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Invacare ® FDX SERVICE MANUAL

1. Requirements e 11mm socket wrench e Side cutting pliers e Cable ties Invacare FDX SERVICE MANUAL Uninstalling batteries battery cables Remove the batteries as described in chapter 8 4 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 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 55 SERVICE MANUAL Invacare FDX 8 4 3 How to handle damaged batteries correctly A O W 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
2. ACS 2 PMB70L ACS PMAS0LG power modules Invacare FDX SERVICE MANUAL Co e o REM B REM 550 Can be connected to ACS 2 PMB70 ACS 2 PMB70L ACS PMA90LG power modules Can be connected to ACS 2 PMB70 ACS 2 PMB70L ACS PMA90LG power modules 21 SERVICE MANUAL Invacare FDX 5 A 22 Maintenance plan once a year 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 for Measures Remarks P Restraining belt restraining belt damaged replace e Function of the belt F the belt is See chapter 9 1 buckle damaged replace e Damage to the i the arm pad is armrests damaged replace e Fixation of the a screws a armrests e Damage tothe side e Replace the side e Fixation screws of e Tighten screws the side parts e Damage to the e Replace parts if backrest damaged Seams e Tighten screws e e Fastening e Replace cable or e Check cable motor if necessary e Electric backrest if available Check function Check fastenings e Tighten screws welding seams and e Replace parts if battery box necessary Frame chassis battery compart
3. Check all functions of the vehicle and go for a test drive Invacare FDX SERVICE MANUAL 9 Installing accessories 9 1 Replacing the restraining belt wW Requirements wy e 10mm socket wrench e 4mm Allen key Uninstalling the restraining belt e Loosen the screw 3 and the corresponding nut not shown in the illustration with a 4 mm Allen key and a 10 mm socket wrench e Remove the nut including the washer Remove the screw together with the restraining belt and the washer 2 and also the washer behind it Note ca Another nut is used between the washers as a spacer so that the belt bracket can move freely e Replace the restraining belt 1 Installing the restraining belt e Assemble the parts in reverse order 149 SERVICE MANUAL Invacare FDX 9 2 Fitting the stick holder wW Requirements iV e 5mm Allen key e Phillips screwdriver size 2 J z Di le 4 fh up itan oe Ay afi 1 oO L e o g 2 o gt r e Insert the Phillips screw 2 through the borehole of the loop 3 e Attach the Phillips screw and the loop to the borehole 1 of the handlebar and tighten the Phillips screw with a Phillips screwdriver e Loosen and remove the two Allen screws 6 incl the washers on the lower part of the backrest hinge 4 e Hold the lower mounting 5 with the fastening holes in front of the boreholes of the backrest hinge e Refit the t
4. Battery voltage is too low to operate mobility aid Replace the batteries See chapter 8 4 1 Invacare FDX SERVICE MANUAL 7 Test procedures 7 1 Testing the motor wW Requirements V 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 1 out of the electronic module e Connect the digital multimeter to the motor plug contacts 3 and measure the resistance between the contacts Note a 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 FDX 7 2 Testing the electro mechanical parking brake Note e This test should only be carried out on mobility aids with conventional motor transmission units wW Requirements IV e Phillips screwdriver size 2 e digital multimeter with resistance measurement e Remove the rear panel as described in Chapter 8 1 2 o am AEN p SN AAN e ON JENN y NN L VA LQ V4 Be A ae EQS VTL Ps a Y 3 f Af ae TO lt a o A AN f E El mal z t ay jes a 4 e Connect the digital multimeter to the adjacent central motor plug contacts 3 and measure the resistance between the contacts e If t
5. e Engage the drive e Before raising the vehicle secure the wheels by blocking them with wedges ATTENTION Fire and burn hazard due to electrical short circuit e The mobility device must be 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 13 SERVICE MANUAL Invacare FDX 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 resul
6. 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 Safety goggles e Acid resistant gloves e Acid resistant container for transportation e Always wear appropriate safety clothing when handling damaged batteries e Place damaged batteries in an acid resistant container immediately after removing them e Only ever transport damaged batteries in an appropriate acid resistant container e Wash all objects that have come into contact with acid with lots of water Disposing of dead or damaged batteries correctly Dead or damaged batteries can be given back to your dealer or directly to Invacare 8 4 4 Replacing the main fuse 56 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 4 2 Invacare FDX SERVICE MANUAL 8 4 5 Checking the cables wW Requirements wy e Side cutting pliers e Cable ties e Remove the covers disconnect the battery plug connections and pull the batteries out of the battery compartment as described in chapter 8 4 1 e Check the fuse cable 1 the battery cable
7. 2 Remove the seat including the seat frame as described in chapter 8 13 and 8 14 Remove the batteries as described in chapter 8 4 1 If necessary remove the conventional rear lighting system as described in chapters 8 6 10 and 8 6 13 Remove the anti tipper wheels as described in chapter 8 9 Remove the motor gearbox mounting including suspension as described in chapter 8 12 Remove the fixation rings as described in chapter 8 19 Replace the battery box Installing the battery box Install the fixation rings as described in chapter 8 19 Install the motor gearbox mounting including suspension as described in chapter 8 12 Install the drive wheels as described in chapter 8 8 1 Install the anti tipper wheels as described in chapter 8 9 If necessary install the conventional rear lighting system as described in chapters 8 6 10 and 8 6 13 Install the batteries as described in chapter 8 4 1 Install the seat including the seat frame as described in chapter 8 13 and 8 14 Install all electronic modules that are fitted in the rear on the battery box as described in chapter 8 2 2 Install all plastic covers as described in chapter 8 1 Install the drive wheels as described in chapter 8 8 1 Perform a comprehensive driving and function test with the wheelchair 59 SERVICE MANUAL Invacare FDX 8 6 Lighting system Note a There are two different lighting units A conventional lighting unit with bulb
8. 2 and the battery connections 3 for visible damage and pinches e Replace damaged cables as described in chapter 8 4 2 Note D The positions of the plugs are described in chapter 4 2 P 57 SERVICE MANUAL Invacare FDX 58 Check all cables for visible damage and crushing Replace damaged cables Pull on each plug 1 carefully The plug must not come out of the socket If a plug is loose apply slight pressure to push the plug into the socket The plug must snap in place securely Check whether the connector is fitted firmly If not repeat the previous step Assemble the parts in reverse order Check all functions of the vehicle and go for a test drive Invacare FDX SERVICE MANUAL 8 5 Wi a Replacing the battery boxes Requirements 7 mm socket wrench 8 mm socket wrench 10 mm socket wrench 13 mm socket wrench 16 mm socket wrench 22 mm socket wrench 13 mm open ended wrench 3 mm Allen key 4 mm Allen key 5 mm Allen key 6 mm Allen key Small flat screwdriver Torque wrench 5 30 Nm or similar Torque wrench 10 80 Nm or similar Side cutting pliers Cable ties Two oblong wooden blocks at least 14 x 14 x 30 cm Uninstalling the battery box Remove the drive wheels as described in chapter 8 8 1 Uninstall all plastic covers as described in chapter 8 1 Remove all electronic modules that are fitted in the rear on the battery box as described in chapter 8 2
9. Phillips head screws 2 to remove the headlight from the bracket Replace the headlight Installing headlights Assemble all parts again in reverse order Install the cables carefully and secure them with the cable clamps and cable ties Tighten the screws hand tight Check all vehikel functions Perform an approximate adjustment of the headlight using the ratchet plate as a guide The final adjustment can be performed by the user according to the instructions found in the User Guide Invacare FDX SERVICE MANUAL 8 6 5 Replacing the head lamps completely LED lighting system until 03 2012 wW Requirements ry e 3mm Allen key e Side cutting pliers e Cable ties Uninstalling head lamps e Remove the rear cover as described in chapter 8 1 2 e Take exact note of the positions of all cables and the sockets 1 that they are connected to Mark the connectors and sockets or take a photograph with a digital camera e Disconnect the cable of the affected head lamp from the lighting circuit board e Remove all cable ties and pull the cable out of the wheelchair e Loosen the hexagon socket head screw 1 with a 3 mm Allen key and remove the head lamp from the bracket e Replace the head lamp 65 SERVICE MANUAL Invacare FDX 66 Installing head lamps Assemble all parts again in reverse order Install the cables carefully and secure them with cable ties Make sure that the cables not are not pinche
10. Replace clutch See chapter 8 11 3 defective Bearing Replacing the See chapter 8 11 1 defective motor Collector Measure internal See chapters 7 1 defective resistance of and 8 11 1 motor replace motor if defective Motors do not None Bad Check all cabling See chapter 8 4 5 run connections Fuse burnt out Check cabling and replace fuse See chapters 8 4 5 and 8 4 4 Batteries Replace batteries See chapter 8 4 1 defective Cabling to check cabling See chapter 8 4 5 electronic 27 SERVICE MANUAL Invacare FDX PROBLEM OTHER POSSIBLE SOLUTION DOCUMENTATION SYMPTOMS CAUSE module or joystick defective Electronic Replacing the See chapter 8 2 2 module electronic module defective Corroded Water salt or Check cabling See chapter 8 4 5 contacts urine has replace if penetrated necessary Motor makes None Clutch es Replace clutch See chapter 8 11 3 clicking noise defective Bearing Replacing the See chapter 8 11 1 defective motor Collector Measure internal See chapters 7 1 defective resistance of and 8 11 1 motor replace motor if defective Scraping noise None Clutch es Replace clutch See chapter 8 11 3 or motor defective blocked Bearing Replacing the See chapters 8 11 1 defective motor and 8 11 3 Transmission Replace See chapters 8 11 1 defective transmission and 8 11 3 Transmission None Transmission Replace See chapters 8 11 1 makes cl
11. 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 Thread M4 M5 M6 M8 M10 M12 M14 M16 Tightening torque 3 Nm 6Nm 10Nm 25Nm 49Nm 80 Nm 120 Nm 180 Nm in Nm 10 A 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 15 SERVICE MANUAL Invacare FDX 4 Arrangement of sub assemblies and components 4 1 Overview In the rear under the seat Electronic modules The electronic modules are located under the rear cover 1 Electronic module 2 Actuator module optional 3 Lighting circuit board optional amp not shown in the illustration The electronic modules that are installed are described in chapter 4 2 In the front under the seat 1 Actuator module optional 2 Lifter actuator optional 3 Tilt actuator optional On the right next to the spring seat pN 1 G Trac sensor optional j Invacare FDX 4 2 Electronic modules SERVICE MANUAL Various different types of electronic modules can be installed in the wheelchair Before you connect components of the wheelchair such as adjustment motors or actuat
12. crossbar at the rear and remove them e Release the two upper front Allen screws 9 on the seat mounting plate and remove them e Loosen the four Allen screws at the front 7 and at the rear 8 that can be found on the side of the seat mounting plate in order to release tension and facilitate moving the plates Do not remove these screws entirely 117 SERVICE MANUAL Invacare FDX e Pull or push the seat mounting plate 2 to the desired width A scale 3 is included on the lower part of the seat support You can read off the seat width in centimetres on the scale e Repeat these work steps on the other side of the seat e Now tighten all the screws again 118 Invacare FDX SERVICE MANUAL 8 15 2 Adjusting the seat depth Note ij The seat depth can be adjusted in stages between 38 and 53 cm Please also observe preceding chapter 8 15 1 on adjusting the seat width wW Requirements 1M e 4mm Allen key e 8mm jaw spanner e Oblique pliers e Cable ties Note ij Certain holes in the seat support must be used for the screws depending on the desired seat depth It may possibly be necessary to replace the seat support plates e Use the following illustration and the table to determine which holes must be used for the desired seat depth and whether the seat support plates possibly have to be replaced sad dvs ile ed Seat frame front 1524550 are 1524555 i Bic Seat frame re
