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SERVICE MANUAL

1. Erie ar k Po EE S oO EENE ey a NOOO NMNPMPONDN H N O NM PND PY ON oO A ice baer BWW ONA S backrest Inspection Remedy e Check electric functions on NOTE ING IOVSIICK GOXI pe naper ee e A continuity test can be performed e BUS plug defective gt Replace BUS cable at the actuator motor BUS cable damaged gt Replace BUS cable Also a performance test can be e Joystick tight or damaged gt Replace joystick box conducted by applying a voltage e Screwings Ogee gt Tighten screws o A Jelo be peromed as e Holder defective gt Replace parts or holder described in chapter 14 0 for the e Actuator defective gt Replace actuator motor actuator motors e Switch box damaged gt Replace switch box 97 Disassembly Joystick Box e Detach BUS cable 22 from the joystick box 1 e Loosen screw 38 open clamp 37 and detach joystick box 1 from the receiving tube 5 Assembly e The assembly is performed in the reverse order Disassembly Actuator e Detach actuator connection cable 40 from the wheelchair and put aside e Remove caps 21 loosen nuts 13 completely and detach together with washers 12 e Support actuator 29 remove screws 11 and detach actuator from the backrest holder 2 and from the swivel arm 3 z NOTE The guide rod 4 is to be dismounted in a similar way Assembly e The guide
2. ssembly NOTE The assembly is performed in the reverse order If necessary replace the compression rivets 12 with plastic rivets or tapping screws during the assembly 22 9 3 10 13 16 19 Legrests with Single Footboard Legrests assembled Legrests complete 2 Legrest upper part left Insert tube 18 5 mm left 5 Sport footboard ALU Calf belt 8 Clamp 22 mm Cap nut M8 11 Washer 8 4x17x1 6 Caps A8 14 Leaf spring Hinge bolt 7 8x30 mm 17 Hinge bolt 7 8x35 mm Legrest locking device spring weighed Legrests disassembled 3 Insert tube 18 5 mm right locked in the footboard 6 Rubber mat glued 9 Button headed screw M8x25 12 Slide piece SL 18 15 Tapping screw 4 2x16 18 Plastic washers 7 8x20x1 0 for hinge bolt not shown Inspection Remedy Calf belt missing or damaged gt Replace exchange calf belt Screwings loose gt Tighten screwings Rubber mat damaged gt Replace rubber mat Footboard damaged gt Replace footboard Footboard receptacle damaged gt Replace footboard receptacle Weldment joints or insert tube defective gt Replace insert tube Weldment joints or upper part of legrest defective gt Replace footrest upper part Slide pieces or caps missing or damaged gt Replace exchange slide pieces or caps Complete Disassembly Remove calf belt 7 from insert tubes 3 and 4 Hold footboard 5 by its left side and turn upwards until it is released from the
3. 15 0 Check and Repair Work on the Lighting System 15 1 Causes of Malfunctions Head light and or flasher not working Light bulbs defective Chapter 15 2 Contacts in lampholder bent Chapter 15 2 Power supply from distributor in Chapter 18 0 to rear light board to lamp interrupted Chapter 17 0 Switch at joystick box defective Entire lighting system out of order Check status display on joystick box NOTE e 2x flashing of status display points to an error in the connection cable from the module to the distributor in the rear light board Check wheelchair programming NOTE e The channel for the CLAM Lighting adjustment module or for the 12V 24V lighting module must be enabled Chapter 16 2 Chapter 19 0 15 2 Check Lighting Check light bulb Light bulb defective Chapter 15 3 nein Check contacts in the socket Contacts bent oxidized Fix contacts or Chapter 15 3 aaa replace lamp 15 4 and 15 6 I nein Check voltage in Lamp holder No voltage Check cable from the yes distributor in the rear light board Chapter 18 0 to the lighting unit ae Electric tension breaking down due to burden i Defect in the power supply Chapter 12 0 79 15 3 Disassembling Testing Headlight Headlight assembled Headlight disassembled er 3 4 Headlight glass with mirror Tapping screw 2 9x15 Lamp holder Light bulb H
4. Designation of Module Designation on the Module Label Main module Power Module Lighting module 24 V Lighting Module 24 V Lighting module 12 V TUV Version Lighting Module 12 V Lighting actuator module Combined Lighting Actuator Module Standard joystick box DX REM 24 DX REM 24 AS Joystick box for attendant DX ACU 1AS DX REM 24 S Control unit for actuators DX ARC 5 Joystick box for table or centre control DX REM 41 REM 41 S Chin control Voltage transformer for RECARO seat DX ACC 1 or DC DC Converter 4 2 Apart from the controlling functions the electronic control has the following additional functions e Monitoring of the modules e Monitoring of the driving system e Monitoring of the actuator motors e Error check NOTE The control unit for the Recaro seat s adjustment functions is integrated into the seat and is not part of the ACS Connection Cables of the Modules The connection cables of the modules are designated as BUS cables The cables are arranged as four conductor cables Two of the conductors serve the power supply and two serve the transfer of data Grouping of Cables Power supply black earth cable red positive cable Data transfer yellow cable CAN high violet cable CAN low Standard Joystick Box H 9 DD Control Unit Actuator Modules Table Central Control Chin Control BUS Plug Power Supply 10 4 3 Status Displays Er
5. Actuatordete tive Replace actuator Chapter 14 3 Servo lighting module Replace servo lighting Joystick box defective Replace joystick box Chapter 17 1 17 5 Adjustment control Replace adjustment defective control Bbus cable defective Replace bus cable Status display is flashing after 4 sec the driving mode display is flashing too Joystick was not in Te 7 neutral position when PORN EEEE Chapter 12 2 switched on g Joystick box defective Replace joystick box Chapter 12 2 Lighting system defective Defective lamp Replace lamp Chapter 11 1 and 11 2 Defective cable plug Check replace Chapter 11 1 and 11 2 cable plug Defective Replace servo lighting servo lighting module Ghapter12 3 Consult Manual on Rene Wrong software programming device or PCD software Battery charging not possible Defective battery Replace battery Chapter 10 1 Defective charger Replace charger Chapter 10 3 Defective horn Replace joystick box Chapter 12 2 Malfunctions ii i 18 8 0 Error Messages on Joystick Box 8 1 Error Codes of Joystick Box The error codes specified as follows refer to the different STORM versions Perform the following test before evaluating error codes e Switch joystick box repeatedly off and on again Wait approx 5 seconds each time before switching on again The test examines wether the error can be eliminated by the electronics itself and might deactivate the flashing of the status display on the
