Invacare ® Leo SERVICE MANUAL
Contents
1. Only lift the vehicle by the chassis Note Pay attention to the positions of small parts such as screws and washers during disassembly Put small parts aside in such a way that they can be re fitted in the correct order Requirements 12 mm spanner 13 mm spanner 32 mm spanner Phillips screwdriver Remove the seat Hemove the motor cover Disconnect the battery cable 1 Remove the plastic plugs 1 or the rear view mirrors if fitted from the threaded holes Invacare Leo SERVICE MANUAL Remove the screws 1 beneath the control console Remove screws 2 Remove the control lever Pull the control console up out of the front fixation 1 Loosen and remove the screws 1 of the rear steering column cover Remove the steering column cover Remove the fixation screws of the front basket holder Remove the basket holder Remove the distance bushings 25 SERVICE MANUAL 26 Disconnect cables 1 2 from the cable loom Loosen and remove the screws 3 of the front steering column cover Remove the front steering column cover Slide the rubber sleeve upwards Loosen and remove the fixation screw of the steering column 1 using the 12 mm spanner Loosen screw 2 using the 13 mm spanner Further tasks Place the chassis upright on its seat adapter 1 Secure the chassis against falling over Invacare Leo Invacare Leo Removing the rubber mat from2. Clean contacts and terminals Evaluate blinking code Tighten or replace fixing Replace cable connecting plug Replace drive lever Replace cable connecting plug or console Invacare Leo SERVICE MANUAL m Check drive electronics program version Newer version available Drive program 15 SERVICE MANUAL Invacare Leo 5 Operational Faults 5 1 Operational faults Please proceed as follows if you have any problems First assess the possible cause of the problem using the following table Check the drive console status display Evaluate the blink error code Carry out the necessary checks and repairs as recommended in the following table 5 1 1 Drive fault diagnosis PROBLEM OTHER POSSIBLE SOLUTION Documentation SYMPTOMS CAUSE Scooter will Status display batteries Replace See operating manual not start on operating defective batteries console does completely Pre charge discharge battery batteries not illuminate Power supply to Check master See operating operating console fuse instructions for main fuse possibly position interrupted Check cable See Replacing the between electronics on page 40 modules for loose connections or damage Operating Replace See Replacing console defective operating operating console on console page 36 Operating unit Various causes Assess error See Error Codes and status display code Diagnostic Codes on blinking page 17 Invacare
3. Leo 5 2 Scooter judders in drive mode Drive motor defective Drive lever potentiometer defective Batteries None batteries not being defective charged SERVICE MANUAL Replace See Replacing the motor s drive motor on page 19 See Replacing the potentiometer on page 38 Replace See operating manual batteries Replacing the potentiometer LEDs blinking Charging unit Replace See charging unit on charging unit defective charging unit operating manual Scooter runs too slowly Operating console defective Replace operating console See Replacing operating console on page 36 batteries Replace See operating manual defective batteries Scooter does not reduce speed on bends Speed reducer for bend travel not adjusted Adjust speed reducer Speed reducer Replace speed See chapter Replacing defective reducer speed reducer Error Codes and Diagnostic Codes Blink Fault Consequence code for the Scooter Battery must be Continues to charged drive Battery voltage too Stops driving Battery voltage too Stops driving Comments The batteries are discharged Charge the battery as soon as possible The batteries are depleted Charge batteries If you switch the Scooter off for a few minutes the battery can often recuperate to such a stage that a short journey is still possible The battery voltage is too high If the battery charger is conn