13. in reverse order e To conclude check all the mobility aid functions 131 SERVICE MANUAL Invacare FDX 8 17 1 1 Adjusting the belt back The belt back can be individually adapted to the back shape of the user e Pull apart the front and back of the back cushion 1 and remove it Front and back of the back cushion is held together by Velcro e Open Velcro straps of the back straps 2 and set it to the desired length e Refit the back cushion and fasten with Velcro 132 Invacare FDX SERVICE MANUAL 8 17 2 Replacing the EasyAdapt back iV e 5mm Allen key e Oblique pliers e Cable ties 1 A Requirements Dismantling the back unit e Remove the back cushion e Pull the actuator cable out of the actuator module under the seat e Pull the cable out of the mobility aid Remove any cable ties which are fitted e Loosen and remove the Allen screws 5 incl the washers on the left and right side of the seat e Carefully remove the back section 1 together with the lower part 2 from the seat support 3 The two parts are interconnected via the arm 4 Refitting the back unit e Refit the parts in reverse order e To conclude check all the mobility aid functions 133 SERVICE MANUAL Invacare FDX 8 17 3 Replacing adjusting the universal backrest frame for the EasyAdapt backrest wW Requirements sd Measuring tape Adhesive tape 13 mm open end wrench 4 mm Allen key 5 mm Allen key Phillip
14. key at the same time e Liftthe seat off 100 Invacare FDX SERVICE MANUAL Uninstalling the seat frame A front seat frame B rear seat frame Use a 6 mm Allen key to loosen the hexagon socket head screws 2 Pull the seat frame 1 up and off Installing the seat and seat frame Assemble all parts in reverse order When installing the seat pay attention to its heavy weight When installing the seat pay attention to the adjustment settings of the seat tilt Tighten the screws to a torque of 25 Nm Check all functions of the vehicle and go for a test drive 101 SERVICE MANUAL Invacare FDX 8 14 8 14 1 e A W 102 Replacing the tilt module lifter module Replacing the tilt module without lifter Note This chapter describes how to replace the tilt module on a wheelchair without a lifter Similar tasks are described In the following chapters e Replacing the seat frame alone chapter 8 13 e Replacing a lifter tilt module chapter 8 14 2 e Replacing just the tilt actuator chapter 8 14 3 e Replacing just the lifter actuator chapter 8 14 4 WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Leta second person help you Requirements e 13mm open ended wrench 4 mm Allen key 6 mm Allen key Side cutting pliers Cable ties Note Take careful note of the exact position of the seat Mark the positio
15. order e To conclude check all the mobility aid functions 140 Invacare FDX SERVICE MANUAL 8 18 4 Replacing the microswitch wW Requirements WA e 4mm Allen key e Size 2 Phillips recessed head spanner Dismantling the microswitch e Loosen and remove the four Allen screws on the backrest plastic cover using a 4 mm Allen key e Remove the plastic cover Pull the plugs 2 out of the microswitch 1 Loosen and remove the two Phillips screws 3 Replace the microswitch Refitting the planetary gear e Refit the parts in reverse order e To conclude check all the mobility aid functions 141 SERVICE MANUAL Invacare FDX 8 18 5 Fitting back plates to the base support of the back with ergonomic length Wd 142 adjustment Requirements e 4mm Allen key Loosen the three Allen screws 1 but do not remove them completely Move the back plate 2 so that the large boreholes 3 are above the lower screw holes of the centre back plate Tighten the three Allen screws slightly Repeat this on the second back plate Move the back of the seat to the rearmost position Slide the two lower slot nuts 4 in the left hand and right hand groove right down to the bottom Push the upper ones so far to the top that the distances of the slot nuts coincide with the distances of the screw holes Place the centre part of the back plate 3 on the backrest so that the four boreholes coincide
16. person help you Requirements 6 mm Allen key Torque wrench 5 30 Nm or similar Protractor Side cutting pliers Cable ties Wooden block Note Take careful note of the exact position of the seat Mark the position it is mounted in the angle and so on If necessary make photographs with a digital camera Any modification of the adjustment of the seat affects the centre of gravity of the wheelchair Removing the seat e Switch the wheelchair off e Remove the front cover and the rear covers as described in chapters 8 1 1 and 8 1 2 e Take exact note of the positions of all cables and the sockets 1 that they are connected to Mark the connectors and sockets or take a photograph with a digital camera e Detach all cables from the electronic modules which run from the seat to the chassis e Place the cables so that they do not get in the way when you remove the seat 99 SERVICE MANUAL Invacare FDX e Insert a suitable wooden block 2 between the seat 1 and the chassis 3 This will prevent the seat from falling down when you loosen and remove the screws A WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Leta second person help you e Use the 6 mm Allen key to loosen and remove the screws 4 on both sides in the front at the same time e Hold the seat securely and loosen the rear hexagon socket head screw 5 on both sides with a 6 mm Allen
17. the front battery 2 e Remove the rear cover as described in chapter 8 1 2 e Take exact 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 e f necessary remove the cable ties that secure the bundles of cables to the chassis on both sides of the electronic modules e Position the bundles of cables so that they lie outside of the fixation screws 1 of the electronic module brackets e Loosen and remove both fixation screws of the electronic module brackets including the washers with a Phillips screwdriver 52 Invacare FDX SERVICE MANUAL e Disconnect the plug in connection 1 of the rear battery 2 e Disconnect the battery cable from the electronic module e Lift the electronic module bracket up and remove it Pull the bracket towards the rear and let it hang over the back end of the wheelchair e Pull both batteries backwards out of the chassis and remove them Take into account the heavy weight of the batteries Installing batteries e Install the batteries in reverse order e 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 53 SERVICE MANUAL Invacare FDX 8 4 2 Replacing batteries replacing battery cables O A gt Gor P gt We 54 Note To replace the fuse the battery cable
18. the instructions found in the User Guide Invacare FDX SERVICE MANUAL 8 6 7 Replacing the head lamp bracket conventional lighting system until 03 0212 wW Requirements H e Phillips screwdriver size 2 e 8mm socket wrench Uninstalling the head lamp bracket Loosen both of the cap nuts 1 with an 8 mm socket wrench and remove the head lamp with the bracket from the rubber mounting Not shown in the illustration are two Phillips head screws with which the head lamp is secured to the bracket Loosen both of these Phillips head screws to remove the head lamp from the bracket Replace the bracket Installing the head lamp bracket Assemble all parts again in reverse order Tighten both screws hand tight Check all vehicle functions Perform an approximate adjustment of the head lamp using the ratchet plate as a guide The final adjustment can be performed by the user according to the instructions found in the User Guide 69 SERVICE MANUAL Invacare FDX 8 6 8 Replacing headlamp brackets conventional lighting system starting 03 2012 wW Requirements dii e Phillips screwdriver size 2 e Open end wrench 8 mm Uninstalling the tail light bracket e Loosen both of the nuts 1 with an 8 mm open end wrench and remove the headlight with the bracket from the rubber mounting e Loosen both Phillips head screws 2 to remove the headlight from the bracket e Replace the bracket Installing
19. the remote or the ACS 2 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 module 49 SERVICE MANUAL Invacare FDX 8 3 50 Wi 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 ACS 2 remotes which are activated ex works WARNING Every alteration
20. 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 130 Invacare FDX SERVICE MANUAL 8 17 Back unit 8 17 1 Replacing the standard back wW Requirements seal e 5mm Allen key e socket spanner 13 mm QY s E Ss l SA S t NN i OR Dismantling the back unit e Remove the back cushion e Loosen and remove the handwheels 3 and the Allen screws 4 including the washers on the left and right side of the mobility aid e Carefully remove the rear pipe 1 of the back bracket 2 e If the backrest holders also need to be replaced undo and remove the Allen screws 5 including the washers on the left hand and right hand side of the chair Refitting the back unit e Refit the parts
21. the two Allen screws 6 with a 5 mm Allen key e Remove the Allen screws 6 incl the washers and the stick holder 5 if necessary e When replacing both planetary gears or dismantling the entire back section also now loosen and remove the Allen screws 6 incl the washers on the other side of the mobility aid e Undo the two Allen screws 2 with a 5 mm Allen key You will need an additional 13 mm jaw spanner for the opposite nut on the right side of the mobility aid e Remove the Allen screws 2 incl the washers and the nut if necessary e Pull the planetary gear from the axle e Replace the planetary gear 138 Invacare FDX SERVICE MANUAL Refitting the planetary gear e Refit the parts in reverse order e To conclude check all the mobility aid functions 139 SERVICE MANUAL Invacare FDX 8 18 3 Replacing the servo motor wW Requirements Aai 4 mm Allen key 5 mm Allen key 10 mm socket spanner 13 mm jaw spanner Size 2 Phillips recessed head spanner Snap ring pliers Fitting the planetary gear e Disconnect the two motor plugs 1 e Dismantle the entire back section and remove both planetary gears as described in chapter 8 18 2 e Loosen and remove the two nuts 2 only the upper nut is visible in the illustration e The motor 5 and the gear 4 form one unit Pull them from the axle together 3 e Replace the motor gear unit Refitting the planetary gear e Refit the parts in reverse
22. 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 terminals 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 caretully 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
23. 8 3 Replacing the servo motor 140 8 18 4 Replacing the microswitch 141 8 18 5 Fitting back plates to the base support of the back with ergonomic length adjustment 142 8 18 6 Fitting the handlebar 143 8 18 7 Replacing the travelling armrest 144 8 18 8 Replacing the arm support on the travelling armrest 145 8 18 9 Retrofitting a travelling armrest 146 8 19 Fixation rings 147 8 19 1 Replacing a front fixation ring 147 8 19 2 Replacing a rear fixation ring 148 SERVICE MANUAL 9 INSTALLING ACCESSORIES 9 1 Replacing the restraining belt 9 2 Fitting the stick holder 9 3 Further accessories Invacare FDX 149 149 150 151 Invacare FDX SERVICE MANUAL 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 orthop
24. E PLAN ONCE A YEAR 22 6 OPERATIONAL FAULTS 25 6 1 Drive fault diagnosis 26 6 2 REM remotes Error codes and diagnostic codes 30 6 3 Diagnosis of charging device faults 32 SERVICE MANUAL Invacare FDX 7 TEST PROCEDURES 33 7 1 Testing the motor 33 7 2 Testing the electro mechanical parking brake 34 8 REPAIR WORK 36 8 1 Covers 36 8 1 1 Open front cover 36 8 1 2 Opening the rear cover 37 8 1 3 Opening the lateral cover 38 8 1 4 Opening the cover of the rear wheel cantilever arm 41 8 2 Electronic modules 42 8 2 1 Replacing remotes 42 8 2 2 Replacing electronic modules 42 8 2 3 Replacing the G Trac sensor 45 8 2 4 Drive program selection after component replacement 47 8 2 4 1 Profile selection with G90A remote 47 8 2 4 2 Profile selection with remote REM A or REM B 48 8 2 4 3 Profile selection with remote REM 550 49 8 3 Updating the driving program 50 8 4 Batteries cables amp battery chargers 51 8 4 1 Removing the batteries 51 8 4 2 Replacing batteries replacing battery cables 54 8 4 3 How to handle damaged batteries correctly 56 8 4 4 Replacing the main fuse 56 8 4 5 Checking the cables 57 8 5 Replacing the battery boxes 59 8 6 Lighting system 60 8 6 1 Replacing light bulbs in the front conventional lighting system 60 8 6 2 Replacing the LEDs in the front LED lighting system 60 8 6 3 Replacing the complete head lamp assembly conventional lighting system until 03 12 61 8 6 4 Replacing headlamps completely conventional lightin
25. Invacare FDX SERVICE MANUAL 8 19 Fixation rings 8 19 1 Replacing a front fixation ring VW Requirements e 13mm socket wrenches two of them e Torque wrench 0 30 Nm or similar Removing a front fixation ring e Switch the wheelchair off e Remove the front cover and the rear covers as described in chapters 8 1 1 and 8 1 2 e Remove the seat as described in chapter 8 13 and 8 14 e Loosen and remove both of the self locking nuts 3 e Pull the fixation ring 2 up and off of the seat frame 1 Installing a front fixation ring e Assemble all parts in reverse order e Tighten the screws 3 to a torque of 25 Nm e When installing the seat pay attention to its heavy weight e When installing the seat pay attention to the adjustment settings of the seat tilt e Check all functions of the vehicle and go for a test drive 147 148 SERVICE MANUAL Invacare FDX 8 19 2 Replacing a rear fixation ring wW Requirements e 13 mm socket wrenches two of them e Torque wrench 0 30 Nm or similar Removing a rear fixation ring e Switch the wheelchair off e Remove the front cover and the rear covers as described in chapters 8 1 1 and 8 1 2 Use both 13 mm socket wrenches to loosen and remove both screws 1 e Pull the fixation ring 2 backwards out of the bracket Installing a rear fixation ring e Assemble all parts in reverse order Tighten the screws 1 to a torque of 25 Nm