6. For a joystick box any model can be u original joystick box INVACARE joystic forward compatible Modules for the wheelchair lighting or for the actuators for the adjustment of the seat and legrest angles can be installed additionally sed that is no older than the k boxes are backward but not Module EE et and Cable Equipment u UUN ae 5 1 Wheelchair Equipment without lighting without actuators Main Module De Joystick Box Modules e Main module power module e Joystick Box Battery Cable Cables e BUS cable to joystick box e Battery cable 5 2 Wheelchair Equipment with lighting 24 V without actuators Module and Cable Equipment Modules e Main module power module p Modul quip Lighting module 24 V Lighting 24 V oe a ae N e Joystick box Lighting _ gt q 5 Module x i Cables e BUS cable to joystick box N E BUS cable from main module to lighting module e Battery cable e Lighting cable 5 3 Wheelchair Equipment without lighting with actuators Battery Cable _ Lighting Cable gt Joystick Box Module and Cable Equipment e Main module power module e Lighting adjustment module Combined lighting actuator module e Joystick box e Control unit for actuators In older joystick boxes the actuators cannot be controlled via the joystick box Modules Cables e BUS cable to joystick box e BUS cable from the main module to the lighting actuator modul
7. SERVICE MANUAL This manual includes e Information on troubleshooting e Information on testing parts e Repair instructions F392044 Edition 01 99 General information This service manual contains all information necessary for maintenance and servicing of the STORM wheelchair e Maintenance and servicing work is to be carried out in accordance with this service manual e Comply with all safety instructions e Information on operation general maintenance and servicing can be found in the operating manual of STORM e Refer to the replacement parts catalog for information on ordering replacement parts e We reserve the right to make changes in the interests of technical progress e Maintenance and repair work on the STORM may only be performed by qualified personnel Maintenance technicians should at least be trained in a relevant field e g as two wheeled vehicle or orthopaedics technicians or have an equivalent amount of professional experience Personnel should also be familiar with electrical measurement equipment multimeters e Should you encounter difficulties or have any questions please contact INVACARE SERVICE e INVACARE can not be held liable for changes to the STORM resulting from maintenance and servicing work carried out incorrectly or not according to the relevant instructions Information concerning transportation e f the wheelchair has to be sent away to the manufacturer for mo
8. The cutouts of the rim halves means of a torque wrench 25 to 30 Nm must embrace the valve nflate tyre to the filling pressure of 2 5 bar and screw on valve cap 12 e Make sure that the inner tube Place wheel 3 on hub 9 and 10 respectively insert countersunk does not get pinched between screws 8 and tighten cross wise the rim halves 55 11 4 Parking Brake and Wheel Hubs Brake lever assembled Brake lever complete Cover for brake housing Plastic knob Parking brake assembled 4x Adjusting screw M6x24 5 2x Tapping screw 4 8x16 6 Bowden wire cover 530 mm 7 Bowden wire covering 830 mm 8 Inner brake cable 2000 mm 9 2x Cap 10 Brake housing half 1 11 Brake housing half 2 12 2x Countersunk screw M6x10 13 Brake lever 14 Brake holder part 2 15 2x Drive unit 16 Brake backing plate cpl LH RH 17 Brake lining set cpl w spring 18 4x Hexagon receiving unit 19 4x Screw M6x10 20 4x Washer 6 4 21 2x Cable locking screw M6 22 Wheel hub with brake drum 23 Bowden wire holder LH RH 24 Screw M6x30 and washer 25 Compression spring LO 110 26 Retaining plate 27 Bushing 28 Round magnet 29 Bushing 30 Slide piece SL 35 31 Lock nut M12x1 5 32 Washer 13 33 Rear wheel cpl 34 Wing or Allen screw 35 Wheel hub standard Inspection Remedy e Brake pulling to one side or not reacting Adjust brake replace brake linings e Bowden cable or Bowden cable cover damaged Replace parts e Brake housing or brake lever damaged Replac
9. e Hinge bolt damaged gt Replace hinge bolt Actuator cable or plug defective gt Test replace motor See chapter 14 0 Seat recline adjustment damaged gt Repair replace recline adjustment gt gt V Tighten screwings Replace mounting plate Weld or replace frame Screwings loose Mounting plate damaged Weldment joints at frame or frame damaged S NOTE For maintenance and repair work on the chassis 33 or on the seating system itself the Recaro seat can be separated entirely from the chassis as follows e Detach joystick box and brake lever if existing from the side parts e f necessary detach the electrical connections for the actuators legrest adjustment e Remove legrests e Free connection cable from the clamping pieces under the seat e Remove the quick release bolt 29 of the seat recline adjustment not shown or from the actuator 21 Place the Recaro seat forward on top of the chassis 33 Detach nuts 16 at the upper part of the mounting plate 31 completely and separate with washers 15 from the screws 14 Support Recaro seat remove screws 14 with washers 15 and lift the Recaro seat completely from the chassis 33 Disassembly legrest receptacle complete e f necessary detach the electrical connections of the actuators legrest e Release legrest lock and detach legrests e Use a suitable sleeve such as a strip of leather and hold the locking bolt with
10. gt Replace if necessary 66 Checking Overall Voltage of the Batteries Charging Socket e Check the overall voltage of the batteries with a multimeter range 50V 25 DC at the charging socket of the joystick box Inspection Remedy e Voltage below 24V gt Charge batteries see chapter 12 2 e Voltage below 19V gt Check individual voltage of each battery e Voltage at zero gt Check individual voltage of each battery Battery inside NOTE e The internal battery has external contacts 2 with the 24 V supply of the wheelchair as well as internal contacts 5 with the serial connection with the external contacts of the external battery To measure the voltage open the locking belt 9 and remove the lid of the battery box 1 Testing the individual voltage of the batteries e For the removal of the batteries see Disassembly below 1 Battery box lid e Measure the individual voltages of both batteries with a 2 External contacts of the cable harness multimeter range 50V 25V DC 3 Connection diagram for the batteries 4 Cable harness complete Inspection Remedy 5 Internal contacts of the cable harness e Voltage below 9 5 V gt Precharge batteries see chapter 12 2 6 Terminal and master fuse e Voltage at zero gt Check master fuse 50A of the battery ae plus internal cables and replace 9 Loc n belt if necessary or replace battery 10 Guide pins Disassembl
11. 25 Pinch off the final caps 24 and pull the Bowden wire 22 from its covering 23 Lift off the Starlock cap 35 loosen screw 17 and detach the adjusting lever 28 together with the Bowden wire receptacle 25 from the seat frame f necessary loosen nuts 33 completely and detach together with washers 81 f necessary hold the support bracket 18 with your hand remove screws 32 with washers 81 and detach support bracket 18 from the seat frame CAUTION Do not remove support bracket 18 completely as otherwise the seat frame will only be supported by the threaded spindle or the actuator of the seat Assembly inclination adjustment and thus will become instable As to the disassembly of the support bracket see Proceed with the assembly in the reverse order chapter 9 14 NOTE e When assemblying the compression spring must be screwed into the fork shape piece up to the limit stop e The Bowden wire must be adjusted in a way that with the compression spring screwed in the flat link in the fork shaped piece has a play of about 15 mm when the adjusting level is moved e After a new Bowden wire has been pulled in the final caps must be squeezed off e Insert the back paddings 1 carefully in order not to damage the clamping pieces plastic 39 9 12 Seat cushion apron with pocket and seat plate Storm Comfort complete et V7 N oorok PT Ge lt d 1 Seat cushion 2 Apr