4. SERVICE MANUAL 4 Service plan 1x annually Welded seams fixings and upholstery Seat suspension Frames Check fixings chassis battery mounting battery mounting suspension and for tight fit Check steering wheels for tight fit float and side play steering linkage Drive units coupling drive and push modes Check clutch mechanism mechanism welded seams and Check battery fixing Wheel Check drive wheels Pneumatic tyre Check tracking and Check functions in Tighten screws Invacare Leo Tighten screws replace parts if damaged Grease the spring See Replacing the generously seat suspension replace parts if spring on page 34 damaged Tighten screws replace parts if damaged Tighten hub nuts replace if necessary Adjust replace See Assembling and disassembling the wheels 4 wheel version and rear wheels on the 3 wheel version on page 21 Repair or replace See operating if damaged manual Tighten screws MEE Check tracking See Replacing and steering Replace motor if the drive motor on page 21 necessary nuts adjust or replace Batteries Check batteries for Replace batteries See operating damage manual Check battery charge batteries See operating voltage manual Check contacts and terminals otatus display flashing Fixing Cable connecting plug Drive electronics Drive lever function Power supply
5. a different size and only fit in one socket Requirements Open spanner 10 mm Open spanner 17 mm Oblique pliers Rubber hammer Phillips screwdriver Supporting wooden block Self locking nut 17 mm Secure the scooter against rolling away Place supporting wooden block under the frames at battery holder height From the operating manual Remove the seat Remove batteries Remove the drive unit Further work Cut through cable ties 1 and remove Fold up electronics cover 2 Invacare Leo SERVICE MANUAL Remove motor cable plug 1 from electronic system Remove motor cable Fold the drive to the rear onto the enclosure and the antitipper Remove wheels 1 see chapter 6 3 Loosen motor fixing bolts 1 on both sides and remove Remove motor downwards out of the vehicle frame Check rubber bearing 1 on motor suspension Replace damaged rubber bearings Reassembly of the motor takes place in reverse order Secure motor cable with cable tie Complete reassembly of vehicle Check all functions trial run 23 SERVICE MANUAL Invacare Leo 6 5 A A Li M 24 Replacing wheel suspension CAUTION Danger of accidents Accidents may result from standing the chassis upright on its end Secure the chassis against falling over WARNING Danger of damage to the scooter The plastic cover can be damaged if you attempt to lift the vehicle by its cover
6. the foot space Press the 6 fixation clips in in the middle of the clips using a screwdriver Remove the fixation clips Remove the foot mat Remove the 4 upper screws of the chassis Remove the 2 lower screws of the chassis Remove the chassis by pulling it upwards Remove the front wheel see chapter 6 2 SERVICE MANUAL 2 SERVICE MANUAL Invacare Leo Pull the fork out This can require a lot of strength as the fork 2 can be difficult to detach from the steering head holder 1 Remove clamp 1 Use the 32 mm spanner to loosen the fork bolt 2 Remove the retaining ring Remove the serrated washer Remove the knurled screw 3 Pull the steering column up and out Remove the ball bearing 1 28 Invacare Leo SERVICE MANUAL Re assembly is done in reverse order Check all functions test drive 29 SERVICE MANUAL Invacare Leo e O gt 30 Replacing the front axle 4 wheel version CAUTION Danger of accidents Accidents may result from standing the chassis upright on its end Secure the chassis against falling over WARNING Danger of damage to the scooter The plastic cover can be damaged if you attempt to lift the vehicle by its cover Only lift the vehicle by the chassis Note Pay attention to the positions of small parts such as screws and washers during disassembly Put small parts aside in such a way that they can be re fitte
7. Invacare Leo SERVICE MANUAL Edition 28 03 12 SERVICE MANUAL These instructions contain information about Testing work Repair Instructions This manual is part of the instructions for use Service addresses Fm CA i Fx any Les A j U E EN rm LM el LA a Ra Invacare Austria GmbH Herzog Odilostrasse 101 A 5310 Mondsee Austria Invacare n v Autobaan 22 B 8210 Loppem Brugge Belgium Invacare AG BenkenstraBe 260 CH 4108 Witterswil Switzerland Invacare Aquatec GmbH AlemannenstraBe 10 88316 Isny Deutschland Invacare A S Sdr Ringvej 37 DK 2605 Brendby Danmark Invacare SA c Areny s n Poligon Industrial de Celra E 17460 Celra Girona ESPANA Invacare Poirier SAS Route de St Roch F 37230 Fondettes France Fax WWW Fax WWW Fax WWW Fax WWW Kundeservice Fax Kundeservice WWW Fax WWW Fax WWW 43 6232 5 53 50 43 6232 5 53 54 info invacare austria com www invacare at 32 0 50 83 10 10 32 0 50 83 10 11 belgium invacare com www invacare be 41 0 61487 70 80 41 0 61487 70 81 switzerland invacare com www invacare ch 49 0 7562 70 00 49 0 7562 7 00 66 info invacare aquatec com www invacare aquatec de 45 0 36 90 00 00 45 0 36 90 00 01 denmark invacare com www invacare dk 34 0 972 49 32 00 34 0 972 49 32 20 contactsp inv
