Invacare® Typhoon II SERVICE MANUAL
Contents
1. Pull each plug slightly It should not disconnect from the socket e If a plug is loose push it lightly into the socket again It must engage e Check whether the plug is sitting firmly in its socket Otherwise repeat the previous steps e Refix the enclosure e Check all vehicle functions 38 7 6 d Replacing the ACS Remote Pre requisites e Phillips screwdriver e To modify a drive programme you will need Programming software or a Handheld Programmer and the Installation Manual of the ACS Electronics available from Invacare NOTE All ACS remotes are supplied with a standard drive programme If the driving programme has been customised then you will have to perform this customisation again after installing the new electronic module 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 trained Invacare dealers Invacare can only assume a warranty for the safe vehicle handling of the wheelchair in particular tipping stability for unaltered standard drive programmes e Switch off the remote e Pull the bus cable 1 out of the remote e Loosen the thumb screw 2 e Pull the remote and the remote holder out of the guiding device e Unscrew both remote holder screws 1 using the crosstip screwdriver 39 40 Installatio2. complete 27 7 2 Replacing electronic components Al Required parts tools e Phillips screwdriver e Remove enclosure 1 e Remove all electrical connections 1 from the electronic modules e The CLAM can be simply pulled vertically out of its holder 28 If the power module is to be replaced this can also be pulled upwards including its retaining frame Loosen and remove the three retaining bolts 1 on the power module 29 d 30 Replacing batteries CAUTION BURN HAZARD e Please take care with damaged batteries or ensure that batteries do not become damaged Any leaking acid can cause chemical burns to the skin and eyes e facid comes into contact with your skin rinse off with plenty of water immediately e If acid comes into contact with your eyes rinse out with plenty of water immediately and seek medical help CAUTION Danger of crushing e Secure the lifter against unintentional folding using the mechanism provided e Check the battery straps for damage and lift the batteries out carefully Caution burn and scald hazard if battery terminal is short circuited e When replacing the batteries the battery terminals must not come into contact with wheelchair metal components otherwise a short circuit may occur e Ensure that the battery terminal covers are in the correct position again once the batteries have been replaced CAUTION Environmental protection
3. e Used batteries must never be disposed of with household rubbish or simply dumped Always dispose of batteries properly by handing them over to your local toxic substance collection point Required parts tools e jaw spanner 11 mm e Allen key 8 mm e spare battery s Please note A second person is required to help when carrying out this work e Run the seat lifter into the top position e Remove legrests Pull actuator bolt locking out of belt One person lifts the seat upwards a second person ensures that the actuator bolt head 1 is guided out of the holder and does not jam Push the holding mechanism 1 completely to the front so that it engages Run the actuator bolt completely down again 31 32 Pull the enclosure forwards Loosen the screws 1 on both sides with the 8 mm Allen key and remove them Push the bottom actuator holder inwards together with the regulator motor then lift it 1 and pull completely out the front 2 When doing so it helps if you put one hand under the chassis to guide the actuator holder locking pin into the position from which it can be pulled out upwards Remove all the actuator connecting plugs and place the actuator holder and all its components to the side amp Loosen the locking device 1 on the battery locking bar and remove the bar Remove the terminal covers from the battery terminals 1 First loosen the bolts
4. not loosened and removed in the prescribed sequence e Only ever loosen and remove the bolts in the prescribed sequence Bolts 1 to 5 must be loosened and removed in a prescribed sequence The numbering of the bolts is not fixed in other words there is no particular bolt permanently numbered 1 What is really meant is that the operation can start with any bolt This is then number 1 Number 2 is then the next bolt in a clockwise direction 3 the next one and so on e Loosen and remove bolts 1 and 3 using the 6 mm Allen key e Now unscrew bolts 2 4 and 5 by one turn in a clockwise direction one after the other until all are loosened and removed e Remove the wheel rim halves the tyre and the puncture proof inner tube from the wheel 7 1 1 3 Continuing dismounting the motor e Open the circlip 1 securing the top bolt using the circlip pliers and remove it Loosen and remove the bolt 1 using the 5 mm Allen key then loosen bolt 2 21 22 Loosen and remove the rubber pad 1 using the pliers and the 10 mm open ended spanner Loosen and remove the retaining bolts 1 on the anti dive mechanism bearing shell with the 5 mm Allen key Pull the drive unit down from the main bearing bolts Loosen and remove the motor fixing bolts Replace motor 7 1 1 4 7 1 1 5 CAUTION There is a danger that the anti tip mechanism will not function correctly after replacing the motor or the ga