12. 30 from the connecting rod of the actuator Only for manual adjustment Rotate threaded out of the adjustment device If required press bushing out of the threaded rod Assembly The assembly is performed in reverse order Disassembly Seat Module and Seat Frame complete If necessary remove headrest See chapter 10 2 in this respect Detach joystick box and if existing brake lever from the side parts Detach side parts from the seat frame 13 See chapter 10 3 in this respect f necessary detach the connection cable of the actuators and remove the cable clamps from the connection cable Release legrest lock and remove legrests Release the quick release bolt 29 of the seat recline adjustment not shown or of the actuator 21 respec tively and place the Recaro seat forward on top of the chassis 33 Loosen nut 16 at the upper part of the mounting plate 31 completely and detach together with washers 15 from the screws 14 Support Recaro seat remove screws 14 with washers 15 and remove the Recaro seat completely from the chassis 83 Place the Recaro seat on its side and remove screws 8 or 11 and 12 completely Separate seat frame 13 from the Recaro seat If necessary remove clamping lever If necessary loosen two screws M8x20 with washers not shown at lower part of the mounting plate 31 completely and detach the mounting plate from the chassis 33 Assembly The assembly is pe
13. 8 care e Inflate tyre up to the prescribed air pressure of 2 5 bar and screw on valve cap 23 e Then mount wheel 7 into the front wheel fork 2 See in this respect Disassembly Assembly Front Wheels z ully and completely on the rim 10 and check for correct fit 51 Disassembly 2 piece rims and tyres Remove front wheel 7 completely See in this respect Disassembly Assembly Front Wheels Remove valve cap 23 and deflate tyre by pressing the spring pin of the valve Unscrew 5 cheese head screws 21 cross wise and detach from rims 11 and 12 Press rim halves 11 and 12 carefully from the outer cover 8 with the aid of a tyre lever Remove bushing 19 and then take the inner tube 9 out of the outer cover 8 f necessary repair inner tube or replace by inner tube size 260x85 f necessary press cap stop nuts 22 out of the rim half 11 f necesary remove wheel bearings 15 from the rim halves 11 and 12 Assembly Press wheel bearings 15 into the rim halves 11 and 12 up to the point where they are level with the rim Press cap lock nuts 22 into the rim half 11 Mount outer cover 8 first onto the rim half 11 nsert the inner tube 9 in such a way that the valve fits correctly into the bore hole of the rim half 11 nflate inner tube 9 only up to the point where it has taken the shape of a ring nsert bushing 19 and press rim half 12 carefully into the outer cover 8 i
14. Do not fasten too tightly it would destroy the stopper 13 3 Testing motor magnetic brake and free wheel switch Testing preparations replacing drive motors e Remove battery boxes e Remove splash protection e Remove cable binders e Remove the connection plug of the motor to be tested or replaced from the socket board NOTE Press down plug lock as otherwise the plugs would be dama ged Wear Limit min 11 mm Running Surface Carbon Brus Solder Cap Stopper Remove BUS plus Motor Cable 71 Testing drive motors Only basic tests can be performed on the drive motors Any further tests are only possible with special testing instruments The following components of the drive motors can be tested by means of a multimeter Motor coils for continuity Motor brakes for resistance Testing hints If the following tests show no results the drive motor should be sent in for testing Any further measurements can only be performed by the INVACARE Service Department Visual test of the plug contacts Test whether the contacts of the plug are not unduly bent up pushed back or oxidized Testing the electric circuit of the motor e Set multimeter to continuity check e Measure the continuity of the motor s electric circuit at the plug contacts shown in the drawing to the right NOTE Instructions on the use of the multimeters can be found
15. and detach compression spring 5 e Remove two stoppers 10 and loosen nut 15 completely e Remove screw 11 with washer 12 and detach kerbstone lifter fork 9 from the lifter support e If necessary remove bushings 13 and press out ball bearing 14 e Loosen four screws 3 completely and remove together with washers 4 e Detach kerbstone lifter support 2 from chassis 1 Montage e The assembly is performed in reverse order 63 11 9 Transport Bracket Taxi Bracket Cane Holder and Reflectors View from the right Accessories disassembled 1 Chassis 2 Cane holder 3 Angle 4 Screw and nut 5 2x Taxi bracket 6 4x Screw with nut 7 Transport bracket 8 4x Screw with nut 9 2x Reflector glued 10 Hook and fleece strap for cane holder at upper part of the backrest frame 11 Fastening points for transport bracket at the rear of the chassis 12 Fastening points for cane holder at side part of chassis Inspection Remedy e Cane holder damaged gt Replace cane holder e Screwings loose gt Tighten screwings e Hook and fleece strap damaged gt Replace hook and fleece strap e Weldment joints or taxi bracket damaged gt Replace taxi bracket e Weldment joints or transport bracket damaged gt Replace transport bracket e Reflector damaged gt Replace reflector Disassembly e The disassembly is performed by unscrewing the respective fastening screws Assembly e The assembly is performed in re
16. blinking 8x excess voltage gt Charger defective gt e Measuring voltage at the See chapter 12 3 b tteriss Charging Socket Voltage below 11 5 V gt Charge with original charger Voltage below 9 5 V Battery fully discharged gt Precharge with unregulated e Voltage difference charger up to 10 V Tolerance 0 2 V in the two See description below batteries gt Replace batteries Charging Process A CAUTION The batteries are not permitted to lie on their sides or up end during the charging process The battery poles must point upwards e In the STORM with ACS only batteries of type Dryfit A 512 55A may be used e Batteries and charger must be exposed to the same ambient temperature since the charging process among other factors is controlled by temperature sensors Extended charging cables and different locations of charger and batteries result in a faulty charging NOTE e Procedure when charging the batteries with the INVACARE charger Also see the STORM s User s Manual e Observe the following order when connecting the INVACARE charger First connect the charging plug then the mains plug Fully discharged batteries cannot be charged with the INVACARE charger If the batteries cannot be fully charged they must be replaced When fully charged the display Full Charge on the charger must light up As soon as a charging voltage of 28 V is achieved the LED s on