8. acare com www invacare es 33 0 247 62 64 66 33 0 247 42 12 24 contactfr invacare com www invacare fr Invacare Leo Invacare Leo Be Bu Tee en Ge B See Ten Invacare Ltd Pencoed Technology Park Pencoed Bridgend CF35 5HZ United Kingdom Invacare Mecc San s r l Via dei Pini 62 36016 Thiene VI Italia Invacare Ireland Ltd Unit 5 Seatown Business Campus Seatown Rd Swords County Dublin Ireland Invacare amp AS Grensesvingen 9 Postboks 6230 Etterstad N 0603 Oslo Norge Invacare B V Celsiusstraat 46 NL 6716 BZ Ede Nederland Invacare Lda Rua Estrada Velha 949 P 4465 784 Leca do Balio Portugal Customer services Fax Customer services WWW Fax WWW Fax WWW Kundeservice Fax Kundeservice WWW Fax WWW 44 0 1656 77 62 22 44 0 1656 77 62 20 uk invacare com www invacare co uk 39 0445 38 00 59 39 0445 38 00 34 italla invacare com www invacare it 353 18 10 70 84 353 18 10 70 85 ireland invacare com www invacare ie 47 0 22 57 95 00 47 0 22 57 95 01 norway invacare com island invacare com www invacare no 31 0 318 69 57 57 31 0 318 69 57 58 nederland invacare com csede invacare com www invacare nl 351 225 10 59 46 351 225 10 59 47 351 225 10 57 39 portugal invacare com www invacare pt SERVICE MANUAL SERVICE MANUAL ak 2 e e S Aterforsal
9. correct order Requirements Phillips screwdriver The crash protection bar 1 serves to protect the scooter from damage From the User Guide Remove the seat Remove the batteries Remove the drive unit Further tasks Place the chassis upright on its seat adapter 1 Secure the chassis against falling over Invacare Leo Loosen and remove the 6 fixation screws of the crash protection bar using a Phillips screwdriver Pull the crash protection bar up and out Assembly of the crash protection bar is carried out in the reverse order Test all functions test drive SERVICE MANUAL 33 SERVICE MANUAL Invacare Leo Vid 34 Replacing the seat suspension spring ATTENTION Risk of accident Accidental rolling can lead to accidents Secure the scooter against rolling away Note When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence Note The following seat support tubes are available for the seat suspension tube 136 kg 908 5 mm SP1528986 933 5 mm SP1528987 Requirements 2 open spanners 17 mm Secure the scooter against rolling away Remove the seat mia im vi pe Loosen the securing bolt of the seat support aT x tube AU rei Lead S S Invacare Leo SERVICE MANUAL Remove the bolt 7 nut and washers 2 Remove the seat support tube 2 from
10. d in the correct order Requirements 17 mm spanner 19 mm spanner From the User Guide Remove the seat Remove the batteries Remove the drive unit Further tasks Place the chassis upright on its seat adapter 1 Secure the chassis against falling over Remove the wheel 1 see chapter 6 3 Loosen and remove the nut on the track rod 1 see note below Remove the track rod from the steering knuckle Loosen and remove the nut of the axle suspension 2 Counter the axle suspension bolt 3 with a spanner so it cannot rotate while performing this task Pull the bolt 8 out and remove the axle assembly Invacare Leo SERVICE MANUAL Counter the tie rod end with a spanner while removing the nut 1 so it cannot rotate Re assembly of the axle is carried out in the reverse order Test all functions test drive 31 SERVICE MANUAL Invacare Leo 6 7 A A Li W 32 Replacing the crash protection bar CAUTION Danger of accidents Accidents may result from standing the chassis upright on its end Secure the chassis against falling over WARNING Danger of damage to the scooter The plastic cover can be damaged if you attempt to lift the vehicle by its cover Only lift the vehicle by the chassis Note Pay attention to the positions of small parts such as screws and washers during disassembly Put small parts aside in such a way that they can be re fitted in the
11. ected disconnect it from the Scooter The electronic system charges the batteries when running downhill and when braking This fault is caused when the battery voltage becomes too high during this process Switch the Scooter off and on again 17 SERVICE MANUAL Invacare Leo Blink Consequence Comments code for the Scooter Power time exceeded The maximum current was exceeded over too long a period probably because the motor was overloaded or has been working against an immovable resistance Switch the scooter off wait a few minutes and then switch on again Stops driving The electronic system has determined a motor short circuit Check the wiring harness for short circuit and check the motor