5. on the negative terminals black cable with the 11 mm jaw spanner After this loosen the bolts on the positive terminals red cable CAUTION Danger of crushing The batteries are extremely heavy Please ensure that they do not fall onto the ground when they are removed from the chassis Pull the batteries out to the front CAUTION Fire hazard Cables can get jammed and frayed Please ensure the cables have the correct polarity They must not protrude into the lifter area Use cable clamps if necessary 33 gt 34 When installing new batteries cables must never be routed between the front battery and the lifter actuator If so they can be damaged when the lifter is operated RIGHT e Installation takes place in reverse order Please note The battery terminals on the rear battery must face the rear and terminals on the front battery must face the front The batteries cannot be connected in any other fixing direction CAUTION Danger of crushing e Please ensure that the actuator head slides into the top holder e Run the actuator bolt into the top position and ensure that it slides into the top holder 1 e Lift the seat slightly and loosen the holding mechanism 1 Lower the seat slowly until the lifter weight is resting on the actuator again e Check all vehicle functions e Check the new battery status and charge completely 35 N P Replacing
6. or the work surface e Connect the programming device The programming device displays The programming device Necessary input PIE NEE DX HHp V1 20 GB Select language GB D NL S TECH View system or edit YES DIAG TECH Technician mode Enter code 592 with keys D1 to D3 then select EXIT Enter password 000 EXIT D1 D2 D3 Technician mode NEXT Master JS module JOYSTICK CALIBRATION EXIT YES NEXT MAIN MENU YES View GB power module or edit NEXT YES GB inspection NEXT Torque XX EXIT NEXT DOWN UP GB inspection NEXT Vibration damping XX EXIT NEXT DOWN UP GB inspection NEXT Speed sequence XX EXIT NEXT DOWN UP GB inspection NEXT Turn sequence XX EXIT NEXT DOWN UP 26 The programming device Necessary input BIR JEVEN GB inspection EXIT NEXT YES GB MOTOR CALIBRATION Wheels will move Drive wheels raised EXIT YES Calibrate motors YES YES if drive wheels raised GB MOTOR CALIBRATION Wheelchair will drive Wheels raised EXIT YES YES if drive wheels raised GB MOTOR CALIBRATION BEGIN to start Wheels will turn EXIT BEGIN BEGIN if drive wheels raised GB MOTOR CALIBRATION taking place Please wait No entry necessary Wait till end of calibration GB MOTOR CALIBRATION Successful EXIT EXIT e Disconnect the programming device from the wheelchair Calibration is
7. page 38 Connection loose defective or motor defective Left motor e Engage motor Shut See User Manual disengaged GB electronics down and then motors switch on again Both motors e Engage motors Shut See User Manual disengaged electronics down and then standard motors switch on again 6 x flashes Fault brake fault e Check plug in See Checking the on right hand connections cables on page 38 motor Connection loose defective or motor defective Right motor e Engage motor Shut See User Manual disengaged GB electronics down and then motors switch on again 7 x flashes Battery dead e Pre charge battery See User Manual 8 x flashes Battery voltage too e Switch lights on to lower See User Manual of battery high battery voltage charger e Check battery charger 16 Flash code _ Meaning Solution Notes 9or 10x Faulty data e Remove all electronic flashes transmission modules except the Power between modules Module and the Remote Re attach modules one by one to determine which one is causing the fault See Replacing electronic components on page 28 11x flashes Motors overloaded e Switch remote on and off overheated wait if necessary 12x flashes Module used has e Remove incorrect module See Replacing electronic compatibility components on page 28 problems 17 7 1 18 Repair Work CAUTION Risk of damage to the vehicle Collisions can be caused if shim rings ar