26. Invacare FDX SERVICE MANUAL CE Edition 31 01 2013 SERVICE MANUAL These instructions contain information about Testing work Repair Instructions This manual is part of the instructions for use Service addresses A Invacare Austria GmbH 43 6232 5 53 50 Invacare FDX 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 32 0 50 83 10 10 Autobaan 22 Fax 32 0 50 83 10 11 CL 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 AlemannenstraBe 10 Fax 49 0 7562 7 00 66 88316 Isny info invacare aquatec com Deutschland www www invacare aquatec de 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 Poligon Industrial de Celra contactsp invacare com E 17460 Celra Girona WWW www invacare es ESPA A CF Invacare Poirier SAS 33 0 247 62 64 66 Route de St Roch Fax 33 0 247 42 12 24 F 37230 Fondettes contactfr invacare com France WWW ww
27. 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 46 0 491 1 01 40 Fax 46 0 491 1 01 80 oinvacare invacare com Eastern European Distributor 49 0 5731 75 45 40 european Organisation EDO Fax 49 0 5731 75 45 41 countries KleiststraBe 49 edo invacare com D 32457 Porta Westfalica www et aE Deutschland Invacare FDX SERVICE MANUAL Table of contents Chapter Page 1 INTRODUCTION 9 1 1 General information 9 1 2 Notes on transport 9 1 3 Definition and representation of information and safety information in this manual 10 1 4 Hazard symbols and symbols used 11 1 5 Images in this manual 12 2 SAFETY AND FITTING INSTRUCTIONS 13 2 1 Before any inspection or repair work 13 2 2 Personal safety equipment 13 2 3 General safety information and information about fitting removal 13 3 TIGHTENING TORQUES 15 4 ARRANGEMENT OF SUB ASSEMBLIES AND COMPONENTS 16 4 1 Overview 16 4 2 Electronic modules 17 4 2 1 ACS 2 PMB70 ACS 2 PMB7OL electronic module 18 4 2 2 ACS 2 PMASQOL electronic module 18 4 2 3 Actuator module ACT 18 4 2 3 1 Actuator module ACT2 18 4 2 3 2 Actuator module ACT 4 19 4 2 4 Lighting circuit board 19 4 3 Remotes 20 5 MAINTENANC
28. The following lines in italics refer to actions which serve to avoid such hazards CAUTION The signal word CAUTION refers to hazards which could lead to material damage if they are not avoided e The following lines in italics refer to actions which serve to avoid such hazards Note The signal word Note is used to denote general information which simplifies the handling of your product and refers to special functions Invacare FDX SERVICE MANUAL 1 4 99 e FP P PP PH Sp X Hazard symbols and symbols used Different types of hazard symbols and symbols are used throughout this manual General hazards This symbol warns you of general hazards e Always follow the instructions to avoid injury to the user or damage to the product BURN HAZARD This symbol warns you of the danger of chemical burns for example due to the discharge of battery acids e Always follow the instructions to avoid injury to the user or damage to the product DANGER OF CRUSHING This symbol warns you of crushing hazards due to inattentive working with heavy components e Always follow the instructions to avoid injury to the user or damage to the product EXPLOSION HAZARD This symbol warns you of an explosion hazard which can be caused by excessive tyre pressure in a pneumatic tyre e Always follow the instructions to avoid injury to the user or damage to the product Wear safety shoes T
29. a photograph with a digital camera e The illustration shows the electronic module 1 and the optional actuator module 2 The optional lighting circuit board is not shown in the picture but it would be installed at position 3 if it was present e Disconnect the plugs 1 from the electronic module and if installed from the optional actuator module and the optional lighting circuit board 43 SERVICE MANUAL Invacare FDX 44 Use the 8 mm socket wrench to loosen and remove the nuts 1 Remove the actuator module together with the mounting plate 2 If the actuator module is to be replaced Use the 7 mm socket wrench and a Phillips screwdriver to loosen and remove the nuts 3 If the electronic module is to be replaced Remove the electronic module Replace the defective modules Installing electronic modules Install the various modules in reverse order Reconnect all cable connectors to their former positions If you have replaced ACS 2 electronic module please select the correct drive program as described in chapter 8 2 4 Update the drive program in case a new software version is available as described in chapter 8 3 Modify the drive program using the programming software as needed The last step is to test all functions of the vehicle Invacare FDX SERVICE MANUAL 8 2 3 Replacing the G Trac sensor wW Requirements wy e 10mm socket wrench e Side cutting pliers e Cable ties Uni
30. aedic 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 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 FDX 1 3 bP BP D Definition and representation of information and safety information in this manual Different types of information and signal words are used throughout this manual HAZARD The signal word HAZARD refers to immediate hazards e The following lines in italics refer to actions which serve to avoid such hazards WARNING The signal word WARNING refers to possibly occurring hazards which can lead to death or serious injuries if they are not avoided e The following lines in italics refer to actions which serve to avoid such hazards ATTENTION The signal word ATTENTION refers to possibly occurring hazards which can lead to minor injuries and or material damage if they are not avoided e
31. ar o er 119 SERVICE MANUAL Invacare FDX Seat Holes used in seat frame Holes used in seat frame Required seat support depth in front rear late cm Order no 1524550 Order no 1524555 P 38 6 amp 7 A amp B SHORT oe DEG Order no 1526437 43 4 amp 6 A amp C 43 4 amp 6 A amp C MEDIUM 46 eos AEC Order no 1526438 48 2 amp 4 A amp C 48 2 amp 4 A amp C LONG ies aa Order no 1526439 53 1 amp 2 B amp C e Adjust the seat depth as described in the following chapters According to chapter 8 15 2 1 if the seat support plates do not have to be replaced According to chapter 8 15 2 2 if the seat support plates have to be replaced 120 Invacare FDX SERVICE MANUAL 8 15 2 1 Adjusting the seat depth without replacing the seat support plates Remove the armrests Remove the seat cushion Remove the cover plates 1 Loosen and remove the two Allen screws 8 on the rear side of the seat support plate connecting this to the cross braces 4 Repeat this work step on the other side of the seat Loosen and remove the two Allen screws 5 incl the washers Assembly Pull the seat support to the desired length so that the Allen screws 5 can be placed in the holes according to the table see above Refit the Allen screws 5 incl the washers and tighten them Fit the two Allen screws 8 on the rear side of the seat support connecting this to the cross brace
32. cable and on the tail light plug in connection are aligned with each other 39 SERVICE MANUAL Invacare FDX e Push the cover from the side between the seat and the chassis e Position both screws 1 including the washers and tighten the screws hand tight 40 Invacare FDX SERVICE MANUAL 8 1 4 Opening the cover of the rear wheel cantilever arm wW Requirements Mv e 4mm Allen key Removing the rear cover e Use the 4 mm Allen key to loosen and remove the hexagon socket head screw 1 e Pull the cover up in the rear and remove it The cover is held in place by additional Velcro fasteners Installing the rear cover e Assemble the parts in reverse order 41 SERVICE MANUAL Invacare FDX 8 8 2 1 i 8 2 2 e 42 2 Electronic modules Replacing remotes Note The procedure to replace remotes is trivial and is not described in detail However when replacing a REM remote in connection with a DX ACS or ACS 2 electronic module please make sure to select the correct drive programme as described in chapter 8 2 4 Replacing electronic modules Note When replacing a REM remote in connection with a DX ACS or ACS 2 electronic module please make sure to select the correct drive programme as described in chapter 8 2 4 Various different types of electronic modules can be installed in connection with different remotes in the wheelchair The electronic modules that migh
33. cure the vehicle against rolling away by placing wedges under the wheels wW Requirements Ad e 22 mm socket wrench e 4mm Allen key e Oblong wooden blocks at least 14 x 14 x 30 cm Uninstalling a wheel fork e Use the 4 mm Allen key to loosen and remove the hexagon socket head screw 1 e Pull the cover up in the rear and remove it The cover is held in place by additional Velcro fasteners 78 Invacare FDX SERVICE MANUAL Prop up the wheelchair on multiple wooden blocks with the help of a second person Use the 22 mm socket wrench to loosen and remove the self securing nut 2 Pull the wheel fork 4 downwards out of the rear wheel cantilever arm 1 Pay attention to the washers 3 spacer washers and the separable ball bearings not visible in the illustration Installing a wheel fork Assemble the parts in reverse order When installing the ball bearings make absolutely sure that the wide inner rings are visible on the outside Adjust the wheel fork as described in chapter 8 7 3 The last step is to test all functions of the vehicle 79 SERVICE MANUAL Invacare FDX 8 7 3 Adjusting the wheel fork A WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Leta second person help you wW Requirements ad e 22mm socket wrench e Use the 4mm Allen key to loosen and remove the hexagon socket head screw 1 e Pull the cover u
34. d or stretched Tighten both screws hand tight Check all vehicle functions Perform an approximate adjustment of the head lamp using the ratchet plate as a guide The final adjustment can be performed by the user according to the instructions found in the User Guide Invacare FDX SERVICE MANUAL 8 6 6 Replacing headlamps completely LED lighting system starting 03 2012 wW Requirements ad e 4mm Allen wrench e Side cutting pliers e Cable ties Uninstalling headlights e Remove the rear cover as described in chapter 8 1 2 e Take exact 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 e Disconnect the cable of the affected headlight from the lighting circuit board e Open the cable clamps 1 remove all cable ties and pull the cable out of the wheelchair 67 SERVICE MANUAL Invacare FDX 68 e Loosen the hexagon socket head screw 1 with a 4 mm Allen wrench and remove the headlight from the bracket e Replace the headlight Installing headlights e Assemble all parts again in reverse order e Install the cables carefully and secure them with the cable clamps and cable ties e Tighten the screws hand tight e Check all vehicle functions e Perform an approximate adjustment of the headlight using the ratchet plate as a guide The final adjustment can be performed by the user according to
35. e actuator from the tilt module Installing the tilt actuator e Assemble all parts in reverse order e Perform a function test 110 Invacare FDX SERVICE MANUAL 8 14 4 Replacing the lifter actuator il 8 14 4 1 Note This chapter only describes how to replace the lifter actuator To replace the complete lifter module please follow the procedures explained in chapter 8 14 2 Possible methods The lifter actuator is very easy to replace when the lifter is in a raised position It is a little more complicated to replace when the lifter is in a lowered position and cannot be raised due to a fault The individual work steps for both methods are described hereafter e To replace the raised lifter please follow the procedures explained in chapter 8 14 4 1 e To replace the lowered lifter please follow the procedures explained in chapter 8 14 4 2 Method 1 uninstalling the lifter actuator with the lifter raised WARNING Danger of crushing The seat is very heavy Danger of injury to the hands if the seat falls down unintentionally e Leta second person help you e Carefully secure the seat before removing the actuator Requirements e Spring ring pliers e Side cutting pliers e Cable ties Note Take careful note of the exact position of the seat Mark the position it is mounted in the angle the positions of all cables and so on If necessary make photographs with a digital camera Any modificatio
36. e carbon brushes are easier to access 94 Invacare FDX SERVICE MANUAL e Loosen all four plastic caps 3 with a flat screwdriver and remove the caps e Pull the carbon brushes 4 out of their holders slightly Take note of the installation position and orientation of the carbon brushes Note i If the carbon brushes are just to be checked and not replaced then you must take note of the position and orientation of the brushes Used carbon brushes must be reinstalled in exactly the same position and orientation as they are in before to ensure optimum contact with the collector e Mark the motor and the carbon brush to ensure correct installation e Completely remove the carbon brush from the socket 2 e Check the carbon brush and the tension spring for wear broken pieces and discolouration Installing carbon brushes e Depending on the condition of the carbon brush and the tension spring Reinstall the same carbon brush exactly as it was before or Install a new carbon brush e Reposition the plastic caps and tighten them e Install the drive wheels as described in chapter 8 8 1 e Run the motor in as described in chapter 8 11 5 95 SERVICE MANUAL Invacare FDX 8 11 5 Running the motor in O A 96 W a Note The following procedure is necessary to run in the motor after replacing the carbon brushes to guarantee maximum performance WARNING Danger of accidents Danger to pe