Contact your Invacare dealer Brake failure Stops driving Ensure that the disconnection lever is pressed in There is a defect in the braking coil or in the cabling Check the magnetic brake No neutral position when switching Scooter on and cabling for open or short circuited circuitry Contact your Invacare dealer Stops driving Drive lever is not in neutral when the keyswitch was turned Put the drive lever in neutral turn the power off and then turn on again It may be necessary to recalibrate the drive lever Contact your Invacare dealer Fault in soeed potentiometer Stops driving The drive lever electronics could be faulty or incorrectly connected Check the cabling for open or shor
12. from the operating console Remove potentiometer 3 Set the potentiometer to the middle position see below Reassembly takes place in the reverse order Complete reassembly of vehicle Check all operating console displays Setting the potentiometer to the middle position Loosen the bolts 1 on the drive lever mounting Twist the potentiometer shaft 2 until the same resistance approx 5kOhm is measured between the central connection cable 3 and both outputs 4 Retighten the bolts on the drive lever mounting Check settings and repeat the adjustment if necessary SERVICE MANUAL 39 SERVICE MANUAL Invacare Leo 6 11 A A Vid 40 Replacing the electronics ATTENTION Risk of accident When parking the scooter on the scooters support wheels it is no longer slowed by the engine brake The scooter can roll away out of control Place the scooter rear frame on a supporting wooden block before you remove the wheels ATTENTION Burn and scald hazard if power cable is short circuited Turn off the power completely before removing any power supply components of the electric vehicle Therefore take out the batteries Avoid a bridging of the contacts during measurements on live electrical components WARNING Any changes to the drive program can affect the driving characteristics and the tipping stability of the mobility aid Changes to the drive program may only be carried ou
13. ings for the mobility aid seat armrests backrest etc and the associated cable connecting plugs before dismantling This makes reassembly easier All plugs are fitted with mechanical safety devices which prevent release of the connecting plugs during operation To release the connecting plugs the safety devices must be pressed in When reassembling ensure that these safety devices are correctly engaged A WARNING Any changes to the drive program can affect the driving characteristics and the tipping stability of the vehicle Changes to the drive program may only be carried out by trained Invacare specialist dealers Invacare supplies all mobility aids with a standard drive program ex works Invacare can only give a warranty for safe vehicle driving behaviour especially tipping stability for this standard drive program Invacare Leo SERVICE MANUAL 3 Tightening torques The tightening torques stated in the following list are based on the thread diameter for the nuts and bolts for which no specific values have been determined All values assume dry and de greased threads Tightening torque 3Nm 6 Nm 10Nm 25Nm 49Nm 80 Nm 120 Nm 180 Nm in Nm 10 CAUTION Damage can be caused to the mobility device due to improperly tightened screws nuts or plastic connections Always tighten screws nuts etc to the stated tightening torque Only tighten screws or nuts which are not listed here fingertight 13
14. inor injuries and or material damage if they are not avoided The following lines in italics refer to actions which serve to avoid such hazards CAUTION The signal word CAUTION refers to hazards which could lead to material damage if they are not avoided The following lines in italics refer to actions which serve to avoid such hazards Note The signal word Note is used to denote general information which simplifies the handling of your product and refers to special functions Invacare Leo SERVICE MANUAL 1 4 00 b pb b P uU 3 L Hazard symbols and symbols used Different types of hazard symbols and symbols are used throughout this manual General hazards This symbol warns you of general hazards Always follow the instructions to avoid injury to the user or damage to the product BURN HAZARD This symbol warns you of the danger of chemical burns for example due to the discharge of battery acids Always follow the instructions to avoid injury to the user or damage to the product DANGER OF CRUSHING This symbol warns you of crushing hazards due to inattentive working with heavy components Always follow the instructions to avoid injury to the user or damage to the product EXPLOSION HAZARD This symbol warns you of an explosion hazard which can be caused by excessive tyre pressure in a pneumatic tyre Always follow the instructions to avoid injury to the user or damage to the product Wear safety