17. e Loosen screws 20 and detach joystick box 1 from its holder 3 or from its holding plate 4 respectively Assembly e The assembly is performed in the reverse order Disassembly of the holder for the central control e Detach joystick box 1 as described above e Disengage the clamping piece 9 at the carrier rod 8 and fold away the support arm 7 together with the swivel arm 6 e Loosen set screws not shown at upper part of the side pieces and remove carrier rod 8 and swivel arm 6 completely from the wheelchair e Loosen nuts 13 and pull support arm 7 from the swivel arm 6 e Detach holding plate 4 with washers 12 und pull the clamping pieces 11 from the swivel arm 6 e Remove cap 14 loosen nut 15 and detach e Detach swivel arm 6 with washers 16 and bushes 17 from the guide rod 5 e Loosen screws 10 and detach clamping piece 9 from the support arm 7 e If required detach slide pieces 18 and 19 Assembly JY NOTE During the assembly make sure to insert the bushes 17 and washers 16 correctly into the swivel arm 6 e The assembly is performed in reverse order Disassembly of table plate and holder e Detach joystick box 1 as described above e Loosen nuts 28 and remove together with washers 27 and screws 26 Detach table plate 24 with guide rod 32 from the receiving plate 23 e Loosen nut 81 and remove together with screws 80 Separate guide
18. gt Rep gt Strai gt Rep gt Tigh gt Rep gt Rep ace support wheel ghten or replace support plate ace shock absorber ten screws ace rear reflector ace rear wheel link e Loosen completely screw 9 and nut 10 at lower part of the support plate 3 e Remove support castor 4 completely with bushings 12 and 13 plus washers 11 from the support plates 3 NOTE Montage e The support plates 3 are available in 2 versions e The disassembly is performed reverse order long and short 59 Disassembly support plates Remove rear battery box and jack up wheelchair if appropriate f required remove rear wheel See chapter 11 3 in this respect Loosen screw 9 and nut 10 at the lower part of the support plate 3 completely Remove support castor 4 completely with bushings 12 and 13 and washers 11 from the support plates 3 Loosen all screws 9 completely and remove together with nuts 10 and washers 11 Detach support plates 3 from the chassis 1 and from the shock absorber 5 Assembly The assembly is performed in the reverse order Disassembly shock absorber Remove rear battery box and jack up wheelchair if appropriate f required remove rear wheel See chapter 11 3 in this respect Loosen nut 10 at the lower part of the shock absorber 5 completely and remove together with washer 11 Loosen screw 6 at the upper part of the shock absorber comple
19. 11 nflate inner tube 9 only to a point where it has taken the shape of a ring Press rim half 12 carefully into the outer cover 8 in such a way that the cutout is located over the valve nsert screws 16 and nuts 17 and tighten cross wise nflate tyre to the prescribe pressure of 2 5 bar and screw on valve cap Then mount wheel 7 into the front wheel fork 2 See in this respect Disassembly Assembly Front Wheels Disassembly front wheel forks Remove front wheel 7 completely See in this respect Disassembly Assembly Front Wheels Loosen slide piece 3 for example with a screwdriver and detach Hold front wheel fork 2 loosen nut 4 completely and detach with washer 5 Remove front wheel fork 2 with adjusting washer 6 downwards out of the slide bearing in the chassis 1 Assembly The assembly is performed in the reverse order CAUTION e Check and tighten nut 4 after 5 operating hours and once again after another 10 hours e The nut 4 must be tightened to a degree where the forks turn freely without any vertical play 54 11 3 Rear wheels and tyres Rear wheels assembled Rear wheel disassembled 1 Chassis 2 Drive complete 3 Rear wheel 3 00 8 4 Rim 1 5x8 rim body outside 5 Rim 1 5x8 rim body inside 6 Outer cover 3 00 8 7 Inner tube 3 00 8 8 4x Countersunk screw M8x20 PB 9 Wheel hub standard 10 Wheel hub with brake drum 11 5x Allen screw M6x35 12 Valve cap
20. 28 and detach from footplate tube 22 Loosen tapping screws 29 completely and detach footplate 23 from footplate tube 22 Loosen nut 20 completely and detach together with washer 19 screw 18 and clamping piece 17 from legrest elbow tube 9 Loosen two screws 38 and separate calfplate holder 31 from calfplate 32 Loosen nut 37 and together with washer 86 bushing 84 screw 35 and calfplate holder 81 sepa rate from calfplate joint 30 Loosen screws and remove calfplate joint 30 from legrest elbow tube 9 Lift up starlock cap 16 for example with a screw driver to release the guide rod 13 from the legrest upper part Loosen screw 11 and nut 12 completely and detach legrest lelbow part 9 and bushing 10 from egrest upper part 6 Lift up Starlock cap 16 for example with a screw driver to free the release lever 14 Pull release lever 14 from the legrest elbow tube 9 and detach the backlocking unit 89 together with washers 15 and guide rod 13 from the legrest elbow tube 9 Release 12 nut and separate guide rod 13 from the backlocking unit 39 NOTE Do not lose misplace the individual parts of the backlocking unit release plate release block and spring If necessary remove slide pieces 7 and 8 and cap 33 NOTE The slide pieces are inserted They can be lifted up with a suitable tool such as a screwdriver 31 Assembly JS N
21. 7 e Battery cable 18 e BUS cable 0 8 m 6 e Joystick box 1 2 or 3 All modules and control devices are to a large extent maintenance free That is why only basic tests can be performed on them Joystick boxes 1 2 and 3 are equipped with status displays from which error messages can be read in the form of flashing codes The electronic modules too have status displays however these show only if the respective module is operative Defective modules must be replaced and must be sent to the INVACARE Service Department 85 16 2 Testing Joystick Boxes NOTE Joystick Boxes Before inspecting the joystick boxes check the Standard Table centre charging status of the batteries joystick box control e Then check status display for error codes Inspection Remedy e Status display flashing gt Check error codes See chapter 8 0 e BUS plug defective gt Replace BUS cable BUS cable damaged gt Replace BUS cable e Joystick tight or damaged gt Replace joystick box Chin control e Joystick box fastening damaged gt Renew wing screws replace EN J TOA X holding device if necessary wa a e Displays or key pad defective gt Replace joystick box e Power supply to the gt Check joystick box defective Battery charge BUS plug For measuring see below BUS cable main module Checking Power Supply to Joystick Box BUS Plug e Pull BUS plug from the joystick box lock e Measure volta