37. e parts in reverse order e When installing the plastic cover make sure that the slots on the sides 3 and the lower hooks on the cover latch onto the chassis 4 e Tighten both knurled head screws hand tight Invacare FDX SERVICE MANUAL 8 1 2 Opening the rear cover Removing the rear cover e Loosen and remove both of the knurled head screws 1 e Remove the rear cover 2 Installing the rear cover e Assemble the parts in reverse order e Tighten both knurled head screws hand tight 37 SERVICE MANUAL Invacare FDX 8 1 3 Opening the lateral cover wW Requirements e 10 mm socket wrench e 6mm Allen key e Two oblong wooden blocks at least 14 x 14 x 30 cm Removing the lateral cover e Remove the drive wheel as described in chapter 8 8 1 e Remove the front cover and the rear covers as described in chapters 8 1 1 and 8 1 2 e Use the 10 mm socket wrench to loosen both screws 1 e Hold the cover firmly with one hand e Completely remove both screws 1 including the washers e Pull the cover off towards the side e Disconnect the plug in connections if there are tail lights installed in the lateral cover see illustration below 38 Invacare FDX SERVICE MANUAL Installing the lateral cover e Connect the plug in connections if there are tail lights installed in the lateral cover Make sure that the markings 1 red tail light and 2 yellow flasher on the power supply
38. e rear brackets 2 out of their guides e Remove the seat e Remove the retaining rings 1 with a pair of spring ring pliers e Push the bolt 4 out of the guide Pay attention to the bushings 3 114 Invacare FDX SERVICE MANUAL e Swing the tilt lever arm 1 forwards e Remove the retaining rings 1 from the front bolt 4 of the lifter actuator 2 with the spring ring pliers e Pull the bolt out of the guide with a pair of bent nose pliers until the bolt almost touches the tilt actuator 5 Pay attention to the bushings 3 115 SERVICE MANUAL Invacare FDX e Lift the tilt actuator 5 up a little e Pull the bolt 4 of the lifter actuator under the tilt actuator and out of the guide 9 2 e Remove the retaining rings 1 from the rear bolt 3 of the lifter actuator 2 with the spring ring pliers e Push the bolt out of the guides e Remove the actuator from the lifter module Installing the lifter actuator e Assemble all parts in reverse order e Perform a function test 116 Invacare FDX SERVICE MANUAL 8 15 Seat support 8 15 1 Adjusting the seat width Note ij The seat width can be adjusted in stages between 38 and 53 cm Please also observe the following chapter 8 15 2 on adjusting the seat depth wW Requirements iv e 4mm Allen key e Remove the seat cushion e Remove the cover plates 1 e Release the two Allen screws 6 on the
39. ee instruction voltage manual Legrests e Check contacts and e Clean contacts See the safety terminal clamps and terminal notes in chapter clamps 8 4 1 and 8 4 3 for information on correctly handling batteries 23 SERVICE MANUAL Invacare FDX Component Check for Measures Remarks e Remote status Pe the error See chapter 6 2 Remote display flashing E code i e Fixations e Tighten fixations replace if necessary e Cables and plug in e Check all cables connections and plug in connections for secure fit replace Joystick function Replace joystick if necessary Replace remote if Power supply Check all cables and plug in connections for secure fit replace Check the version of Update the See chapter 8 3 Drive program the program in the software if a newer R driving electronic version is available 24 Invacare FDX SERVICE MANUAL 6 Operational faults The various electronic modules can be fitted in connection with differing remotes in the mobility aid 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 are only an excerpt from the original manufacturer s manuals You can obtain the original manuals from Invacare If you have problems with the mobility aid please proceed as follows e First assess the pos
40. eelchair on one side and have a second person place a 14 cm high wooden block underneath the battery compartment so that the wheels are off the ground and can rotate freely Repeat this on the other side of the wheelchair Remove the drive wheel as described in chapter 8 8 1 Remove the front rear and lateral covers as described in chapter 8 1 1 8 1 2 and 8 1 3 Remove the drive wheel as described in chapter 8 8 1 Use the 5 mm Allen key to loosen and remove both screws 1 Remove the black plastic stop that is held by the screws Push the rear wheel cantilever arm 4 downwards Remove the spring 3 97 SERVICE MANUAL Invacare FDX e Use the 22 mm socket wrench to loosen and remove the self securing nut 2 e Remove the washer e Pull the motor gearbox fixation and rear wheel cantilever arm off of the pivot point Assembling the motor gearbox fixation and rear wheel cantilever arm e Assemble the parts in reverse order e Tighten the self locking nut 2 hand tight and check the whole assembly moves freely 98 Invacare FDX SERVICE MANUAL 8 13 0 A W Seat seat frame without lifter Note This chapter describes how to replace the seat frame on a wheelchair without a lifter or tilt module To replace a lifter or tilt module please follow the procedures explained in chapter 8 14 WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Leta second
41. eplace the parts in the reverse order e To complete check all vehicle functions The new armrest will need to be adjusted to suit the user Please refer to the mobility device operating manual for detailed information 144 Invacare FDX SERVICE MANUAL 8 18 8 Replacing the arm support on the travelling armrest wW Requirements 1 e 4mm Allen key Dismantling the arm support e If necessary remove the remote together with its cable e Rotate the armrest upwards e Undo the two holding bolts 1 with a 4 mm Allen key e Replace the arm support Refitting the travelling armrest e Replace the parts in the reverse order e To complete check all vehicle functions The new armrest will need to be adjusted to suit the user Please refer to the mobility device operating manual for detailed information 145 Invacare FDX SERVICE MANUAL 8 18 9 Retrofitting a travelling armrest 146 NOTE The travelling armrest can only be retrofitted if the entire backrest is replaced since the torque support must be fitted with the correct guides Retrofitting the travelling armrest e Fit the backrest for the travelling armrest as described in chapter 8 17 2 e Fit the armrests as described in chapter 8 18 7 e Fit the arm supports as described in chapter 8 18 8 The new armrest will need to be adjusted to suit the user Please refer to the mobility device operating manual for detailed information
42. es and so on If necessary make photographs with a digital camera Any modification of the adjustment of the seat affects the centre of gravity of the wheelchair Uninstalling the tilt actuator 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 Disconnect the plug from the actuator module e Open the cable clips on the underside of the seat e Free up the actuator cable so it can be removed from the tilt module later along with the actuator 109 SERVICE MANUAL Invacare FDX A WARNING Danger of crushing The seat is very heavy Danger of injury to the hands if the seat falls down unintentionally e Leta second person help you e Carefully secure the seat against falling down unintentionally before removing the actuator If there is no means to secure the seat from falling down remove it entirely e n a combined lifter tilt module the tilt actuator is located in the upper part of the module 2 e Remove the retaining rings 1 with a pair of spring ring pliers e Push the bolts 4 out of the guides Pay attention to the bushings 3 on the front bolt e Remove th
43. g system starting 03 201 2 63 8 6 5 Replacing the head lamps completely LED lighting system until 03 2012 65 8 6 6 Replacing headlamps completely LED lighting system starting 03 2012 67 8 6 7 Replacing the head lamp bracket conventional lighting system until 03 0212 69 8 6 8 Replacing headlamp brackets conventional lighting system starting 03 2012 70 8 6 9 Replacing the front bulb holder LED lighting system until 03 2012 71 8 6 10 Replacing a light bulb in the rear conventional lighting system 72 8 6 11 Replacing the LEDs in the rear LED lighting system 72 8 6 12 Replacing the complete tail lamp assembly conventional lighting system 73 8 6 13 Replacing the tail lamp bracket conventional lighting system 75 8 6 14 Replacing the tail lamps completely LED lighting system 76 8 7 Rear wheels 77 8 7 1 Replacing a rear wheel 77 8 7 2 Replacing a rear wheel fork 78 8 7 3 Adjusting the wheel fork 80 8 8 Drive wheels 82 8 8 1 Replacing a drive wheel 82 8 8 2 Replacing a tyre 83 8 8 3 Replacing a drive wheel hub 84 Invacare FDX SERVICE MANUAL 8 9 Replacing the spring in the rear 86 8 10 Replacing the anti tipper wheels 88 8 11 Drive unit 89 8 11 1 Replacing the motor gearbox unit 89 8 11 2 Replacing or rotating the motor gearbox unit sealing ring 91 8 11 3 Replacing the motor gearbox coupling 92 8 11 4 Replacing the carbon brushes 94 8 11 5 Running the motor in 96 8 12 Replacing the motor gearbox fixation and rear wheel can
44. he 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 batteries e Wear eye protection when this symbol is shown Wear safety gloves This symbol refers to the requirement for wearing safety gloves for example when working with batteries e Wear safety gloves when this symbol is shown Note This symbol identifies general information which is intended to simplify working with your product and which refers to special functions Requirements e This symbol identifies a list of various tools components and items which you will need in order to carry out certain work Please do not attempt to carry out the work if you do not have the listed tools available Always dispose used or damaged batteries correctly The symbol refers to information for the correct disposal of used or damaged batteries 11 SERVICE MANUAL Invacare FDX 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 FDX SERVICE MANUAL 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 ob
45. he wheelchair on one side and have a second person place a 14 cm high wooden block underneath it so that the drive wheel is off the ground and can rotate freely e Repeat this if necessary on the other side of the wheelchair e Loosen the five 6 mm hexagon socket head screws 1 e Pull the wheel 2 off the hub Installing a drive wheel e Install the wheel in reverse order e Tighten the screws to a torque of 25 Nm Invacare FDX SERVICE MANUAL 8 8 2 Replacing a tyre Vv Requirements e 5mm Allen key e Two oblong wooden blocks at least 14 x 14 x 30 cm e Three c clamps with plastic caps e Torque wrench 5 30 Nm or similar e Talcum powder Uninstalling a tyre e Remove the wheel as described in chapter 8 8 1 CAUTION EXPLOSION HAZARD The tyre is under high pressure There is danger of injury Parts can be projected at you causing serious injury if you do not secure the wheel rims e Secure the wheel rim halves with c clamps e Secure the wheel rim halves with three c clamps to prevent them from unintentionally popping apart Be careful not to scratch the rims in the process e Loosen the five 5 mm hexagon socket head screws 2 on the inside of the wheel e Carefully loosen the c clamps in small increments one after the other until you can safely remove the rim halves e Remove the inner ring 3 and outer ring 1 of the rim from the tyre 4 e Replace defective or worn out compo
46. here is a defect replace the motor and send it to Invacare Service for inspection or repair 34 Invacare FDX SERVICE MANUAL i A 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 brake CAUTION Material damage can be caused to the electronic module due to short circuit 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 8 A 8 1 8 1 1 36 Invacare FDX Repair Work 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 Covers Open front cover Removing the front cover e Remove the leg rests e Loosen and remove both of the knurled head screws 1 e Press the front cover 2 slightly upward then pull the cover forward and off Installing the front cover e Assemble th
47. 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 123 SERVICE MANUAL Invacare FDX Installing the manually operated centre mounted legrest e Assemble the parts in reverse order e Test all functions of the wheelchair 124 Invacare FDX SERVICE MANUAL 8 16 2 A W Replacing the electrically operated centre mounted legrest WARNING Danger of crushing The legrest is very heavy Danger of injury to hands and feet e Pay attention to the heavy weight Requirements 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 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 125 SERVICE MANUAL Invacare FDX 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 b