8. possibly remote on the ACS Remote on page defective wheelchair in 39 order to rule out the possibility that the remote is causing the fault Remote Various causes e Assess error See REM24 Error status display code Codes and Diagnostic blinking Codes on page 16 13 14 PROBLEM OTHER POSSIBLE SOLUTION Documentation SYMPTOMS CAUSE Status display Speed e Replace cable See Adjusting and on remote controller on or switch replacing the speed blinking 2x lifter possibly reduction switch on drive display defective or not page 43 on U connected Wheelchair None Batteries e Replace See Replacing on judders in possibly batteries page 30 drive mode defective voltage unstable Drive motor s e Replace See Replacing and possibly motor s calibrating drive defective motor on pages 18 and Replacing and calibrating drive motor on page 18 Batteries None Batteries e Replace See Replacing on not being possibly batteries page 30 charged defective LEDs blinking Charging e Replace See charging unit on charging device possibly charging unit operating manual unit defective Wheelchair Status display Seat lifter is not e Run the seat See operating manual runs too on remote in drive position lifter to the drive slowly blinking 2x either too high position drive display or too low and on U has activated automatic speed regulation Speed e Adjust regulator See Adjusting and control
9. small tappet in the centre of the valve CAUTION If the wheelchair is fitted with puncture proof tyres the liquid in the tyres can block the valve when air is released if the valve is at the bottom The air cannot then be released e Before releasing air from the wheel always turn the wheel so that the valve is at the top Injury hazard The wheelchair will drive in an uncontrolled manner if the GB motors are not calibrated after being fitted new e Ensure that the GB motors have been calibrated after being fitted W Injury hazard If the bolts which secure the wheel are not tightened firmly enough or if the threaded holes in the casing are damaged by being tightened too much the wheel can come loose during travel e Always position the nuts manually in their holes when fitting the drive wheels e Never use electrical or pneumatic screwdrivers e Tighten the Allen screws with a torque of 25 Nm e The Nordlock washers must be fitted exactly as they were before removal NOTES REGARDING GB MOTOR GUARANTEE If motors become defective within their guarantee period they will either be replaced or repaired on Invacare s decision This guarantee does not cover pay for working hours We also accept no liability for physical injuries or unauthorised repairs Invacare s sole obligation and its exclusive remedy during this guarantee is limited to such repair and or replacement measures Required parts
10. Invacare Typhoon Il SERVICE MANUAL This document contains information on Troubleshooting Maintenance Repair Version 08 02 08 43 6232 55 350 i Mobitec Mobilitatshilfen GmbH 4 Herzog Odilostrasse 101 Fax 43 6232 55 35 4 A 5310 Mondsee office mobitec austria com Austria austria invacare com WWW www mobitec austria com ri CR Invacare n v a 32 0 50 83 10 10 k A Autobaan 22 Fax 32 0 50 83 10 11 gt B 8210 Loppem Brugge belgium invacare com k A Belgium WWW www invacare be CH Mobitec Rehab AG a 41 0 61 48 77 080 tT Benkenstra e 260 Fax 41 0 61 48 77 08 1 7 CH 4108 Witterswil office mobitec rehab ch Switzerland switzerland invacare com WWW www mobitec rehab ch D Invacare Aquatec a 0 75 62 7 00 251 KM Alemannenstrae 10 Fax 08 00 6 73 81 72 88316 Isny info invacare aquatec de Deutschland WWW www invacare aquatec de DK Invacare A S T Kundeservice 45 0 36 90 00 00 stw Sdr Ringvej 39 Fax Kundeservice 45 0 36 90 00 01 S DK 2605 Br ndby denmark invacare com Danmark WWW www invacare dk i Ej Invacare SA a 34 0 972 49 32 00 w L c Aren s n Fax 34 0 972 49 32 20 8 Poligon Industrial de Celra contactsp invacare com 17460 Celra Girona WWW www invacare es ESPA A E V Invacare Poirier SAS a 33 0 247 62 64 66 TI Route de St Roch Fax 33 0 247 42 12 24 F 37230 Fondett
11. a positioning aid and to align them Screw in three M8 x 30mm bolts by hand in positions 1 3 and 5 Tighten bolts 1 3 and 5 successively in a clockwise direction by one rotation each until a torque of around eight Nm is reached check with torque wrench if necessary This is necessary to ensure that the wheel rim is evenly tightened onto the rotor housing Screw two of the original M8 x 25 mm bolts at positions 2 and 4 in and tighten to fingertight max 8 Nm Unscrew M8 x 30 mm prestressing bolt at et e Position 5 screw in M8 x 25 mm original bolt and tighten to fingertight max 8 Nm r V Unscrew M8 x 30 mm prestressing bolt at Position 1 screw in M8 x 25 mm original bolt and tighten to fingertight max 8 Nm Unscrew M8 x 30 mm prestressing bolt at Position 3 screw in M8 x 25 mm original bolt and tighten to fingertight max 8 Nm The last thing to do is to tighten all bolts to 25 Nm 25 7 1 2 Calibration of GB motors Below we describe calibration using the hand programming device A Injury hazard The wheelchair may start to move in an uncontrolled manner if one or both drive wheels touch the floor during calibration e Itis imperative that both drive wheels not just those on one side are raised before calibration A Required parts tools SS e dynamic DX HHP hand programming device e Support the wheelchair with wooden blocks The drive wheels must not be touching the floor