22. 8 from the receptacle 6 e Loosen wing screw 2 below at seat frame 15 and remove armrest holder 1 from the seat frame 15 e If necessary replace slide pieces 3 Assembly e The assembly is performed in reverse order 46 10 4 Seat module and seat frame Seat Model DS OMANODAARWND Seat module LX Back module LX Headrest LX or DS Back module attachment Stopper Recline adjustment Reclining mechanism 4x Screws with washers Push handle disassembled Seat model DS with control Screws washers rear Screws washers front Seat frame J 2x Screws M8x50 2x Washer 16x8 3x1 5 2x Lock nut M8 2x Hinge bolt 7 8x30 2x Hinge bolt 7 8x35 2x Stopper 4x Lock nut M6 Actuator Connection plug Seat Module LX NOTE For the seat recline adjustment also a manual adjustment device can be mounted Recaro Seat disassembled SS XY q Nv 27 2x Washer 16x8 4x1 5 28 Lock nut M8 29 Quick release bolt 30 Connecting rod top 31 Mounting plate 32 Legrest receptacle 33 Chassis Hexagonal head screw M10x50 Nut M10 Stop 2x Washer 19 5x10 2x2 Hexagonal head screw M8x45 47 Inspection Remedy V e Padding damaged Replace Recaro seat e Adjustment functions for Recaro seat module Check voltage converter see chapter 16 6 electrical or manual defective If necessary replace Recaro seat e Legrest locking tight or defective gt Smoothen locking device or replace
23. Check status display on joystick box and evalute the error codes according to chapter 8 1 if necessary e Perform the necessary testings repairs Observe the cross references to the respective chapters in the manual or to the respective documentation 7 2 Troubleshooting Wheelchair does not start Disengage drive motors Chapter 13 0 Engage motors Defective batteries Replace battery Chapter 12 0 Batteries fully discharged Precharge battery Chapter 12 2 Power supply Check battery fuse interrupted Check voltage on joystick box Check voltage on Chapter 16 3 main module Status display and LEDs on joystick box extinguished Chapter 12 0 Chapter 16 2 Check voltage on servo ighting Chapter 16 4 modules Error codes 1 12 Evaluate error codes Chapter 8 0 Microswitch defective only T V version 10 km h Check microswitch Chapter 6 7 o Z 2 w Status display on joy stick box flashing Drive motor bucking when in driving operation Batteries discharged Charge batteries Chapter 12 2 Batteries defective Replace batteries Chapter 12 0 Motor defective Replace motor Chapter 13 4 Consult Manual Wrong programming Check programming on programming device or PCD software fi 17 An actuator reacting irregularly or not at all Motor or adjustment Check flashing code Chapter 8 0 module defective on joystick box p i No flashing code
24. Crossbeam 13 Clamping lever M8x60 14 Seat cushion firm padding 15 Seat cushion standard 16 Seat plate 17 4x Tapping screw 4 8x18 18 Apron with pocket 19 Seat recline adjustment manually 20 Threaded spindle left handed 21 Spindle right handed thread 22 Bearing bush 18x10 2x22 23 2x Washers 24x10 2x2 24 Quick release bolt 25 Hexagonal head screw M10x50 26 2x Washers 19 5x10 2x2 27 Nut M10 Stop 28 Battery box holder 29 Actuator 30 Legrest lock constisting of locking lever bolt 8x6x50 spring 8x30 and lock nut M5 31 Legrests 32 Chassis 42 Inspection e Legrest locking tight or defective e Hinge bolt damaged e Actuator cable or plug defective e Seat recline adjustment damaged Screwings loose e Clamping lever damaged e Crossbeam damaged Mounting plate damaged e Seat cushion seat plate or apron with pocket damaged e Weldment joints at frame or frame damaged Sf NOTE Remedy gt gt gt gt gt gt gt gt gt V Smoothen or replace locking device Replace hinge bolt Check replace actuator See chapter 14 0 Repair replace recline adjustment Tighten screwings Replace clamping lever Replace crossbeam Replace mounting plate Repair replace parts See chapter 9 12 Weld or replace frame For maintenance and repair work on the chassis 32 or on the seating system itself the entire seating system can be separated from the chassis as follows e Detach joystick
25. Footboard one piece Headlight Flasher front Front wheels complete Reflector Disengaging lever Drive motor right Rear wheel complete Rear light assembly bar Actuator for backrest r9 r9 5 r9 i r4 OORUN O0OO0OONODOOOA UN i ON oOoaBKR WDM 10 11 12 13 14 15 16 Storm Comfort 1 Rear view fixing balls OMAN ODOaAKRWBN Headrest complete Back frame tube Actuator for backrest Brake lever for parking brake Side part complete Actuator for seat Legrest complete Footboard one piece Front wheel fork Front wheels complete Reflector Disengaging lever Drive motor left Rear wheel complete Rear light assembly bar Seat frame Quick release bolt Cable harness for rear light board Seat plate Cable for actuator backrest adjustment Bowden wire for parking brake Battery box holder tube frame welded Driving units complete Storm Comfort with headrest and electric backrests plus seat adjustment view from the left OnNoOABRWDY Fret go OES S aK wWNMN 0 O push button press to release Main module for driving electronics Lighting and adjustment module 24 V Lighting module 12 V Headrest holder Back frame tubing Standard joystick box Mounting kit for joystick box swiveling BUS cable for joystick box Rear lights complete Cable harness for light assembly bar complete Connection socket for cable harness battery box Battery box c
26. actuator to be tested out of the socket board e Apply a testing voltage of 24 V direct current to the plug contacts at the inspection windows see drawing at right e Interchange the testing connections to reverse the moving direction CAUTION SN reveni to bridge the contacts by all means gt Danger of Fire and Burning lt Disoreder Cause Remedy No measurable continuity Performance test negative Cable parted Replace actuator motor Motor defective Replace actuator motor Inspection by changing the polarity Plugs for Electric Actuators DENA DSA Left Legrest Backrest adusi reg ment Plugs of the Actuators Performance Test Testing Voltage 24 V Change the moving direction 14 3 Replacement of Actuators for Legrests Actuator for Legrest Fastening Screw Disassembly M8 x 35 SW 13 mm e Pull the plug of the actuator to be replaced out of the socket e Remove the cap of the upper actuator fastening e Now disassemble the actuator by removing two fastening screws SW 13 mm Apacs Screw M8 x 35 SW 13 mm Assembly Actuator Upper Actuator Fastening e Install the new actuator and fasten it by tightening the two fastening screws Fastening screws Washer M8 x 35 SW 13 mm e Lead the actuator cable to the corresponding socket board and plug the plug into the socket e Conduct a performance test E n oe 1 Cap NOTE Tapped Ke 4 e Do
27. and remove Assembly Press first wheel bearing into the rim 10 to a point where it is level with the rim Press second wheel bearing into the rim 10 to a point where it is level with the rim Mount outer cover 8 sideways on the rim 10 nsert inner tube 9 correct Mount outer cover 8 carefully and completely onto the rim 10 and check for correct fit ly and inflate only to a point where the inner tube has taken the shape of a ring nflate tyre to the prescribed pressure of 2 5 bar and screw on valve cap Then mount wheel 7 into the front wheel fork 2 See in this respect Disassembly Assembly Front Wheels Disassembly 2 piece rims and tyres Remove front wheel 7 completely See in this respect Disassembly Assembly Front Wheels Remove valve cap not shown and deflate tyre by pressing the spring pin of the valve Loosen 5 screws 16 and nuts 17 cross wise and detach Press rim halves 11 and 12 carefully from the outer cover with the aid of a wheel lever Take inner tube 9 out of the outer cover 8 f required repair inner tube or replace by inner tube size 200x50 f required press wheel bearings out of the rim halves 11 and 12 Assembly Press wheel bearings 11 and 12 into the rim halves up to a point where they are level with the rim Mount outer cover 8 first on rim 11 nsert inner tube 9 in such a way that the valve is correctly located in the bore hole of the rim half