48. icking defective transmission and 8 11 3 noise Drive wheel Tighten drive See chapter 8 8 1 loose wheel secure bolts with Loctite if necessary Transmission None Sealing ring on Replace See chapters 8 11 1 losing oil drive shaft transmission if and 8 11 3 defective sealing ring defective Check carbon See chapters 8 11 1 brushes for oil 8 11 3 and 8 11 4 wetting replace motor if brushes wet Irregular None Drive shaft Check drive shaft See chapters 8 11 1 running movable or bent replace and 8 11 3 transmission if defective Parts lost None Parts lost Reattach parts once found Batteries not None Fuse burnt out Check cabling and See chapters 8 4 5 28 being charged cable defective replace fuse and 8 4 4 Batteries defective Replace batteries See chapter 8 4 1 Invacare FDX SERVICE MANUAL PROBLEM OTHER POSSIBLE SOLUTION DOCUMENTATION SYMPTOMS CAUSE LEDs blinking Charging unit Replace charging See charging unit on charging defective unit operating manual unit Short charging None One of the Replace batteries See chapter 8 4 1 period batteries could be defective Mobility aid None Remote Replace remote See chapter 8 2 1 runs too slowly defective Batteries Replace batteries See chapter 8 4 1 defective Actuator does Remote shows Lighting Replace lighting See chapter 8 2 2 not react blinking E or actuator module actuator m
49. ies e Only use the battery type defined in the technical specifications CAUTION Risk of fire and burns if battery terminals 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 caretully 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 Phillips screwdriver size 2 e Side cutting pliers e Cable ties Uninstalling the batteries e Remove the legrests e Remove the front cover as described in chapter 8 1 1 51 SERVICE MANUAL Invacare FDX e Disconnect the plug in connection 1 of
50. ions connecting out cables Motor brake Measure internal See chapters 7 2 defective resistance of and 8 11 1 brakes replace motor if defective Motors stop None Voltage decline Stop journey and and start allow electronic to irregularly cool down Motor runs but None High motor Stop journey and loses power loading causes allow electronic to electronic cool down Invacare FDX SERVICE MANUAL PROBLEM OTHER POSSIBLE SOLUTION DOCUMENTATION SYMPTOMS CAUSE module to decrease voltage Motors stop None High motor Leave mobility aid and do not loading causes switched on and start again electronic allow electronic module to module to work decrease Charge batteries voltage overnight with mobility aid switched on None Fuse burnt out Check cabling and See chapters 8 4 5 replace fuse and 8 4 4 None Motor defective Check carbon See chapter 8 11 4 brushes and replace if necessary Measure internal See chapters 7 1 resistance of and 8 11 1 motor replace motor if defective None Electronic Replacing the See chapter 8 2 2 module electronic module defective Motors lose None Bad Switch mobility aid See chapter 8 4 5 power during connections off wait 10 journey seconds switch mobility aid on again Check all cabling Motor judders None Carbon brushes Check carbon See chapter 8 11 4 or runs worn brushes and irregularly or replace if only one motor necessary tuns Clutch es
51. laced Use the 6 mm Allen key to loosen both screws 4 on the corresponding side of the wheelchair Remove the screws and the washers Remove the tilt mounting bracket If one of the seat frame mounting brackets 5 are to be replaced Disassemble the seat frame mounting brackets as described in chapter 8 13 starting from the section header Uninstalling the seat frame Installing the tilt module Install the tilt module in reverse order Make sure that seat tilt mounting brackets 2 are affixed with screws to the top holes in the seat frame brackets 5 Tighten the connecting screws of the seat tilt mounting brackets and the seat frame mounting brackets to 18 Nm When installing the cables again make sure that they are placed in such a way that they cannot be crushed or damaged in any position of the tilt module WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Leta second person help you Install the seat Install all covers again Check all functions of the vehicle and go for a test drive Invacare FDX SERVICE MANUAL 8 14 2 Replacing the lifter tilt module A W Note This chapter describes how to replace the seat frame on a wheelchair with a lifter tilt module Similar tasks are described In the following chapters e Replacing the seat frame alone chapter 8 13 e Replacing a tilt module chapter 8 14 1 e Replacing just the tilt ac
52. le using a 4 mm Allen key and a 13 mm open end wrench e Together with a second person lift the seat up off of the lifter module tilt module 106 Invacare FDX SERVICE MANUAL e Open the power supply chain of the lifter Flip the cover 1 up Pull the flap 2 out of the cover Repeat this procedure link by link e Remove both cable ties that secure the cable at the ends of the power supply chain e Pull the cable out of the power supply chain 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 5 107 SERVICE MANUAL Invacare FDX 90000000 O 3 0000909000 Use the 6 mm Allen key to loosen and remove the four hexagon socket head screws 3 on both sides of the wheelchair Remove the screws and the washers Lift the tilt module 1 up off of its brackets 2 If one of the seat tilt mounting brackets 2 are to be replaced Use the 6 mm Allen key to loosen both screws 4 on the corresponding side of the wheelchair Remove the screws and the washers Remove the tilt mounting bracket If one of the seat frame mounting brackets 5 are to be replaced Disassemble the seat frame mounting brackets as described in chapter 8 13 starti
53. luding the washers Remove the motor gearbox unit Installing the motor gearbox unit Replace the defective components Before installing a new motor gearbox unit make sure the sealing ring 2 is correctly mounted The sealing ring securely attaches the motor 3 and the gearbox 5 The ring must be installed such that the self locking nut 4 is located on the outside If the sealing ring is incorrectly installed rotate it around as described in chapter 8 11 2 Refit the motor transmission unit in reverse order a riy Use the scale to align the motor to the centre axis 1 aY I 2 pole motors and 4 pole motors m Left 0 OL i i O Right 0 j1 i eg Make sure that the motor cable cannot be pinched or bent and H PO that it is not exposed to chafing in any place JN i To conclude you should always carry out a trial run to test the vehicle functions Invacare FDX SERVICE MANUAL 8 11 2 Replacing or rotating the motor gearbox unit sealing ring A W CAUTION Danger of crushing The motor gearbox unit is very heavy Danger of injury to the hands e Pay attention to the heavy weight Requirements e 10mm socket wrench Uninstalling the sealing ring Uninstall the motor gearbox unit as described in chapter 8 11 1 Use the 10 mm socket wrench to loosen and remove the self securing nuts 4 including the washers Remove the carriage bolt which secures the sealing ri
54. ment dheal e Check tight fit of the e Adjust replace See chapter 8 8 1 eer drive wheels and wheel hubs and 8 8 3 suspension and ayiai run out a wheels e Check tight fit of e Replace wheels See chapter 8 7 steering wheels wheel fork or Check required wheel bearing motor to body clearance and axial run out eo ae eee if damaged eS ae ners if damaged e Check directional e Replace wheels See chapter 8 7 stability wheel fork or and 8 8 wheel bearing Invacare FDX SERVICE MANUAL Component Check for Measures Remarks e coupling e Check functions e Check the carbon See chapter 8 11 1 mechanism during drive brushes replace if and 8 11 4 operation and when necessary pushing e Replace motor if e Check coupling necessary mechanism e Tighten screws nuts adjust or replace if e Check welding e Tighten replace if See chapter 8 16 amp seams locking necessary the User Guide devices screws and foot plates e Check cable e Replace cable if See chapter 8 16 amp Electric legrests Check contacts necessary the ecru if available e Check functions Seale a e Check cable e f necessary See chapter 8 6 Lighting if e Check function replace light or available cable e Check battery box e Replace if Battery box and fastening belt for necessary damage e Check batteries for e Replace batteries See chapter 8 4 1 e Check battery e Charge batteries voltage e Check battery e Charge batteries S
55. n it is mounted in the angle and so on If necessary make photographs with a digital camera Any modification of the adjustment of the seat affects the centre of gravity of the wheelchair Uninstalling the tilt module 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 Invacare FDX SERVICE MANUAL e Completely remove both knurled head screws 1 including the washers e Remove the cover 2 e Disconnect the plug from the actuator module e Open the cable clips on the underside of the seat e Free up all cables so that you can lift the seat off A WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Leta second person help you e Loosen the four screws 1 that attach the seat to the tilt module using a 4 mm Allen key and a 13 mm open end wrench e Together with a second person lift the seat up off of the lifter module tilt module 103 SERVICE MANUAL Invacare FDX 104 90000000 O 3 0000909000 Use the 6 mm Allen key to loosen and remove the four hexagon socket head screws 3 on both sides of the wheelchair Remove the screws and the washers Lift the tilt module 1 up off of its brackets 2 If one of the seat tilt mounting brackets 2 are to be rep
56. n of the adjustment of the seat affects the centre of gravity of the wheelchair 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 111 SERVICE MANUAL Invacare FDX 112 D e Completely remove both knurled head screws 1 including the washers e Remove the cover 2 e Disconnect the plug from the actuator module e Open the cable clips on the underside of the seat e Free up the actuator cable so it can be removed from the lifter module later along with the actuator WARNING Danger of crushing The seat is very heavy Danger of injury to the hands if the seat falls down unintentionally e Leta second person help you e Carefully secure the seat against closing or falling down unintentionally before removing the actuator If there is no means to secure the seat from falling down remove it entirely e Inacombined lifter tilt module the lifter actuator is located in the lower part of the module 2 e Remove the retaining rings 1 with a pair of spring ring pliers e Push the bolts 4 out of the guides Pay attention to the bushings 3 on the front bolt e Remove the actuator from the lifter module Installing the lifter actuator e Assemble all parts in reve
57. nents Installing a tyre e Assemble the tyre in reverse order on the rim e When assembling the rim halves make sure that the smooth and threaded holes for the screws are aligned exactly on top of each other e Apply the three c clamps e Tighten the c clamps in small increments one after the other until the rim halves are squarely pressed together e Tighten the hexagon socket head screws 2 to a torque of 25 Nm 83 84 SERVICE MANUAL Invacare FDX 8 8 3 Replacing a drive wheel hub A WARNING Danger of damage to the wheelchair Collisions can be caused if shim rings are removed from the drive wheels during installation work e 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 e Please install all shim rings in exactly the same positions they were before disassembly wW Requirements dai e 19mm socket wrench e Torque wrench 10 80 Nm or similar Uninstalling a drive wheel hub e Use the 19 mm socket wrench to loosen and remove the axle nut 4 e Remove the washer 3 e Pull the wheel hub 5 off of the axle 2 e Remove the feather key 1 from the axle Installing a drive wheel hub Invacare FDX SERVICE MANUAL e Assemble the parts of the wheel hub in reverse order e Between the wheel and the motor drive unit distance rings of various wid
58. ng 2 Carefully bend the sealing ring apart and remove it Installing the sealing ring Install the sealing ring so that the square hole for the carriage bolt is on the inside of the wheelchair Insert the carriage bolt through the sealing ring 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 91 SERVICE MANUAL Invacare FDX 8 11 3 Replacing the motor gearbox coupling 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 24 e 10mm socket wrench Uninstalling the motor gearbox coupling e Uninstall the motor gearbox unit as described in chapter 8 11 1 e Use the 10 mm socket wrench to loosen and remove the self securing nut 4 e Remove the carriage bolt which secures the sealing ring 2 e Carefully bend the sealing ring apart and remove it A WARNING Danger of damage to the wheelchair if the coupling is not serviced correctly e Be careful not to damage the coupling mechanism during maintenance work e Carefully pull the motor 3 and the gearbox 1 apart e Remove the component parts of the coupling e f necessary replace the coupling 92 Invacare FDX SERVICE MANUAL Installing the motor gearbox coupling as C8 Place the new clutch 7 on the m
59. ng from the section header Uninstalling the seat frame Installing the tilt module Install the tilt module in reverse order Make sure that seat tilt mounting brackets 2 are affixed with screws to the top holes in the seat frame brackets 5 Tighten the connecting screws of the seat tilt mounting brackets and the seat frame mounting brackets to 18 Nm When installing the cables again make sure that they are placed in such a way that they cannot be crushed or damaged in any position of the tilt module A WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Leta second person help you 108 Install the seat Install all covers again Check all functions of the vehicle and go for a test drive Invacare FDX SERVICE MANUAL 8 14 3 Replacing the tilt actuator i A W Note This chapter only describes how to replace the tilt actuator To replace the complete tilt module please proceed as described in chapters 8 14 1 and 8 14 2 WARNING Danger of crushing The seat is very heavy Danger of injury to the hands if the seat falls down unintentionally e Leta second person help you e Carefully secure the seat before removing the actuator Requirements e Spring ring pliers e Side cutting pliers e Cable ties Note Take careful note of the exact position of the seat Mark the position it is mounted in the angle the positions of all cabl