12. as a result of incorrectly or improperly executed maintenance or overhaul work lead to the exclusion of all liability on the part of INVACARE e If you have any problems or questions please contact INVACARE SERVICE Notes on transport e If the electric vehicle has to be shipped back to the manufacturer for major repairs you should always use the original packaging for transport e You should also include as accurate a fault description as possible Important symbols in this manual WARNING This symbol warns you of danger 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 an example of 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 BURN HAZARD This symbol warns you of burns due for example to leaking battery acid e Always follow the instructions to avoid injury to the user or damage to the product 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 2 1 2 2 A Safety and assembly instructions These safety instructions are intended to preve
13. cing electronic components Replacing batteries Replacing the main fuse Checking the cables 30 36 38 7 6 Replacing the ACS Remote 39 7 7 Updating the software 41 7 8 Checking an actuator motor 42 7 9 Adjusting and replacing the speed reduction switch 43 7 10 Replacing the steering head bearings on the front and rear steering wheels 44 7 10 1 Front steering wheels 44 7 10 2 Rear steering wheels and 45 Introduction General information e All maintenance and overhaul work must be carried out in accordance with these repair instructions e Please observe all safety instructions e Information about operation or about general maintenance and care work should be taken from the electric vehicle Operating Manual e You can find information about ordering spare parts in the spare parts catalogue e Use only genuine Invacare spare parts Using parts from any other source will void the warranty e We reserve the right to make any alterations on the grounds of technical improvements e The electric vehicle may only be maintained and overhauled by qualified personnel e The minimum requirement for service technicians is relevant training such as in the cycle or orthopaedic mechanics fields or suitably long term job experience Experience and knowledge of electrical measuring devices Multimeter is also a requirement Special Invacare training sessions are recommended e Alterations to the electric vehicle which occur
14. den block under the battery case on the side on which you wish to carry out the work so that the wheelchair is supported e Remove the black plastic cover 1 over the end of the steering head tube using the small screwdriver e Loosen the nut 1 with the 19 mm socket spanner and remove it Hold the wheel so that it does not rotate when you remove the nut e Pull the steering head shaft down and out of the steering head tube e Remove the washer and the rail ring from the head of the tube The other rail ring should remain on the shaft IMPORTANT ASSEMBLY INFORMATION The illustrations show the wide border of the rail ring exterior on one side A and the narrow border on the interior B The bearings must always be mounted so that the narrow rings are placed opposite each other interior The steering head bolts and the nuts must always press against the wide external edges Otherwise the bearings will be pressed apart by the bolt pressure The steering wheels should always rotate freely after mounting but the bearings may not have any play e First tighten the nuts up to 20 Nm 2 Nm e Then loosen the nuts slightly e Now retighten them up to 15 Nm 1 5 Nm 7 10 2 Rear steering wheels and e Remove the black plastic cover 1 over the end of the steering head tube using the small screwdriver e Loosen the 19 mm nut with the socket spanner and remove it Hold the wheel so that it does not rotate w
15. e 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 Please install all shim rings in exactly the same positions they were in before dismantling Replacing and calibrating drive motor The following two sections describe how a GB motor is replaced and a new motor is calibrated We recommend that you read these instructions completely through before commencing work GUIDELINE First find out whether the vehicle is fitted with puncture proof tyres or pneumatic tyres The course of action during disassembly is different depending on whether the vehicle is fitted with puncture proof tyres or standard pneumatic tyres You can recognise puncture proof tyres by the fact that they do not have a valve Replacing the motor CAUTION Danger because wheelchair can tip or roll away e Prevent the wheelchair from tipping by inserting a wooden block which is long and wide enough under the battery case If the wooden block is too short or too narrow the wheelchair can still tip e Switch the wheelchair off at the remote EXPLOSION HAZARD If the wheelchair is fitted with pneumatic tyres the wheel can explode if the air is not released from the tyre before removing the wheel e Always release the air from the wheel before it is removed depress the