28. clips 7 e Loosen screws with washers and nuts 11 completely and detach lighting bar 3 e If required loosen screws 9 completely and remove rear light caps e f required remove lamps 5 separate plug connections in the lamps loosen screws with nuts 10 completely and detach the rear lights 4 from the lighting bar 8 e f required detach the microswitch 14 from the rear covering 2 2 countersunk screws M4x20 e Loosen screws with washers 12 completely and remove together with the rear covering 2 from the chassis Assembly e The assembly is performed in reverse order 65 12 0 Check and Repair Work on the Power Supply 12 1 Testing Batteries Battery Boxes and Battery Voltage NOTE e Make sure that both batteries are charged If the total voltage is below 24 V charge batteries completely see chapter 12 2 e f the battery voltage drops below 21 V during operation the driving speed will be reduced step by step to minimize power consumption If the voltage drops below 17 V the power supply will be cut off entirely e The voltage of each individual battery should not be less than 9 5 V e A voltage drop can be checked during driving operation with turned on lighting and activated hand brake CAUTION Handle tools carefully Do not bridge the battery poles gt Danger of Short Circuit lt e Take into account the weight of the batteries of approx 22 kg gt Danger of Crushing
29. performed in the reverse order Removing Rear Light Glass ar cA So ca rR Sd Fastening screws Removing Light Bulb Rear Light Flasher Testing voltage rear light The batteries must be removed first before detaching the rear lights gt Danger of Short Circuit Fire and Burning lt 84 16 0 Check Work on the Driving Electronics Testing of Modules 16 1 General Overview of the electronic modules and cables RR 10 Standard joystick box Table center control Se Chin control Joystick box for attendant Control unit for adjusting options BUS cable 0 8 1 1 or 1 6m Connection of joystick box main module Main module Lighting module or lighting adjustment meni ry oar WNh BUS cable 0 3 m ACS cable distributor lighting ACS cable distributor lighting and actuators ACS cable distributor actuators Y BUS cable 0 25 m ACS lighting module TUV Battery cable RECARO TUV and fuse 15 A Battery cable RECARO with fuse 15 A Battery cable TUV Battery cable 19 ACS cable distributor lighting TUV 20 ACS module RECARO seat Microswitch TUV version 22 Holder for battery cable it 0 00N APTE E E S ES EA OnN OOK WP NO The equipment of the wheelchairs with joystick box electronic modules and corresponding cables depends on the respective type of wheelchair The most simple type for example is equipped with the following e Main module
30. piece 6 can also be removed from the guide rod 7 after loosening the wing nut e The assembly is performed in the reverse order Do not forget the bushing 8 when assembling Disassembly Switch Box e Detach connection cable 40 from the wheelchair and put aside e Loosen nut 27 completely and detach together with screw 26 e Detach switch box 28 from the switch box rod 23 e If required loosen the wing screw 7 and detach the switch box rod 23 Assembly e The assembly is performed in reverse order Disassembly Holder complete e Detach joystick box 1 as described above e Remove actuator 29 and guide rod 4 as described above f required remove switch box 28 and switch box rod 23 as described above e Loosen clamping lever 20 and remove together with screw 19 and washer 12 from the receiving tube 5 e Detach receiving tube 5 with clamps 18 carefully from the swivel arm 8 while uncovering the BUS cable 22 e Remove BUS cable 22 completely from the swivel arm 3 and detach from the wheelchair e Remove cap 17 loosen nut 16 and detach swivel arm 3 with bushing 14 and washers 15 from the backrest holder 2 e Loosen wing screws 7 or clamping lever 20 respectively and detach backrest holder 2 from the holding devices 31 or 34 respectively Recaro seat e Loosen 4 nuts 27 and detach together with washers 33 e Remove screws 32 and detach holdin
31. retainer disassembled 1 Battery box retainer 2 2x Screw M8x20 3 6x Washer 16x8 4x1 5 4 2x Screw M8x35 5 2x Nut M8 Stop 6 Splash protection 7 2x Tapping screw 3 8x10 8 2x Screw M3x27 9 2x Nut M3 Stop 10 4x Washer 7x3 2x0 4 11 Main module 12 Lighting module 13 Lighting adjustment module 14 Actuator seat adjustm 15 Connection socket with holder 16 Screw M10x50 with washer and lock nut M10 17 Bore holes for modules 18 Screws M5x16 with washers and lock nuts nuts M5 Inspection Remedy e Splash protection damaged gt Replace splash protection e Screwings loose gt Tighten screws e Battery box retainer damaged gt Replace battery box retainer Disassembly splash protection e Lift seating system and lock if necessary e Loosen tapping screws 7 completely and detach splash protection 6 from the battery box retainer Assembly e The assembly is performed in the reverse order Disassembly Battery Box Retainer e Separate seating system from chassis and remove splash protection of the modules e Remove battery boxes e Detach the plug for the drive motors from the main module and if necessary detach the plugs of actuators and lighting from the lighting or lighting adjustment module e Remove screw with washers and nut 16 completely and separate actuator 14 or threaded spindle from the battery box retainer e f required remove cable binders of the connection cable from the actuator 14 e Remove scr
32. rod 82 from the table plate 24 Separate holder 29 from the angle joints 33 e Mark the position of the angle joints 33 and unscrew the joints from the guide rod 32 e Loosen wing screw 25 and remove holder 3 from the guide rod 82 e Loosen set screw not shown at the upper part of the side part and detach the guide rod 5 together with the swivel arms 21 and 22 completely from the wheelchair e Loosen wing screw 25 and separte the swivel arms 21 and 22 from each other e Remove cap 14 at swivel arm 21 loosen nut 15 and detach e Detach swivel arm 21 with washers 16 and bushes 17 from the guide rod 5 e Remove cap 14 on the swivel arm 22 loosen nut 15 and detach e Remove support plate 23 with washers 16 and bushes 17 from the swivel arm 22 e If necessary remove slide pieces 18 and 19 S NOTE a Assembly e While assembling make sure that the bushes 17 with washers 16 are inserted correctly e The assembly is performed in reverse order into the swivel arm 21 and the support plate 23 respectively The angle joints 83 are to be mounted to he guide rod 32 in such a way that allows the able plate 24 to be screwed together with he holder 29 96 17 4 Chin Control Manually Electrically Swivable in Horizontal Direction Chin control disassembled Joystick box Backrest holder Swivel arm Guide rod Receiving tube Guid