15. jare Tt Invacare AB FI y Fagerstagatan 9 8 163 91 Sp nga Sverige Tillverkare Invacare amp Deutschland GmbH KleiststraBe 49 D 32457 Porta Westfalica Deutschland Eastern European Distributor european Organisation EDO countries KleiststraBe 49 D 32457 Porta Westfalica Deutschland Kundtjanst Fax Kundtjanst WWW M LNDAL Lh Fax LANDSKRONA Fax OSKARSHAMN TI Fax Fax WWW 46 0 8 761 70 90 46 0 8 761 81 08 sweden invacare com finland invacare com www invacare se 46 0 31 86 36 00 46 0 31 86 36 06 ginvacare invacare com 46 0 418 2 85 40 46 0 418 1 80 89 linvacare invacare com 46 0 491 1 01 40 446 0 491 1 01 80 oinvacare invacare com 49 0 5731 75 45 40 49 0 5731 75 45 41 edo invacare com www invacare de Invacare Leo Invacare Leo SERVICE MANUAL Table of Contents Chapter Page 1 INTRODUCTION 7 1 1 General information 7 1 2 Notes on transport 7 1 3 Definition and representation of information and safety information in this manual 8 1 4 Hazard symbols and symbols used 9 1 5 Images in this manual 10 2 SAFETY AND FITTING INSTRUCTIONS 11 2 1 Before any inspection or repair work 11 2 2 Personal safety equipment 11 2 3 General safety information and information about fitting removal 11 3 TIGHTENING TORQUES 13 4 SERVICE PLAN 1X ANNUALLY 14 5 OPERATIONAL FAULTS 16 5 1 Operational faul
16. m with wedges ATTENTION Fire and burn hazard due to electrical short circuit The mobility device must be completely switched off before removal of voltage carrying components To do this remove the batteries Avoid short circuiting the contacts when carrying out measurements on voltage carrying components 11 SERVICE MANUAL Invacare Leo A CAUTION Danger of burns from hot surfaces on the motor Allow the motors to cool down before commencing work on them A ATTENTION Injury hazard and danger of damage to vehicle due to improper or incomplete maintenance work Use only undamaged tools in good condition Some moving parts are mounted in sockets with PTFE coating Teflon Never grease these sockets Never use normal nuts instead of self locking nuts Always use correctly dimensioned washers and spacers When reassembling always replace any cable ties which were cut during dismantling After completing your work before renewed start up of the mobility device check all connections for tight fitting After completing your work before renewed start up of the mobility device check all parts for correct locking Only operate the vehicle with the approved tyre pressures see technical data Check all electrical components for correct function Please note that incorrect polarity can result in damage to the electronics Always carry out a trial run at the end of your work Note Mark all current sett
17. n to the positions of small parts such as screws and washers during disassembly Put small parts aside in such a way that they can be re fitted in the correct order Requirements 12 mm spanner 13 mm spanner Self locking nut 13 mm From the User Guide Remove the seat Remove the batteries Remove the drive unit 19 SERVICE MANUAL Invacare Leo Further tasks Place the chassis upright on its seat adapter 1 Secure the chassis against falling over Removing the wheel Use the 13 mm spanner to loosen the nut 1 Use the 12 mm spanner to counter the axle bolt 2 and prevent it from turning Slowly remove the axle Remove the wheel along with the distance bushings and washer Assembling the wheel Assembly of the wheel is carried out in the reverse order Pay attention to the correct position of the distance bushings and washer Use a new self locking nut Test all functions test drive 20 Invacare Leo SERVICE MANUAL 6 3 A Assembling and disassembling the wheels 4 wheel version and rear wheels on the 3 wheel version ATTENTION Risk of accident When parking the scooter on the scooters support wheels it is no longer slowed by the engine brake The scooter can roll away out of control Place the scooter rear frame on a supporting wooden block before you remove the wheels ATTENTION Risk of accident Accidental rolling can lead to accidents Secure the sco