60. ng wooden blocks at least 14 x 14 x 30 cm WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Leta second person help you 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 Uninstalling a rear wheel e Lift the wheelchair on one side and have a second person place a 14 cm high wooden block underneath it so that the rear wheel is off the ground and can rotate freely e Carefully remove the black plastic cap from the middle of the anti tipper wheel 1 with a small flat screwdriver The cap is not shown in the above illustration e Use the 16 mm socket wrench to loosen the self securing axle nut 2 e Remove the axle nut and the washer e Pull the wheel off the axle Installing a rear wheel e Assemble the parts in reverse order e Tighten the self securing axle nuts just tight enough that the wheel can still rotate without resistance 77 SERVICE MANUAL Invacare FDX 8 7 2 Replacing a rear wheel fork A WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Leta second person help you 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 Se
61. nstalling the G Trac sensor e Switch the electronic of the wheelchair OFF e Remove the front rear and right lateral covers as described in chapter 8 1 1 8 1 2 and 8 1 3 The G Trac sensor is located on the spring seat of the right hand spring e Trace the cable of the G Trac sensor 1 to the electronic module and disconnect it there e Pull the cable out of the wheelchair If necessary remove any attached cable ties 45 SERVICE MANUAL Invacare FDX 46 Use the 10 mm socket wrench to loosen and remove the self securing nuts 3 including the washers Pull the G Trac sensor 2 off of the carriage bolt 1 which is inserted in the spring seat Replace the G Trac sensor Installing the G Trac sensor Assemble the parts in reverse order Reconnect all cable connectors to their former positions The G Trac sensor must be installed with the cable pointing upwards The last step is to test all functions of the vehicle Invacare FDX SERVICE MANUAL 8 2 4 i 8 2 4 1 Drive program selection after component replacement The drive program is saved in the REM remote and also in the DX ACS or ACS 2 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 The system allows normal usage of the mobility aid after component replacement only if the profile is selected af
62. o Allen screws 7 on the front side of the seat support connecting this to the cross braces 4 121 SERVICE MANUAL Invacare FDX e Fit the two Allen screws 8 on the rear side of the seat support connecting this to the cross braces 4 Unlike the dismantling of the old plates other holes of the three pairs of holes may possibly have to be used for the screws e Fit the two Allen screws 9 at the front of the seat support plate e Refit all parts that were removed 122 Invacare FDX SERVICE MANUAL 8 16 8 16 1 Centre mounted legrest electric amp manual Note The centre mounted legrest is the only part of the wheelchair in which screw sizes are indicated in inches Replacing the manually operated centre mounted legrest WARNING Danger of crushing The legrest is very heavy Danger of injury to hands and feet e 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 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
63. odule blink code 2 defective Status diode on lighting actuato r module does not go out even if the remote has been switched off or disconnected None Cable Safeguard cable See chapter 8 4 5 disconnected or connection damaged replace cable if necessary Electrical Check adjusting adjusting motor motor defective Remote Replace remote See chapter 8 2 1 defective 1 Only applies to remote SD24 All remotes except SD24 29 SERVICE MANUAL Note REM remotes Error codes and diagnostic codes Invacare FDX The following table is applicable to remotes G90A REM A REM B und REM 550 which are connected to electronic modules ACS 2 PMB70 ACS 2 PMB70L ACS 2 PMB90LG 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 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 2 2 2 x blink Accessory error e g short Check accessory See chapter 8 4 5 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 stat
64. ople the surroundings and wheelchair e Never leave the wheelchair unattended during the following procedure e Make sure that BOTH drive wheels are raised and CANNOT touch the ground e Secure the surrounding area Requirements e Two oblong wooden blocks at least 14 x 14 x 30 cm e Lift the wheelchair on one side and have a second person place a 14 cm high wooden block underneath it so that the drive wheel is off the ground and can rotate freely e Repeat this on the other side of the wheelchair e Allow the motors to run for an hour in the forward direction e Allow the motors to cool off for 30 minutes e Allow the motors to run for an hour in the backward direction e Lift the wheelchair off of the wooden blocks Invacare FDX SERVICE MANUAL 8 12 Replacing the motor gearbox fixation and rear wheel cantilever arm A W WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Leta second person help you Danger of injury due to uncontrolled movement of the wheelchair e Switch the vehicle s power system off ON OFF key Engage the drive motors Secure the vehicle against rolling away by placing wedges under the wheels Requirements 22 mm socket wrench 5 mm Allen key Torque wrench 20 80 Nm or similar Two oblong wooden blocks at least 14 x 14 x 30 cm Dismantling the motor gearbox fixation and rear wheel cantilever arm Lift the wh
65. ors to the electronic module make sure you know exactly which electronic module is installed The following table provides an overview ACS 2 PMB70 ACS 2 PMB70L ACS 2 PMA90LG ACS 2 with actuator module ACT Actuator module ACT Lighting circuit board G Trac sensor The actuator module is optional The actuator module is optional The lighting circuit board is optional The G Trac sensor is optional 17 SERVICE MANUAL 4 2 1 4 2 2 4 2 3 4 2 3 1 ACS 2 PMB70 ACS 2 PMB7OL electronic module Connections 1 Battery 24V 2 Bus cable to remote or ACT 3 Bus cable to remote or ACT a 4 Motor M1 5 6 E Q Fy Light 8 ACS 2 PMAQOL electronic module Connections Battery 24V Cable to G Trac sensor GYRO Bus cable to remote or ACT 1 2 3 nari 4 Motor M1 erro a jj 5 Light AN 3 oy 6 ale Motor M2 Rubber stoppers for free slots r oo cx 2 amp 3 Order number 1552876 Invacare FDX ry 8 FY Lil ry 8 FY H STIP Actuator module ACT Various types of adjustment motors also called actuators can be installed on the wheelchair These actuators are either connected directly to the electronic module or to a separate actuator module The actuator module is connected to the electronic module via a bus cable Actuator module ACT2 Connections F 1 ACI YE 2 Bus cable to remote or ACT 3 Bus cable to remote or ACT FA See 4 Adjustment motor ac
66. oth 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 126 Invacare FDX SERVICE MANUAL 8 16 3 Replacing an electric legrest actuator A WARNING Danger of crushing The legrest is very heavy Danger of injury to hands and feet e Pay attention to the heavy weight 1 A Requirements A 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 127 SERVICE MANUAL Invacare FDX e Use the 3 8 Allen key and a 1 2 socket wrench to loosen the screw 3 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
67. otor axle Pay attention to the position of the groove Position the locking ring 5 on the motor 4 or the gearbox 1 Carefully insert the motor into the gearbox Pay attention to the position of the groove in the axle of the gearbox If necessary rotate the motor and gearbox to the correct position Insert the carriage bolt through the locking ring Do not forget the spacer sleeve 2 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 Install the motor gearbox unit as described in chapter 8 11 1 93 SERVICE MANUAL Invacare FDX 8 11 4 Replacing the carbon brushes Note i Always replace all carbon brushes on both motors at the same time A WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Leta second person help you wW Requirements nae e Flat screwdriver e 10mm socket wrench e Torque wrench 5 30 Nm or similar e Two oblong wooden blocks at least 14 x 14 x 30 cm Uninstalling carbon brushes e Switch the wheelchair off e Remove the drive wheels as described in chapter 8 8 1 e Disengage the motor by setting the coupling lever to Pushing A N AL r te e Loosen and remove the self locking nut 4 of the retaining ring 2 with a 10 mm socket wrench so that the motor 3 can be rotated against the gearbox 1 This way th
68. p in the rear and remove it The cover is held in place by additional Velcro fasteners 80 Invacare FDX SERVICE MANUAL e Leta second person tilt the wheelchair forward over the drive wheels until the anti tipper wheels prevent it from tipping any farther e Swivel the wheels 5 so that they point upward e Release the wheels so that they can swing downwards e Adjust the nut 2 using a 22 mm socket wrench so that the wheel forks are not too loose but can still rotate freely The wheels should swing up to the other side a maximum of one time before coming to rest pointed downward e Place the wheelchair back on all of its wheels e Test the maneuverability of the wheelchair e Repeat the individual steps if necessary until the coasters are correctly adjusted e Install the cover again 81 SERVICE MANUAL Invacare FDX 8 8 Drive wheels 8 8 1 Replacing a drive wheel A WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Leta second person help you 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 1 A Requirements IU e 6mm Allen key e Two oblong wooden blocks at least 14 x 14 x 30 cm e Torque wrench 5 30 Nm or similar Uninstalling a drive wheel e Lift t
69. rear and lateral covers as described in chapter 8 1 1 8 1 2 and 8 1 3 e Uninstall the complete tail lamp assembly as described in chapter 8 6 12 e Use the 3 mm Allen key to loosen and remove both screws 2 e Replace the lamp bracket 1 Installing the head lamp bracket e Assemble all parts again in reverse order e Check all vehicle functions 75 SERVICE MANUAL Invacare FDX 8 6 14 Replacing the tail lamps completely LED lighting system Note ij Individual LEDs are not intended to be replaced The LEDs are replaced along with the complete bracket assembly This means that the complete red or yellow tail lamp is replaced wW Requirements L e Phillips screwdriver size 1 Uninstalling the tail lamp e Remove the front rear and the applicable lateral cover as described in chapters 8 1 1 8 1 2 and 8 1 3 e Use a Phillips screwdriver to loosen and remove the screw 1 e Remove the transparent cover from the top side not visible in the illustration e Carefully bend both mounting brackets 2 apart e Push the tail lamp 3 including cable and plug out of the bracket Installing the tail lamp e Assemble all parts again in reverse order e Tighten both screws hand tight e Check all vehicle functions 76 Invacare FDX SERVICE MANUAL 8 7 8 7 1 Wd A Rear wheels Replacing a rear wheel Requirements e Small flat screwdriver e 16mm socket wrench e Two oblo
70. rse order e Perform a function test Invacare FDX SERVICE MANUAL 8 14 4 2 Method 2 uninstalling the lifter actuator with the lifter lowered A WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Leta second person help you Y A Requirements WV e Spring ring pliers e Side cutting pliers e Cable ties e Bent nose pliers e 6mm Allen key Note D Take careful note of the exact position of the seat Mark the position it is mounted in the angle the positions of all cables and so on If necessary make photographs with a digital camera Any modification of the adjustment of the seat affects the centre of gravity of the wheelchair 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 Disconnect the plug from the actuator module e Open the cable clips on the underside of the seat e Free up the actuator cable so that you can remove the seat 113 SERVICE MANUAL Invacare FDX e Loosen and remove the hexagon socket head screw 1 of the seat frame on the left and on the right side of the wheelchair A WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Leta second person help you e Lean the seat back and push th
71. s 4 Unlike dismantling different holes in the three pairs of holes must be used for the screws Refit all parts that were removed 8 15 2 2 Adjusting the seat depth and replacing the seat support plates Disassembly Remove the legrests Remove the armrests Remove the seat cushion Remove any existing cable ties holding the remote or lighting cables Release the cables from the stuck on clamps Loosen the cap nuts of the headlight mountings using an 8 mm jaw spanner see chapter 8 6 3 or 8 6 5 Put the headlights and the mounting in a safe place on the rear part of the battery compartment cover Remove the cover plates 1 Loosen the two Allen screws 9 at the top front of the seat support plate and remove them Loosen the two Allen screws 7 on the front side of the seat support plate connecting this to the cross braces 4 Loosen the two Allen screws 8 on the rear side of the seat support plate connecting this to the cross braces 4 Remove the seat support plate 2 Repeat this work step on the other side of the seat Loosen and remove the two Allen screws 5 incl the washers Pull the seat support to the desired length so that the Allen screws 5 can be fitted into the holes according to the table see above Refit the Allen screws 5 incl the washers and tighten them If necessary replace the seat support plates 2 according to the table see above Refit the seat support plate 2 Fit the tw