33. screw 9 and pull legrest upper part 6 from legrest lower part 8 e Loosen tapping screw 11 completely and detach footplate 10 from legrest lower part 8 e f required remove slide pieces 7 and caps 12 NOTE The slide pieces are inserted They can be lifted up with a suitable tool such as a screwdriver Assembly The assembly is performed in the reverse order NOTE e During the assembly pay attention to the correct location of the parts left right e Adjust legrests to equal length Disassembly of Standard Legrests with Angle Adjustment complete e Detach calf belt 13 from the insert tube 14 e Release legrest lock 5 and detach legrest from the hinge bolts 3 and 4 e Loosen screw 9 and pull legrest upper part 6 from the insert tube 14 e Loosen tapping screw 11 completely and detach footplate 10 from the footplate tube 15 e Loosen nut 19 and together with washer 18 separate from screw 16 e Detach screw 16 and washer 18 and separate footplate tube 15 from the draw pull tube 14 f required loosen nut 20 and remove together with tapping screw 17 e f required remove slide pieces 7 and caps 12 NOTE The slide pieces are inserted They can be lifted out with an appropriate tool such as a screwdriver Assembly The assembly is performed in the reverse order S ja During the assembly pay attention to the correct location of the parts l
34. starlock caps commercially available Tigtemeyer Required for the adjustments at the ACS control Programming device item No 6 001 450 Software package incl interface cable and Dongle item No P10 076 3 0 Arrangement of Subassemblies Components and Operational Controls The following illustrations depict the general arrangement of the wheelchair s subassemblies components and operational controls The designations correspond to the designations of the components listed in the spare parts catalogue Basically the STORM is available as models Standard Comfort and Recaro each one consisting of the following main subassemblies e Chassis e Seating system e Electric power supply e Driving electronics e Lighing installation Storm Comfort Depending on the wheelchair model the main sub assemblies are equipped with different subassemblies legrests operational controls modules etc Backrest padding Seat cushion Side padding Standard joystick box Legrest complete Apron with pocket Calfbelt Footplates 9 Front wheel complete 10 Front wheel fork 11 Rear wheel complete wT 12 Flasher and headlight 10 wa rons 13 Chassis N 8 14 Side part complete right ON ooaKR WDM Storm Comfort with headrest and electric backrests plus seat adjustment as seen from the right Headrest complete Backframe tube Side part complete Standard joystick box Seat frame Legrest complete right
35. washer Inspection Remedy e Gear tight gt Replace gear e Gear noises gt Replace gear e Driving unit defective gt Replace driving unit NOTE e For motor inspections checks see chapter 13 0 Disassembly driving unit e Remove battery boxes jack up wheelchair and support driving unit additionally e Lift seating system and lock if necessary e Loosen two screws and remove splash protection of modules See in this chapter 11 7 in this respect e Detach connection plug 6 from main module not shown e f necessary loosen screws washers and nuts completely and remove disengaging mechanism not shown from motor e Loosen two screws 7 and detach drive motor 5 from the gear 4 e Remove rear wheel See chapter 11 3 in this respect e Loosen nut 11 completely remove together with washer 12 and detach wheel hub 10 e f required detach brake backing plate not shown from the gear 4 Loosen nut 15 with washer at lower part of support plate completely and remove screw 14 and washer e Loosen screws 8 completely and detach gear 4 from the rear wheel link 3 Assembly e The assembly is performed in reverse order NOTE e When detaching the wheel hub 10 do not lose the feather key 13 e The Bowden cable holder 9 and the brake backing plate remain with the wheelchair 61 11 7 Splash Protection for Modules and Battery Box Retainer Battery box retainer assembled Battery box
36. with washer 32 Remove wheel hub 22 with brake drum from CAUTION axle So e A feather key is inserted in the axle Remove spring from the brake linings with a pair Do not jase of tongs Hold up bolt not shown loosen nut M8 not shown completely and detach brake lining set 17 completely from the brake backing plate 16 f necessary squeeze off cap 9 from the inner brake cable 8 and loosen cable locking screw 21 Pull inner brake cable 8 out of the locking screw 21 and detach compression spring 25 Loosen screws 19 with washers 20 completely and detach brake backing plate 16 from the hexagon receiving unit 2x 18 f necessary screw hexagon receiving unit 18 out of the drive unit NOTE Montage e For wheel hubs without brake drums 35 the The assembly is performed in the reverse order steps for the components of the parking brake For the assembly of the inner brake cable see do not apply Assembly Bowden cable e In wheelchairs with speed indicators the For the adjustment of the brakes see Adjust Brakes retaining plate 26 bushing 27 the round magnet 28 and bushing 29 might have to be dismounted too Disassembly Bowden cable holder completely Remove rear wheel 33 See in this respect chapter 11 3 Squeeze off cap 9 from the inner brake cable 8 and loosen cable locking screw 21 Pull inner brake cable 8 from the locking screw 21 and detach compression sp
37. 2 volts only under load seat connected and switched on In conditions without load only a level of between 2 5 and 4 volts is to be measured CAUTION AN Avoid by all means bridging the contacts of the power supply gt Danger of Fire and Burning lt Malfunction Cause Remedy Chapter No voltage at the Feeder cable defective Check replace feeder cable 18 0 feeder cable Fuse 15 A defective Replace fuse Power supply to the main module is Check voltage supply 12 1 interrupted Check master fuse 50 A 12 4 Voltage below 19 V Battery fully discharged Pre charge battery 12 2 Replace battery 12 0 Output voltage higher than 4 volts and lower than 2 5 volts Voltage transformer defective Replace voltage transformer 17 7 90 16 7 Testing Microswitch Microswitch complete Testing Preparations e Lift the seat and lock if necessary e Remove splash protection e Fold rear light board upwards to uncover microswitch for switching Testing Microswitch Main Module and 12 V Lighting Module e Remove the plug of the BUS cable from the socket board of the 12 V lighting module BUS cable WA NOTE Press down plug lock as otherwise the plugs will be damaged WA NOTE Information on the use of the multimeter can be taken from the relevant User s Manual e Set the multimeter to continuity test e Measure on the contacts of the BU