18. order Modify the drive program Complete reassembly of vehicle Check all vehicle functions trial run 41 SERVICE MANUAL Invacare Leo 6 12 VW 42 Updating the driving program The driving programs for electric wheelchairs are continually updated and improved by Invacare For this reason you should check whether the version number is still up to date each time a wheelchair comes in for repairs and also during regular inspections If a newer version is available the driving program must be updated The procedure for updating the driving program is described in the user manual of the Wizard software NOTE The electronic system is supplied with a standard drive program If the driving program has been customised you have to perform this customisation again after installing the new driving program WARNING Every alteration to 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 amp can only assume a warranty for the safe vehicle handling of the wheelchair in particular tipping stability for unaltered standard drive programs Pre requisites Dynamic Wizard software User manual for the Wizard software For further information on other requirements such as the minimum system configuration of the PC to be used for programming necessary programming cables see
19. oter against rolling away NOTE When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence Requirements 17 mm spanner Rubber hammer Flat screwdriver Self locking nut 17 mm Block of wood Secure the scooter against rolling away Position the block of wood under the frame in the vicinity the battery box Removing the wheel Use the 17 mm spanner to loosen the nut 1 Remove the wheel If necessary loosen the wheel by tapping it lightly with a rubber hammer Assembling the wheel Assembly of the wheel is carried out in the reverse order Use a new self locking nut Test all functions test drive 21 SERVICE MANUAL Invacare Leo eo PN IU 22 Replacing the drive motor ATTENTION Risk of accident When parking the scooter on the scooters support wheels it is no longer slowed by the engine brake The scooter can roll away out of control Place the scooter rear frame on a supporting wooden block before you remove the wheels ATTENTION Risk of accident Accidental rolling can lead to accidents Secure the scooter against rolling away NOTE When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence NOTE The plugs on the electronic module cannot be wrongly connected because all plugs have
20. r work Read and observe this repair manual and the associated operating manual Observe the minimum requirements for carrying out the work see chapter entitled General information Personal safety equipment Safety shoes The mobility device and some of its components are very heavy These parts can result in injuries to the feet if they are allowed to drop Wear standardised safety shoes during all work Eye protection It is possible that battery acid can be discharged when working on defective batteries or when handling batteries improperly Always wear eye protection when working on any defective or possibly defective batteries Safety gloves It is possible that battery acid can be discharged when working on defective batteries or when handling batteries improperly Always wear acid 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 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 Switch the power supply off ON OFF key Engage the drive Before raising the vehicle secure the wheels by blocking the
21. rews 2 below operating console Invacare Leo Pull the operating console upwards out of the front fixing Remove all plugs 3 from operating console Replace operating console Reassembly takes place in the reverse order Complete reassembly of vehicle Check all operating console displays SERVICE MANUAL 37 SERVICE MANUAL Invacare Leo 6 10 Replacing the potentiometer JN ATTENTION Burn and scald hazard if power cable is short circuited Turn off the power completely before removing any power supply components of the electric vehicle Therefore take out the batteries Avoid a bridging of the contacts during measurements on live electrical components LN CAUTION Risk of accidents The new potentiometer must be set to the middle position before inserting Potentiometers which are not in the middle position can result in dangerous driving situations Vu Requirements dd Phillips screwdriver Allen key open ended spanner 2 mm Digital multimeter From the operating manual Remove the seat Remove the battery and motor compartment cover Disconnect battery plug Further work Remove battery plug 1 Remove plugs from rear mirror fixing 1 or rear mirror depending on fittings 38 Invacare Leo Remove screws 1 below operating console Pull the operating console upwards out of the front fixing 1 Remove drive lever 1 Remove potentiometer plug 2