72. s and a LED lighting unit 8 6 1 Replacing light bulbs in the front conventional lighting system wW Requirements H Phillips screwdriver size 2 e Loosen the concealed Phillips head screw on the back of the head lamp turn indicator combination e Remove the transparent plastic cover e Replace the defective light bulb e Reposition the cap and tighten the Phillips head screw hand tight 8 6 2 Replacing the LEDs in the front LED lighting system e Individual LEDs are not intended to be replaced Replace the complete lighting system as described in chapter 8 6 5 60 Invacare FDX SERVICE MANUAL 8 6 3 Replacing the complete head lamp assembly conventional lighting system until 03 12 wW Requirements H e Phillips screwdriver size 2 e Side cutting pliers e Cable ties Uninstalling head lamps e Remove the rear cover as described in chapter 8 1 2 e Take exact note of the positions of all cables and the sockets 1 that they are connected to Mark the connectors and sockets or take a photograph with a digital camera e Disconnect the cable of the affected head lamp from the lighting circuit board e Remove all cable ties and pull the cable out of the wheelchair 61 SERVICE MANUAL Invacare FDX 62 Loosen both of the cap nuts 1 with an 8 mm open end wrench and remove the head lamp with the bracket from the rubber mounting Not shown in the illustration are two Phillips head scre
73. s hand tight with a 13 mm open end wrench 135 SERVICE MANUAL Invacare FDX e Screw the four Phillips screws 9 into the drill holes provided for this purpose on the backs of the tubes The screws serve as limiters and prevent the backrest from sliding down too far e Remove the marking from the middle tube 136 Invacare FDX SERVICE MANUAL 8 18 Back unit with ergonomic length adjustment 8 18 1 Adjusting the width Note ij Please also observe preceding chapter 8 15 1 on adjusting the seat width By default the seat can be adjusted in width between 38 and 53 cm enn Alen e Remove the back cushion e Loosen the three Allen screws 1 but do not remove them completely e Move the plate 2 until the desired width in centimetres can be read off the scale 3 e Tighten the three Allen screws e Repeat this work step on the other back plate e Fita back cushion in the appropriate width 137 SERVICE MANUAL Invacare FDX 8 18 2 Replacing the planetary gear wW Requirements iM e 4mm Allen key 5 mm Allen key 13 mm jaw spanner Size 2 Phillips recessed head spanner Snap ring pliers Dismantling the planetary gear e Loosen and remove the four Allen screws on the plastic cover 1 using a 4 mm Allen key e Remove the plastic cover e Loosen and remove the Phillips screw 3 e Remove the reflector 4 e Remove the snap ring under the reflector not in the picture e Undo
74. s screwdriver size 2 Uninstalling the universal backrest frame e Remove the backrest cushion e Loosen and remove the four Allen screws 1 with a 5 mm Allen key e Remove the universal backrest frame 2 from the EasyAdapt backrest 134 Invacare FDX SERVICE MANUAL Installing and adjusting the universal backrest frame AN CAUTION The upholstery may get damaged e When adjusting the backrest frame make sure the upholstery cannot collide with other components e Position both of the protective caps 8 in the lower ends of the lateral tubes 1 e Mark the center of the middle tube 2 with a piece of adhesive tape e Insert the middle tube into the upper ends of the lateral tubes e Position the lateral tubes of the EasyAdapt backrest so that the four Allen screws 7 can be screwed into the slot nuts 6 through the oblong holes Tighten the Allen screws just tight enough that the lateral tubes can slide and be adjusted without difficulty e Adjust the distance between the lateral tubes to the desired value using the measuring tape Make sure both lateral tubes are at an equal distance to the center of the seat e Tighten the four Allen screws 7 using a 5 mm Allen key e Adjust the middle tube 2 so it is well centered e Screw both of the threaded pins 5 into the threaded holes 3 with a 4 mm Allen key e Secure the threaded pins additionally with the counter nuts 4 Tighten the counter nut
75. screw hand tight 8 6 11 Replacing the LEDs in the rear LED lighting system e Individual LEDs are not intended to be replaced Replace the complete red tail lamp and or the yellow turn indicator as described in chapter 8 6 14 72 Invacare FDX SERVICE MANUAL 8 6 12 Replacing the complete tail lamp assembly conventional lighting system wW Requirements wy e 8mm socket wrench Uninstalling the tail lamp e Remove the front cover and the rear covers as described in chapters 8 1 1 and 8 1 2 Take exact note of the positions of all cables and the sockets 1 that they are connected to Mark the connectors and sockets or take a photograph with a digital camera e Disconnect the cable of the affected tail lamp from the lighting circuit board e Remove all cable ties and pull the cable out of the wheelchair 73 SERVICE MANUAL Invacare FDX e Remove both plastic covers 2 e Use an 8 mm socket wrench to loosen both nuts e Remove the nuts together with the washers e Pull the tail lamp 1 towards the rear and remove from the tail lamp bracket 3 Installing the tail lamp e Assemble all parts again in reverse order e Tighten both screws hand tight e Check all vehicle functions 74 Invacare FDX SERVICE MANUAL 8 6 13 Replacing the tail lamp bracket conventional lighting system 1 A Requirements 4 e 3mm Allen key Uninstalling the head lamp bracket e Remove the front
76. served 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 work see chapter entitled General information Personal safety equipment Safety shoes The mobility device and some of its components are very heavy These parts can result in injuries to the feet if they are allowed to drop e Wear standardised safety shoes during all work Eye protection It is possible that battery acid can be discharged when working on defective batteries or when handling batteries improperly e Always wear eye protection when working on any defective or possibly defective batteries Safety gloves It is possible that battery acid can be discharged when working on defective batteries or when handling batteries improperly e Always wear acid proof safety gloves when working on any defective or possibly defective batteries General safety information and information about fitting removal WARNING Danger of crushing Various components such as the drive unit batteries seat etc are very heavy This results in injury hazards to your hands e Please note the high weight of some components This applies especially to the removal of drive units batteries and the seat WARNING Injury hazard if the vehicle starts moving unintentionally during repair work e Switch the power supply off ON OFF key
77. sible 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 25 SERVICE MANUAL 6 1 26 Drive fault diagnosis Invacare FDX PROBLEM OTHER POSSIBLE SOLUTION DOCUMENTATION SYMPTOMS CAUSE Mobility aid will The remote Drive motors Engage drive See operating not start status display disengaged motors manual illuminates normally and displays blink code 5 6 Remote status Batteries Replace batteries See chapter 8 4 1 display does defective nor iuminata Completely Pre charge See operating discharge batteries manual battery Power supply to Check master See chapter 8 4 4 remote fuse meruptga Check cables See chapter 8 4 5 between the modules for loose connections and damage Remote Replace remote See chapter 8 2 1 defective Remote status Various causes Assess error code See chapter 6 2 display blinking Mobility aid None Batteries Replace batteries See chapter 8 4 1 judders in drive defective mode unstable voltage Drive motor s Replace motor s See chapter 8 11 1 fecti melee Replace carbon See chapter 8 11 4 brushes Mobility aid None Drive motors Change See chapter 8 3 pulls to left or running programming to right asymmetrically synchronise motors Error message None Bad Check all See chapter 8 4 5 does not go connect
78. t be installed are described in chapter 4 2 The procedure to replace components is described using the ACS 2 electronic module with an optional lighting circuit board and optional actuator module as an example The procedure is identical for other electronic modules The only difference is the position of the plug in connections WARNING Every alteration to the drive programme can influence vehicle handling and the tipping stability of the wheelchair e Alterations to the drive programme must only be carried out by authorised Invacare dealers e Invacare can only assume a warranty for the safe vehicle handling of the wheelchair in particular tipping stability for this standard unaltered drive programme Note All electronic modules are supplied with a standard drive programme If you have performed customer specific modifications to the drive programme then these will need to be recreated manually after installing the new electronic module Requirements e 7mm socket wrench e 8mm socket wrench e To modify a drive programme you will need Programming software or a hand held programming device and the installation manual available from Invacare Invacare FDX SERVICE MANUAL Uninstalling electronic modules e Remove the rear cover as described in chapter 8 1 2 e Take exact note of the positions of all cables and the sockets that they are connected to Mark the connectors and sockets or take
79. t enough that the wheel can still rotate without resistance When rotated very quickly it must not start to wobble Invacare FDX SERVICE MANUAL 8 11 Drive unit 8 11 1 Replacing the motor gearbox unit A WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Leta second person help you 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 wW Requirements Wy 5 mm Allen key 10 mm socket wrench 13 mm socket wrench Torque wrench 0 10 Nm or similar Torque wrench 5 30 Nm or similar Torque wrench 10 80 Nm or similar Two oblong wooden blocks at least 14 x 14 x 30 cm Uninstalling the motor gear box unit e Remove the drive wheel as described in chapter 8 8 1 e Remove the front rear and lateral covers as described in chapter 8 1 1 8 1 2 and 8 1 3 e Disconnect the motor cable plug e Remove the wheel hub as described in chapter 8 8 3 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 89 SERVICE MANUAL Invacare FDX 90 Use the 13 mm socket wrench to loosen the four screws 1 Hold the motor gearbox unit with one hand Completely remove the four screws inc
80. t in damage to the electronic e Always carry out a trial run at the end of your work 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 Note Mark all current settings for the mobility aid seat armrests backrest etc and the associated cable connecting plugs before dismantling This makes reassembly easier All plugs are fitted with mechanical safety devices which prevent release of the connecting plugs during operation To release the connecting plugs the safety devices must be pressed in When reassembling ensure that these safety devices are correctly engaged WARNING Any changes to the drive program can affect the driving characteristics and the tipping stability of the vehicle e Changes to the drive program may only be carried out by trained Invacare specialist dealers e 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 FDX Tightening torques SERVICE MANUAL The tightening torques stated in the following list
81. terwards Profile selection with G90A remote e Connect the plug to the remote or the ACS 2 electronic system respectively e The display 1 will indicate that you should select a profile e Use the arrow keys 2 to select the location where the desired controller profile is stored Remote Il Electronic module e The display will indicate which profile you have selected e Press the Horn key 3 and the Drive Mode key 2 and keep them pressed for 3 seconds to confirm the selection e The system switches itself off and starts again automatically During this process the selected profile is stored in the remote as well as in the electronic module 47 SERVICE MANUAL Invacare FDX 8 2 4 2 Profile selection with remote REM A or REM B 48 Plug the plug into the remote or the ACS 2 controller LEDs 1 and 4 blink Use the bottom rocker switch 5 to select where the required controller profile is saved LED 1 remote LED 4 ACS 2 control system The relevant LED illuminates permanently the other LED is off Press the Horn 2 and 3 buttons on the speed selection and hold them down for 3 seconds to confirm the selection 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 FDX SERVICE MANUAL 8 2 4 3 Profile selection with remote REM 550 e Plug the plug into