16. es contactfr invacare com France WWW www invacare fr GB Invacare Ltd T Customer Service 44 0 1656 664 321 GB South Road Fax Customer Service 44 0 1656 667 532 7 Bridgend Industrial Estate uk invacare com Mid Glamorgan CF31 3PY eire invacare com United Kingdom WWW www invacare co uk ETY Invacare Mecc San s r l a 39 0445 38 00 59 s M Via Dei Pini 62 Fax 39 0445 38 00 34 36016 Thiene VI italia invacare com ITALIA WWW www invacare it Invacare Ireland Ltd a 353 18 10 70 84 Unit 5 Seatown Business Campus Fax 353 18 10 70 85 Seatown Rd Swords eire invacare com County Dublin Ireland Invacare AS Grensesvingen 9 Postboks 6230 N 0603 Oslo Norge Invacare B V Celsiusstraat 46 NL 6716 BZ Ede The Netherlands T Kundeservice Fax Kundeservice WWW T Fax WWW 47 0 22 57 95 10 47 0 22 57 95 01 norway invacare com www invacare no 31 0 318 69 57 57 31 0 318 69 57 58 csede invacare com www invacare nl P Invacare PORTUGAL Lda a 351 225105946 9 Rua Senhora de Campanha 105 Fax 351 225105739 P 4369 001 Porto portugal invacare com PORTUGAL WWW www invacare pt re terf rs ljare T Kundtj nst 46 0 8 761 70 90 k Invacare AB Fax Kundtj nst 46 0 8 761 81 08 Fagerstagatan 9 sweden invacare com if 1 S 163 91 Spanga finland invacare com Sverige WWW www invaca
17. hen you remove the nut e Pull the steering head shaft down and out of the steering head tube e Remove the washer and the rail ring from the head of the tube The other rail ring should remain on the shaft 45 46 IMPORTANT ASSEMBLY INFORMATION The illustrations show the wide border of the rail ring exterior on one side A and the narrow border on the interior B The bearings must always be mounted so that the narrow rings are placed opposite each other interior The steering head bolts and the nuts must always press against the wide external edges Otherwise the bearings will be pressed apart by the bolt pressure The steering wheels should always rotate freely after mounting but the bearings may not have any play e First tighten the nuts up to 20 Nm 2 Nm e Then loosen the nuts slightly e Now retighten them up to 15 Nm 1 5 Nm
18. hich no special values are determined All values apply to dry and grease free threads Thread M4 M5 M6 M8 M10 M12 M14 M16 Tightening torque 3 Nm 6 Nm 10 Nm 25 Nm 49Nm 80 Nm 120 Nm 180 Nm in Nm 10 Caution All other nuts or plastic connectors not noted here must be tightened FINGERTIGHT 4 Layout of modules components and displays and controls The following figure shows the Typhoon II from behind with extended seat lifter and the rear panelling removed 1 2 3 4 5 1 10 Seat lean adjustment Seat frames rear panelling anti collision switch Speed controller Main module power module Lighting actuator module Lifter servo motor 5 Service plan 1x annually e Armrest damage Tighten screws replace Armrests and side and fastening top surface if damaged panels and fixing e Top surface Replace cover e Check adjustable upholstery if damaged seat inclination Replace parts if damaged Seat unit adjustable seat inclination Damage and Replace parts if damaged seams gt Tighten screws e Fixing gt Replace cable or motor if e Check cable necessary e Check function Frame chassis e Check fixings Tighten screws replace batt r mo ntin welded seams and components ry g battery mounting e Check drive wheels Adjust replace wheel See Replacing for tight fit and side and calibrating play drive motor on page 18 e Chec
19. k steering Replace wheels wheel See Replacing wheels for tight fit fork or wheel bearings the steering head float and side play bearings on the front and rear steering wheels on page 44 e Check drive wheel Repair or replace if see operating pneumatic tyres damaged manual Drive units clutch e Check functions in Replace motor if mechanism drive and push necessary modes gt Tighten screws nuts e Check clutch adjust or replace if mechanism necessary seams interlocking necessary screws footplates Electrical legrests Check cable gt Replace cable if aa Check contacts necessary check functions ig te e Check cable Replace bulbs or cable if Homino LS reay damage necessary on page 30 e Check battery charge batteries See operating Jas E bel e Check contacts and Clean contacts and See Replacing terminals terminals on page 30 for safety information on handling batteries Mechanical backrest Electrical backrest Wheel suspension and wheels 11 Component Remote drive electronics Lifter module Drive program 12 Remote status display blinking Fixing Cable connecting plug Joystick function Power supply Check for correct functioning Check locking device function Check drive electronics program version Newer version available Evaluate blinking code Tighten replace Replace Replace joystick Replace cable connecting plug or console gt Re