22. shoes The symbol refers to the requirement for wearing safety shoes Wear standardised safety shoes during all work Wear eye protection This symbol refers to the requirement for wearing eye protection for example when working with batteries Wear eye protection when this symbol is shown Wear safety gloves This symbol refers to the requirement for wearing safety gloves for example when working with batteries Wear safety gloves when this symbol is shown Note This symbol identifies general information which is intended to simplify working with your product and which refers to special functions Requirements This symbol identifies a list of various tools components and items which you will need in order to carry out certain work Please do not attempt to carry out the work if you do not have the listed tools available Always dispose used or damaged batteries correctly The symbol refers to information for the correct disposal of used or damaged batteries SERVICE MANUAL Invacare Leo 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 Invacare Leo SERVICE MANUAL 2 1 Safety and fitting instructions These safety instructions are intended to prevent accidents at work and it is imperative that they are observed Before any inspection or repai
23. t by trained Invacare specialist dealers Invacare can only give a warranty for safe mobility aid driving behaviour especially tipping Stability for unaltered standard drive programs ATTENTION Risk of accident Accidental rolling can lead to accidents Secure the scooter against rolling away Note The electronic system is supplied with a standard drive program If you have carried out customer specific modifications to the drive program you will have to make these changes again after installing the new electronics module Note When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence Note The plugs on the electronic module cannot be wrongly connected because all plugs have a different size and only fit in one socket Requirements Phillips screwdriver Supporting wooden block To adapt the drive program programming software or hand programming device and electronics system installation manual available from Invacare From the operating manual Remove the seat Remove the battery and motor compartment cover Invacare Leo SERVICE MANUAL Further work Remove battery plug 1 Remove cover 2 from electronics system Remove all plugs 1 from electronic system Remove screws 2 on both sides of the electronics system Replace the electronics system Reassembly takes place in the reverse
24. t circuited circuitry Potentiometer is not correctly adjusted Put the potentiometer into the centre position Motor voltage error Stops driving The motor or its cabling is defective Check the cabling for open or short circuited circuitry Miscellaneous Stops driving Contact your Invacare dealer internal fault Push freewheel Stops driving The Scooter has exceeded the mode error permissible maximum speed during pushing or freewheeling Switch the electronics system off and on again 18 Invacare Leo SERVICE MANUAL 6 6 1 A A A d V Repair Work General warning information on installation work CAUTION Risk of damage to the vehicle Collisions can be caused if shim rings are removed from the drive wheels during installation work Shim rings are frequently placed between the drive shaft and the wheel hub to compensate tolerances Collisions can be caused if these shim rings are removed and not re installed Install all shim rings in exactly the same positions they were in before dismantling Assembling and disassembling the front wheel axle 3 wheel version CAUTION Danger of accidents Accidents may result from standing the chassis upright on its end Secure the chassis against falling over WARNING Danger of damage to the scooter The plastic cover can be damaged if you attempt to lift the vehicle by its cover Only lift the vehicle by the chassis Note Pay attentio