82. the black plastic stop 1 e Push the rear wheel cantilever arm downwards Invacare FDX SERVICE MANUAL With a 12 5 x 2 25 inch wheel in conjunction with a hard spring there is a shim located on top of the spring During the next work procedure pay attention to this shim e Remove the spring 2 Installing the suspension e Assemble the parts in reverse order 87 SERVICE MANUAL Invacare FDX 8 10 Replacing the anti tipper wheels Wd 88 Requirements e Small flat screwdriver e Two 13mm socket wrenches Uninstalling an anti tipper wheel Carefully remove the black plastic cap 3 from the middle of the anti tipper wheel 2 with a small flat screwdriver Loosen the self securing axle nut which is located underneath the plastic cap not visible in the illustration using a 13 mm socket wrench Secure the axle 4 against slippage using a second 13 mm socket wrench Remove the axle nut and the washer Pull the wheel 2 off of the axle Replace the wheel and or the ball bearing The ball bearings are inserted in the wheel They can be removed using a small screwdriver Installing an anti tipper wheel Assemble the parts in reverse order When installing the ball bearings make sure you do not forget to insert the distance sleeve between the ball bearings When repositioning the wheel on the axle make sure you do not forget the spacer washer 5 Tighten the self securing axle nuts just tigh
83. the headlight bracket e Assemble all parts again in reverse order e Tighten the screws hand tight e Check all vehicle functions e Perform an approximate adjustment of the headlight using the ratchet plate as a guide The final adjustment can be performed by the user according to the instructions found in the User Guide 70 Invacare FDX SERVICE MANUAL 8 6 9 Replacing the front bulb holder LED lighting system until 03 2012 wW Requirements Ww e 4mm Allen key e 8mm spanner Dismantling the bulbholder e Loosen the Allen screw 1 using a 4 mm Allen key and remove the headlight from the mounting e Loosen the two cap nuts 2 using an 8 mm spanner and remove the headlight with the mounting from the rubber bumpers e Replace the mounting Refitting the bulbholder e Refit the parts in reverse order e Now tighten all the screws finger tight again 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 71 SERVICE MANUAL Invacare FDX 8 6 10 Replacing a light bulb in the rear conventional lighting system wW Requirements eE e Phillips screwdriver size 2 e Loosen the Phillips head screw in the transparent cover of the tail lamp turn indicator combination e Remove the transparent plastic cover e Replace the defective light bulb e Reposition the cap and tighten the Phillips head
84. 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 128 Invacare FDX SERVICE MANUAL 8 16 4 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 129 SERVICE MANUAL Invacare FDX 8 16 5 Replacing the foot plate on the centre mounted legrest 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
85. ths are inserted to adjust the clearance between the wheel and the motor Select the correct width for the distance rings e Use a thin film of lubricant to replace the wheel hub on the axle e Tighten the screws to a torque of 60 Nm 85 SERVICE MANUAL Invacare FDX 8 9 0 A W 86 Replacing the spring in the rear Note Invacare recommends always replacing both springs to ensure optimum performance of the wheelchair WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Leta second person help you 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 Requirements e 5mm Allen key e Two oblong wooden blocks at least 14 x 14 x 30cm Uninstalling the suspension e Lift the wheelchair on one side and have a second person place a 14 cm high wooden block underneath the battery compartment so that the wheels are off the ground and can rotate freely e Repeat this on the other side of the wheelchair e Remove the drive wheel as described in chapter 8 8 1 e Remove the front rear and lateral covers as described in chapter 8 1 1 8 1 2 and 8 1 3 e Remove the drive wheel as described in chapter 8 8 1 e Use the 5mm Allen key to loosen and remove both screws 3 e Remove
86. tilever arm 97 8 13 Seat seat frame without lifter 99 8 14 Replacing the tilt module lifter module 102 8 14 1 Replacing the tilt module without lifter 102 8 14 2 Replacing the lifter tilt module 105 8 14 3 Replacing the tilt actuator 109 8 14 4 Replacing the lifter actuator 111 8 14 4 1 Method 1 uninstalling the lifter actuator with the lifter raised 111 8 14 4 2 Method 2 uninstalling the lifter actuator with the lifter lowered 113 8 15 Seat support 117 8 15 1 Adjusting the seat width 117 8 15 2 Adjusting the seat depth 119 8 15 2 1 Adjusting the seat depth without replacing the seat support plates 121 8 15 2 2 Adjusting the seat depth and replacing the seat support plates 121 8 16 Centre mounted legrest electric amp manual 123 8 16 1 Replacing the manually operated centre mounted legrest 123 8 16 2 Replacing the electrically operated centre mounted legrest 125 8 16 3 Replacing an electric legrest actuator 127 8 16 4 Replacing the calf plate on the centre mounted legrest electric amp manual 129 8 16 5 Replacing the foot plate on the centre mounted legrest electric amp manual 130 8 17 Back unit 131 8 17 1 Replacing the standard back 131 8 17 1 1 Adjusting the belt back 132 8 17 2 Replacing the EasyAdapt back 133 8 17 3 Replacing adjusting the universal backrest frame for the EasyAdapt backrest 134 8 18 Back unit with ergonomic length adjustment 137 8 18 1 Adjusting the width 137 8 18 2 Replacing the planetary gear 138 8 1
87. to the drive program can influence vehicle handling and the tipping stability of the wheelchair e Alterations to the drive program must only be carried out by trained Invacare dealers e 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 used for programming necessary programming cables see the user manual of the Wizard software You find the latest version of the user manual in the download area on http www dynamiccontrols com 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 ACS 2 remote For more information refer to the user manual of the Wizard software and the installation instructions for the electronic modules Invacare FDX SERVICE MANUAL 8 4 8 4 1 A gt Gor P gt We Batteries cables amp battery chargers Removing the batteries 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 batter
88. tuator chapter 8 14 3 e Replacing just the lifter actuator chapter 8 14 4 WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Leta second person help you Requirements 13 mm open ended wrench 4 mm Allen key 6 mm Allen key 6 mm wrench Side cutting pliers Cable ties Note Take careful note of the exact position of the seat Mark the position it is mounted in the angle and so on If necessary make photographs with a digital camera Any modification of the adjustment of the seat affects the centre of gravity of the wheelchair Uninstalling the lifter tilt module 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 2 105 SERVICE MANUAL Invacare FDX e Completely remove both knurled head screws 1 including the washers e Remove the cover 2 e Disconnect the plug from the actuator module e Open the cable clips on the underside of the seat e Free up all cables so that you can lift the seat off A WARNING Danger of crushing The seat is very heavy Danger of injury to hands and feet e Leta second person help you e Loosen the four screws 1 that attach the seat to the lifter tilt modu
89. tuator channel 2 ms 5 Adjustment 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 tbe The ACI connection serves to limit the movement of an actuator or to reduce velocity Invacare FDX SERVICE MANUAL 4 2 3 2 Actuator module ACT 4 Connections Pod fod Lo 1 ACI Q pe ee la le 2 Bus cable to remote or electronic A AE D E DE fe e fe fe A module o T OFF 3 Bus cable to remote or electronic es eo module Actuator channel 4 6 Actuator channel 2 4 5 Actuator channel 3 6 7 Actuator channel 1 Rubber stoppers for free slots 1 Order number 1555701 2 amp 3 Order number 1552876 4 to 7 Order number 1555700 The ACI connection serves to limit the movement of an actuator or to reduce velocity 4 2 4 Lighting circuit board The connections of the lighting circuit board are located directly on the board 19 20 SERVICE MANUAL Invacare FDX 4 3 Remotes Various types of remotes can be installed on the wheelchair Before you connect components of the wheelchair such as adjustment motors or actuators make sure you know exactly which remote is installed The following table provides an overview pema roms REM G90A Remotes Can be connected to ACS 2 PMB70 ACS 2 PMB70L ACS PMAS0LG power modules Can be connected to ACS 2 PMB70
90. us 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 4 5 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 4 5 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 4 5 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 4 5 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 voltage 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 2 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 30 Invacare FDX SERVICE MANUAL BLINK CODE POSSIBLE CAUSE SOLUTION DOCUMENTATION 11 x blink Drive motors overloaded Switch remote on and off overheated wait if necessary 12
91. w invacare fr Invacare FDX GB Invacare Ltd Pencoed Technology Park Customer services Fax Customer services 44 0 1656 77 62 22 44 0 1656 77 62 20 SERVICE MANUAL Pencoed uk invacare com Bridgend CF35 5HZ WWW www invacare co uk United Kingdom CD 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 CIE Invacare Ireland Ltd 353 18 10 70 84 Unit 5 Seatown Business Campus Fax 353 18 10 70 85 Seatown Rd Swords ireland invacare com County Dublin www www invacare ie Ireland Invacare AS Grensesvingen 9 Postboks 6230 Etterstad N 0603 Oslo Norge Invacare B V Celsiusstraat 46 NL 6716 BZ Ede Nederland Invacare Lda Rua Estrada Velha 949 P 4465 784 Le a do Balio Portugal Kundeservice Fax Kundeservice WWW Fax WWW 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 Invacare FDX Invacare AB O terf rs ljare Kundtj nst Fax Kundtj nst 46 0 8 761 70 90 46 0 8 761 81 08 FIN Fagerstagatan 9 sweden invacare com S 163 91
92. with the slot nuts 4 Fit the four supplied Allen screws and tighten them Adjust the desired seat width with the help of the included centimetre scale Tighten the six Allen screws 1 firmly Invacare FDX SERVICE MANUAL 8 18 6 Fitting the handlebar y A Requirements fj y sd e 4mm Allen key e Loosen and remove the four Allen screws 3 on the plastic cover e Remove the plastic cover 2 e Remove the covers on the washer recesses 5 e Arrange the handlebar 1 on the back section in such a way that the boreholes coincide with the tapped holes in the back section e Fit the four Allen screws 4 incl the washers 5 and tighten the screws e Refit the plastic cover e Refit the six Allen screws 3 and tighten them 143 SERVICE MANUAL Invacare FDX 8 18 7 Replacing the travelling armrest wW Requirements IV 4mm Allen key Dismantling the travelling armrest e Undo and remove the four Allen screws in the backrest plastic cover using a 4 mm Allen key e Remove the plastic cover e f necessary remove the remote together with its cable e On the torque support loosen the locating pin 3 bolt 2 with a 4 mm Allen key e Raise the armrest slightly and remove the locating pin e Pull the armrest out of the torque support to the side If you raise and lower the armrest a few times it is easier to remove e Replace the armrest Refitting the travelling armrest e R
93. wo Allen screws 6 incl the washers and tighten the screws 150 Invacare FDX SERVICE MANUAL 9 3 Further accessories Note The installation instructions for additional accessories are available at your Invacare specialist supplier or directly from Invacare 151
94. ws with which the head lamp is secured to the bracket Loosen both of these Phillips head screws to remove the head lamp from the bracket Replace the head lamp Installing head lamps Assemble all parts again in reverse order Install the cables carefully and secure them with cable ties Make sure that the cables not are not pinched or stretched Tighten both screws hand tight Check all vehicle functions Perform an approximate adjustment of the head lamp using the ratchet plate as a guide The final adjustment can be performed by the user according to the instructions found in the User Guide Invacare FDX SERVICE MANUAL 8 6 4 Replacing headlamps completely conventional lighting system starting 03 2012 wW Requirements 4 e Phillips screwdriver size 2 e Open end wrench 8 mm e Side cutting pliers e Cable ties Uninstalling headlights e Remove the rear cover as described in chapter 8 1 2 e Take exact 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 e Disconnect the cable of the affected headlight from the lighting circuit board e Open the cable clamps 1 remove all cable ties and pull the cable out of the wheelchair 63 SERVICE MANUAL Invacare FDX 64 Loosen both of the nuts 1 with an 8 mm open end wrench and remove the headlight with the bracket from the rubber mounting Loosen both
95. x blink Compatibility problems Remove incorrect module See chapter 8 2 2 between modules 31 SERVICE MANUAL 6 3 32 Diagnosis of charging device faults SYMPTOM No LEDs illuminating on battery charger POSSIBLE CAUSE Charging device not connected to mains supply Invacare FDX 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 mobility aid has burnt out Check mobility aid fuses See chapter 8 4 4 Battery charger not connected to mobility aid Ensure that the battery charger has been connected to the mobility aid 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

Invacare ® FDX SERVICE MANUAL

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Invacare ® FDX SERVICE MANUAL