20. ler on replacing the speed seat lifter may reduction switch on be badly page 43 adjusted None Remote e Replace remote See Replacing the possibly ACS Remote on page defective 39 Batteries e Replace See Replacing on possibly batteries page 30 defective 6 1 2 Fault diagnosis with electric actuator motors Please use the following table to assess fault causes when using electric actuator motors PROBLEM OTHER SYMPTOMS POSSIBLE CAUSE SOLUTION Documentation order to rule out the possibility that the remote is causing the fault Electric Remote shows Lighting e Replace See Replacing actuator blinking E actuator lighting actuator electronic motor does status diode on module module components on page not react lighting actuator defective 28 module does not go out even if the remote is switched off or disconnected None Cable e Check to See Checking the possibly ensure that the cables on page 38 disconnected cable has not or damaged been disconnected or damaged Replace cable if necessary Electrical e Test actuator See Checking an actuator motor actuator motor on motor page 42 possibly defective Remote e Replace the See Replacing the possibly remote on the ACS Remote on page defective wheelchair in 39 15 REM24 Error Codes and Diagnostic Codes The drive electronics are capable of rectifying some errors automatically In this case the
21. n of the remote is carried out in reverse order Update the software in case a newer version is available Customise the driving programme with the programming software if required Check all vehicle functions 7 7 Vd Updating the software Driving programmes 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 then the driving programme must be updated The procedure for updating the driving programme is described in the User s Manual of the Wizard Software NOTE If the driving programme has been customised then you will have to perform this customisation again after installing the new driving programme 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 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 programmes Pre requisites e Dynamic Wizard Software e User s Manual for Wizard Software e For further information on other requirements such as the minimum system configuration of the PC to be used for programming necessa
22. ng the electric vehicle make sure all fixations are correctly secured Check all parts for correct interlocking1 e Only operate the electric vehicle with correct tyre pressure see Technical Specifications e Check electrical components for correct functioning incorrect polarity of cables can result in damage to the electronics e Asa last check always carry out a test drive Notes Mark all current settings for the electric vehicle seat armrests backrest etc and the cable connecting plugs associated before any removals 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 alteration to the drive programme can influence vehicle handling and the tipping stability of the electric vehicle e Alterations to the drive programme may only be carried out by trained Invacare dealers e Invacare supplies all electric vehicles from the factory with a standard drive programme Invacare can only assume a warranty for the safe vehicle handling of the electric vehicle in particular tipping stability for this standard drive programme Tightening torques The tightening torques stated in the following table are dependent on the thread diameters for the nuts and bolts for w
23. nt accidents during work and it is imperative that they are observed Before any inspection or repair work e Read and observe this repair manual and the associated operating manual e Observe the minimum requirements for carrying out the work see chapter entitled General information General safety information and notes on assembly disassembly Danger of injury by crushing e Please note the heavy weight of some components This applies especially to removal of drive units and batteries e Prop up the lifted electric vehicle with appropriate supports before starting the disassembly or assembly Danger of fire and burns due to electrical short circuit e The electric vehicle must be switched off before removal of voltage carrying components To do this disconnect the batteries e When making measurements on voltage carrying components avoid short circuiting the contacts Danger of fire and combustion Danger of injury and damage to the vehicle can result from incorrect or incomplete maintenance Only ever use tools which are undamaged in good condition Some moving parts have Teflon bushings These parts must never be lubricated with grease Never use standard nuts instead of self locking nuts Always use correctly dimensioned washers or spacers Cable binders which have been cut off during disassembly should be replaced with new ones during reassembly e After completing maintenance work and before operati