25. t for service technicians is suitable training such as in the cycle or orthopaedic mechanics fields or sufficiently long term job experience Experience in the use of electrical measuring equipment multimeters is also a requirement Special Invacare training is recommended Alterations to the mobility aid which occur as a result of incorrectly or improperly executed maintenance or overhaul work lead to the exclusion of all liability on the side of INVACARE If you have any problems or questions please contact Invacare Service 1 2 Notes on transport If the mobility aid has to be shipped back to the manufacturer for major repairs you should always use the original packaging for transport Please attach a precise description of the fault SERVICE MANUAL Invacare Leo 1 3 b b b b Definition and representation of information and safety information in this manual Different types of information and signal words are used throughout this manual HAZARD The signal word HAZARD refers to immediate hazards The following lines in italics refer to actions which serve to avoid such hazards WARNING The signal word WARNING refers to possibly occurring hazards which can lead to death or serious injuries if they are not avoided The following lines in italics refer to actions which serve to avoid such hazards ATTENTION The signal word ATTENTION refers to possibly occurring hazards which can lead to m
26. the user manual of the Wizard software You find the latest version of the user manual in the download area on http www dynamiccontrols com Invacare Leo SERVICE MANUAL Accessories 8 Requirements 7 7 1 Installing the windshield 13 mm open ended wrench 14 mm open ended wrench Remove the rear view mirror and the stoppers of the plastic cover on the handlebars Remove the threaded bolts of the rear view mirror holder Insert the threaded bolts 1 into the holes in the brackets 2 Screw the threaded bolts instead of the mirror brackets into the holes provided for this purpose but don t tighten the bolts completely yet Make sure the brackets are turned so they point upwards and outwards towards the ends of the handlebars Loosen the wing nuts 1 Insert the non threaded ends of the windshield brackets 2 into the fixtures from below 43 SERVICE MANUAL Invacare Leo Insert the threads of the windshield mounting brackets 3 through the bracket holders 1 Secure the windshield mounting brackets with the self locking nuts 2 Adjust the windshield using the nuts 2 and 4 on both sides so that it is perpendicular to the direction of travel Adjust the windshield so that it is horizontal Tighten the wing nuts Now tighten the threaded bolts Install the rear view mirrors again 44
27. the we receptacle tube 1 Remove the concertina type cover 3 3 including the spring 5 and the plastic end ims pieces 4 and 6 Fit the plastic end pieces 4 and 6 to the new spring S Grease the spring generously The spring 2 should be covered completely a Assemble the concertina type cover 3 lem Install the concertina type cover 3 including oe ai the spring 5 and the plastic end pieces 4 der a and 6 Oe ee C Insert the seat support tube 2 into the AL nr receptacle tube 1 and press down gently Reposition the bolt 7 nut and washers Firmly tighten the seat support bolt Reposition the seat em 35 SERVICE MANUAL Invacare Leo W 36 Replacing operating console ATTENTION Burn and scald hazard if power cable is short circuited Turn off the power completely before removing any power supply components of the electric vehicle Therefore take out the batteries Avoid a bridging of the contacts during measurements on live electrical components Note When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence Requirements Phillips screwdriver From the operating manual Remove the seat Remove the battery and motor compartment cover Disconnect battery cable 1 Remove plugs from rear mirror fixing 1 or rear mirror depending on fittings Remove sc
28. ts 16 5 1 1 Drive fault diagnosis 16 5 2 Error Codes and Diagnostic Codes 17 6 REPAIR WORK 19 6 1 General warning information on installation work 19 6 2 Assembling and disassembling the front wheel axle 3 wheel version 19 6 3 Assembling and disassembling the wheels 4 wheel version and rear wheels on the 3 wheel version 21 6 4 Replacing the drive motor 22 6 5 Replacing wheel suspension 24 6 6 Replacing the front axle 4 wheel version 30 6 7 Replacing the crash protection bar 32 SERVICE MANUAL 6 8 Replacing the seat suspension spring 6 9 Replacing operating console 6 10 Replacing the potentiometer 6 11 Replacing the electronics 6 12 Updating the driving program Invacare Leo 34 36 38 40 42 Invacare Leo SERVICE MANUAL 1 Introduction 1 1 General information Service and maintenance work must be carried out taking this service manual into account lt is imperative that you observe safety information Information about operation or about general maintenance and care work on the mobility aid should be taken from the operating manual You can find information about ordering spare 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 requiremen
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