeeeeeaees 104 8 11 2 Removing the rear wheel suspension alternative Method eee eeeeeeeeeeeeeees 106 8 11 3 Refitting the rear wheel SUSPDENSION eceeeeeeeeeeeeeeeeeeeeeeeeeeeeeteeeeeeseaeeeeeeeeeeeeeeeeeaees 108 8 11 4 Refitting the rear wheel suspension alternative Method ec eeeeeeeeeeeeeeeeeeees 109 Reale SHINO S iaaa he eeertn te tee hacer oa eee east weet acer eats A T 111 8 12 1 Removing the rear SOringS cceceeeeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeaeeeeeeaeeeeeseeeeeeseneaeeeeeeeaees 111 8 12 2 Refitting the rear SPrinS ee eeeeeeeeeeeeeeeeeeeeeeeeeeneeeeeeeaeeeeeseaeeeeeseeeeeeseeeeeeeeeneeeeeeeeeeees 113 Bottom Walking beam csecceceeeeeceeeseeeeeeeneeseennneeseeesnee sees seeeseeeseeeeeenseeeseeeseaeeeenseeeeeenseeeeeenss 115 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 14 8 15 8 16 8 17 8 18 8 19 8 20 8 21 8 22 8 23 8 24 Top walking beam csisceee dence este cca ee ccc cee cece td eccnag ec zuccey es enceatvecacus tasuccerdvsuacedessuceeteecedeestesaceutes 116 8 14 1 Removing the top walking D AM cee ceeeeeeee
139. wheelchair 81 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series e Undo the two cap nuts 1 with an 8 mm socket spanner and remove the cap nuts complete with washers e Replace the rear light Dismantling the rear light e Refit the parts in reverse order e Check all vehicle functions 82 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 8 10 Replacing the rear light complete conventional lighting system starting 08 2014 wW Requirements d e Phillips screwdriver size 2 e socket spanner 8 mm Removing the rear light e Remove the rear panel as described in chapter 8 1 2 e Carefully note the location of the cable and the connection locations of the various plugs Either mark each plug and socket or take a photograph with a digital camera e On the illustration you can see the battery plug 1 the lighting PCB 2 for the electronic module 3 the optional cross connector 4 and the optional actuator module 5 e Loosen the cable leading to the lighting PCB from the rear light affected e Remove all cable ties and pull the cable out of the wheelchair 83 84 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series e Remove the two protect caps 5 Loosen and remove the two nuts 4 and 3 including the washers 6 and insulation ring 2 with an 8 mm socket spanner Replace the rear light and the lamp protector if necessary Dismantling the rear light e Ref
140. y e Remove the seat plate 1 or the sling seat see chapter 8 22 1 e Loosen the socket head screws 2 in the front and rear left and right DO NOT remove e Shift the position of the seat frame e Re tighten the screws e Install the seat plate again 208 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 10 2 2 3 Simple seat TDX SP2 TDX SP2 wW Requirements Ad e 6mm Allen key e Remove the seat plate 1 or the sling seat see chapter 8 22 1 e Loosen the socket head screws 2 and 3 in the front and rear left and right DO NOT remove e Shift the position of the seat frame e Re tighten the screws e Install the seat plate again 209
141. y Loctite to the locations marked B and C e Push the ball joint onto the gas cylinder until the end of the gas cylinder piston touches the release head 5 189 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 24 2 2 Replacing the guide bush Removing Remove the guide bush 1 from the gas cylinder piston 2 Refitting Apply a little Loctite 242 to the end of the gas cylinder piston in the area marked A on the graphic It is imperative that you do NOT apply Loctite to the locations marked B and C Push the new guide bush onto the gas cylinder piston until the end of the gas cylinder piston touches the release head 5 8 24 2 3 Replacing the gas cylinder 190 Removing Remove the guide bush 1 from the gas cylinder piston 2 Remove the guide block fixing 3 from the gas cylinder piston Remove the clamping support 4 from the gas cylinder piston Refitting Refit the clamping support and guide block fixing to the new gas cylinder piston in reverse order Apply a little Loctite 242 to the end of the gas cylinder piston in the area marked A on the graphic It is imperative that you do NOT apply Loctite to the locations marked B and C Push the guide bush onto the gas cylinder piston until the end of the gas cylinder piston touches the release head 5 Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 8 24 3 Refitting the gas cylinder e Move the gas cylinder gu
142. y afterwards Requirements e protective goggles e acid proof gloves e acid proof transport container e If handling damaged batteries always wear suitable protective clothing e Always deposit damaged batteries in suitable acid proof containers immediately after removal e Only transport damaged batteries in suitable acid proof containers e Always wash any objects which were contacted by acid in plenty of fresh water Always dispose used or damaged batteries correctly Used and damaged batteries will be taken back by your medical equipment supplier or Invacare 63 SERVICE MANUAL Invacare TDX SP Series TDX SP2 Series 8 5 5 Checking and replacing the main fuse TDX SP TDX SP2 A CAUTION Fire hazard A short circuit can cause extremely high currents which can result in spark formation and fire Always use an original strip fuse with the approved amperage If the main fuse has blown first rectify the cause before fitting a new one A CAUTION Fire hazard Fitting the incorrect strip fuse causes a fire hazard e Only fix the strip fuses in the sequence shown in the image on the right e Tighten the nuts with 3 3 or 3 5 Nm 1 Strip fuse 2 Spade terminal 3 DIN 6923 nut wW Requirements e e 5 8 Allen key Phillips screwdriver size 2 socket spanner 8 mm torque wrench 0 20 Nm or similar Note e If the fuseholder is damaged you can replace this complete with the battery
143. y and de greased threads 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 Thread M4 M5 M6 M8 M10 M12 M14 M16 Tightening torque in 3 Nm 6Nm 10Nm 25Nm 49Nm 80Nm 120 Nm 180 Nm Nm 10 UNC Thread Tightening torque inNm 1 4 20 11 7 Nm 5 16 20 22 14 Nm 3 8 16 41 25 Nm 7 16 14 67 40 Nm 1 2 13 100 60 Nm 9 16 12 150 90 Nm 5 8 11 210 130 Nm 3 4 1 370 230 Nm 7 6 9 600 370 Nm 1 8 900 550 Nm Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 4 Layout of components and componeniry 4 1 Overview At rear underneath seat Electronic modules The electronic modules are located underneath the rear cover panel 1 The electronic modules used are described in chapter 4 2 In rear cover 1 Operating hours counter optional 15 SERVICE MANUAL At the front underneath the seat 1 actuator module optional 2 lifter actuator optional 3 tilt actuator optional Invacare TDX SP Series TDX SP2 Series Invacare TDX SP Series TDX SP2 Series SERVICE MANUAL 4 2 Electronic modules A variety of electronic modules can be fitted to the wheelchair Before you connect

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