24. pair if necessary See Updating the software on page 41 e Update software d 6 1 1 Operational faults Operational faults on electric wheelchair with ACS If you have problems with the wheelchair please proceed as follows e First assess the possible cause of the problem using the following table e Check the status display on the remote Evaluate the blink error code e Carry out the necessary checks and repairs as recommended in the following table NOTE You can find more information about operational faults on electric wheelchairs with GB motors in the document entitled Dynamic DX GB AS Power Module Assembly Instructions order no 1441533 Drive fault diagnosis Documentation POSSIBLE CAUSE SOLUTION PROBLEM OTHER SYMPTOMS Wheelchair Remote Drive motors e Re engage drive See operating manual will not status display possibly motors start illuminates disengaged normally without showing an error code Remote Batteries e Replace See Replacing on status display possibly batteries page 30 does not defective illuminate Batteries e Pre charge See operating manual possibly over batteries discharged Power supply e Check master See Replacing the to remote fuse main fuse on page 36 possibly interrupted e Check cable See Checking the between cables on page 38 modules for loose connections or damage Remote e Replace the See Replacing the
25. re se Tillverkare Ce 46 0 31 86 36 00 Le N Fax 46 0 31 86 36 06 D 32457 Porta Westfalica ginvacare invacare com Deutschland LANDSKRONA a 46 0 418 285 40 Fax 46 0 418 180 89 linvacare invacare com OSKARSHAMN a 46 0 491 101 40 Fax 46 0 491 101 80 oinvacare invacare com Table of Contents 11 Page Chapter 1 INTRODUCTION 1 1 General information 1 2 Notes on transport 1 3 Important symbols in this manual 2 SAFETY AND ASSEMBLY INSTRUCTIONS 2 1 Before any inspection or repair work 2 2 General safety information and notes on assembly disassembly 3 TIGHTENING TORQUES 4 LAYOUT OF MODULES COMPONENTS AND DISPLAYS AND CONTROLS 10 5 SERVICE PLAN 1X ANNUALLY 6 OPERATIONAL FAULTS 6 1 Operational faults on electric wheelchair with ACS 6 1 1 Drive fault diagnosis 6 1 2 Fault diagnosis with electric actuator motors 6 1 3 REM24 Error Codes and Diagnostic Codes 7 7 7 2 7 3 7 4 7 5 A 7 7 7 7 7 NW REPAIR WORK Replacing and calibrating drive motor 1 Replacing the motor 1 1 1 Removing wheel rim and tyres on vehicle with pneumatic tyres 1 1 2 Removing wheel rim and tyres on vehicle with puncture proof tyres 1 1 3 Continuing dismounting the motor 1 1 4 Reassembling wheel rim and tyres on vehicle with pneumatic tyres 1 1 5 Reassembling wheel rim and tyres on vehicle with puncture proof tyres 2 Calibration of GB motors Repla
26. ry programming cables and so on please see the User s Manual of the Wizard Software 41 7 8 Checking an actuator motor Al Required parts tools Vo e Multimeter e Check the actuator motor electrical resistance If this is approaching infinity the motor is probably burnt out If it is below 10 the motor probably has a short circuit The motor must be replaced in both cases 42 7 9 W Adjusting and replacing the speed reduction switch Find out here how you can adjust and replace the switch that reduces the speed when in the upper lifter position Pre requisites e Small pliers e Move the lifter to the upper and lower position several times In doing so check whether the contact switches e If the contact does not switch bend the plate 1 slightly e If the contact is faulty replace the entire cable harness e Check all vehicle functions 43 44 7 10 Replacing the steering head bearings on the front and rear steering wheels A CAUTION Incorrect reassembly can damage the bearings or cause the steering wheels to fall out The single row angular ball bearing rings are not identical on both sides For this reason they can only be fixed using one correct method You must ensure that the fitting manual is followed correctly yA Required parts tools de e small flat screwdriver e open ended spanner 19 mm e torque wrench 7 10 1 Front steering wheels e Push a woo
27. s pressure spring due to a change in distance between the triggering pin on the gas pressure spring and the counter bolt e Itis imperative that you check that the anti tip mechanism is functioning correctly after replacing a motor and readjust if necessary e The drive unit is refitted in reverse order e Tighten the wheel bolts to 25 Nm Reassembling wheel rim and tyres on vehicle with pneumatic tyres e Replace the inner tube in the tyre e Insert the wheel rim halves once again e Insert the countersunk screws and tighten slightly e Pump alittle air into the inner tube e Screw the wheel rims tightly together e Ensure that the tyre outer is seated correctly e Pump the tyres up to 3 bar air pressure e Check that the tyre is seated correctly once again e Screw the valve cap back on Reassembling wheel rim and tyres on vehicle with puncture proof tyres e In order to refit tyres with puncture proof inner tubes the inside and outside edges of the tyre 1 and 3 and the inside surface of the core 2 must be coated with tyre fitting paste soft soap 23 24 Push the tyres with puncture proof cores onto the motor on the rotor housing Position the wheel rim halves in the tyres The holes for the bolts in the wheel rim halves and those in the rotor housing must be aligned While doing so it can be helpful to use the notches in the wheel rim halves and in the rotor housing for the nonexistent valves as
28. status display will cease to flash Please switch the remote on and off several times Wait approx 5 seconds each time before switching the remote on again If this does not rectify the error locate the error using the flash codes shown below Flash code Meaning Solution Notes 1 x flash Module defective e Replace defective module See Replacing electronic components on page 28 2 x flashes Accessory error e Check accessory See Checking an e g actuator connections check actuator motor on page short circuit accessories 42 Lifter raised or e If lifter is raised lower in See User Manual lowered too far stages until the status seat not at driving display stops flashing If height lowered too far raise lifter in stages until the status display stops flashing If at all possible only drive when the seat is at driving height 3x flashes Connection on the e Check plug in See Checking the left motor connections cables on page 38 loose defective Left motor e Check replace motor See Replacing and defective calibrating drive motor on page 18 4x flashes Connection onthe e Check plug in See Checking the right motor connections cables on page 38 loose defective Right motor e Check replace motor See Replacing and defective calibrating drive motor on page 18 5 x flashes Fault brake fault e Check plug in See Checking the on left hand motor connections cables on
29. the main fuse CAUTION Fire hazard e Only ever use original plate fuses and admissible current strengths e Ifthe main fuse blows the cause must be rectified before any new fuse is inserted A4 Required parts tools ad e ring spanner 8 mm e replacement fuse e large flat screwdriver Please note If the fuse holder is damaged this can be replaced complete with the battery cable e Remove enclosure 1 The position of the fuse 1 is shown in the figure on the right A Caution Danger of fire if the strip fuse is fitted incorrectly e Only ever fit the strip fuses in the sequence shown in the figure on the right Always tighten nuts with a torque of 3 3 to 3 5 Nm 1 Strip fuse 2 Terminal end 3 DIN 6923 nut 36 Open the fuse holder cover 1 If one of the plate fuses 2 has blown you must first determine the cause The main fuse may only be replaced once the problem has been rectified Loosen the nuts 1 which hold the plate fuse 2 secure using an 8 mm socket or ring spanner Insert a new plate fuse 2 and secure using both nuts 1 Close the fuse holder cover again Insert the fuse holder into the electronics holder again until you hear a click Close the electronics cover Check all vehicle functions 37 7 5 Checking the cables e Run the lifter into the top position e Remove enclosure 1 e Check all cables for signs of damage and breakage e
30. tools e wooden block to support vehicle Allen key 4 mm Allen key 5 mm Allen key 6m Allen key 10 mm circlip pliers jaw spanner 10 mm Torque wrench Additional parts tools for fitting puncture proof tyres e tyre fitting paste soap based e 3 bolts M8 x 30mm for provisional positioning of wheel rim during fitting NOTE Take note of small parts and the sequence in which components have been fitted Arrange these in a tidy sequence so that they are easier to refit in the correct sequence e Loosen the fixing bolts 1 on the dirt arrester using the 4 mm open ended spanner and remove them 19 7 1 1 1 A 20 e Support the wheelchair with wooden blocks e Loosen the bolt 1 and disconnect the motor cable plug Removing wheel rim and tyres on vehicle with pneumatic tyres EXPLOSION HAZARD If the wheelchair is fitted with pneumatic tyres the wheel can explode if the air is not released from the tyre before removing the wheel e Always release the air from the wheel before it is removed depress the small tappet in the centre of the valve e Unscrew valve cap e Reduce the air pressure in the tyre by depressing the valve tappet 1 e Loosen the five bolts 2 using the 6 mm Allen key e Remove the wheel rim halves and the inner tube from the wheel 7 1 1 2 Removing wheel rim and tyres on vehicle with puncture proof tyres A CAUTION Danger of damage to motor if the bolts are
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