38. 28 is riveted to the plate 6 and must be replaced completely with cable e Besides the above shown type 33 another holding device is available for the Standard Comfort seat consisting of two clamp halves with bushings and screw which is to be fixed to the backrest tube frame Inspection Test electrical functions on the joystick box BUS plug defective BUS cable damaged Joystick tight or damaged Screwings loose Parts or holder completely defective Actuator defective Switch box damaged Remedy WA NOTE e A continuity check can be performed on the motor e Also a performance test can be conducted by applying a voltage 24 V e The tests must be performed according to the description on actuators contained in chapter 14 0 See chapter 16 2 gt Replace BUS cable gt Replace BUS cable gt Replace joystick box gt Tighten screws gt Replace parts or holder gt Replace motor gt Replace switch box 99 Disassembly Joystick Box e Detach BUS cable 26 from the joystick box 1 e Loosen screw 30 open clamp 29 and detach joystick box 1 from the receiving tube 4 Assembly e The assembly is performed in the reverse order Disassembly Motor e Detach actuator connection cable 38 from the wheelchair and put aside e Remove locking ring 17 from the bolt 14 to separate the actuator 8 from the backrest holder 2 e Loosen nut 87 completely and detach togethe
39. 28 Slide piece SL18 29 Tapping screw 4 2x13 30 Cap A8 31 Leaf spring 32 Slide piece SL22 33 Calf belt not shown Inspection Remedy Replace exchange calf belt Tighten screwings e Calf belt missing or damaged e Screwings loose e Rubber mat damaged e Footboard damaged e Footboard receptacle damaged e Weldment joints or sliding tube defective e Weldment joints or legrest upper part defective Replace rubber mat Replace footboard Replace footboard receptacle Replace sliding tube Replace legrest upper part e Weldment joints or insert tube defective Replace draw pull tube e Weldment joints or width compensation defective e Slide piece or caps missing or defective Replace width compensation Replace exchange slide part or caps VV VV VV VV VOY 24 Disassembly complete The following steps apply to both legrests e Remove calf belt 83 from footboard receptacle 9 e Grasp footboard 11 by its left side and turn upwards until it is released from the left footboard receptacle 9 e Release legrest lock 5 and lift legrest from the hinge bolts 3 and 4 e Loosen wing screw 22 and pull the footboard receptacle 9 with the width compensation 10 out of the insert tube 8 NOTE In the preceding step the footboard receptacle 9 the width compensation 10 and the footboard 11 of the right legrest are simultaneously separated from the insert tube 8 e Release cap nut 21 an
40. 2x Washer 16x8 3x1 5 9 2x Bushing 12x8 5x23 10 4x Washer 24x8 3x2 11 2x Lock nut M8 12 Quick release bolt 13 Actuator motor 14 Hex head cap screw M10x50 15 2x Washer 19 5x10 5x2 1 16 Lock nut M10 17 Connection plug 18 Support bracket 19 4x Hexagon head screw M8x50 20 8x Washer 16x8 3x1 5 21 4x Lock nut M8 22 Safety belt 23 Seat frame 24 Headrest holder NOTE The back element can be equipped with back padding 1 or with back belting 4 Inspection Remedy Back padding damaged gt Replace back padding Backbelting damaged gt Replace back belt Safety belt damaged gt Replace safety belt Screwings loose gt Tighten screwings Weldment joints or back frame tube defective gt Replace back frame tube Support bracket damaged gt Replace support bracket Actuator or cable defective gt Check replace actuator chapt 14 0 Connector plug defective gt Replace connector plug gt Replace quick release bolt Quick release bolt defective 36 Disassembly complete If existing then remove the headrest first See chapter 9 1 in this respect Remove connection plug 17 from the socket in front on the lower part of battery holder Remove quick release bolt 12 on the upper part of the back frame tube 6 and put the actuator aside Loosen nut 16 at lower part of support bracket 18 completely and detach together with washer 15 Support the actuator with your hand remove screw 14 with washer 15 and detac
41. 4x Lock nut M5 Z NOTE Table Central Control and Fixing Devices disassembled 2 BUS cable 1 6 m 5 Guide rod 8 Carrier rod 11 2x Clamping piece 14 Cap SKS 12 17 2x Bushing RD 19x3 5x25 20 4x Screw M4x10 23 Support plate for table 26 4x Phillips screw M6x20 29 2x Holder for guide rod 32 Guide rod M8x560 12 15 18 21 24 27 30 33 20 18 Holder for table control Swivel arm Clamping piece PVC 4x Washer 8 4x 17x1 6 Lock nut M12 Slide piece 15x15 Swivel arm part 1 Acrylic table 660x540x8 4x Washer 6 4x12 5x1 6 4x Screw M5x22 2x Angle joint M8 e The joystick box and a number of fixing parts are identical in the table control as well as in the central control e The central control is available in versions for left handers and for right handers e In the central control an adapter for options consisting of an adapter and a joystick box support bar with screws can be mounted additionally Inspection Check electric functions BUS plug defective BUS cable damaged Joystick tight or damaged Screwings loose Parts or holder completely defective Table damaged Remedy See gt Rep gt Rep gt Rep gt Tigh gt Rep chapter 16 2 ace BUS cable ace BUS cable ace joystick box ten screws ace screws replace parts or holder if necessary gt Rep ace table and or parts 95 Disassembly joystick box e Detach BUS cable 2 from the joystick box 1
42. ARO Seat Module and Cable Equipment The basic equipment of the RECARO seat consists of the following components Main Module to Joystick Box Voltage Transformer Modules e Main module power module Bd e Voltage transformer e Joystick box Cables e BUS cable to joystick box e Battery cable e Power supply cable for 15A Fuse voltage transformer with 15 A fuse Connection for RECARO Seat The voltage transformer serves the power supply of the RECARO seat Depending on the type of wheelchair the further equipment can be added according to chapters 5 2 to 5 3 14 6 0 Inspection Plan Assembly Headrest Armrests and Side Parts Standard and Comfort Seat Seat Seat Surface and Seat Plate Standard and Comfort Seat Backrest with Safety Belt Actuators Recaro Seat Chassis with Battery Retainer Rear Wheel Links and Kerbstone Lifter Wheel Suspension and Wheels Check Headrest shell and padding Headrest holder and astenings Damage and fastening of armrests Damage and screwing of side parts irror Damage screwings and seams Check quick release bolt Adjustment function Damage screwings and seams Belt and buckle Check quick release bolt Check damage and function Check damage and function Check screwings weld seams splash guard of modules reflectors etc Function and damage of shock absorbers Check rear wh
43. Back element holder damaged Replace back padding Replace back belt Replace safety belt Tighten screwings Replace back frame tube Replace back element holder VV VV VV Disassembly complete f existing then remove the headrest first See chapter 9 1 in this respect Loosen clamping lever 7 and pull back frame tube 5 from the back element holders 6 Detach safety belt 12 from the backframe tube 5 Remove tapping screws with caps 4 and detach back belting 3 from the back frame tube 5 or remo ve tapping screws with caps 2 and detach back padding 1 from the back frame tube 5 Remove caps 11 and loosen nuts 10 completely Remove screws 8 with washers 9 and detach back element holder 6 from seat frame 13 CAUTION Detach only one back element holder from the seat frame at a time If both back element holders are removed at the same time then the seat frame will be supported only by the threaded spindle or the actuator of the seat inclination adjustment and will become unstable Assembly The assembly is performed in the reverse order 35 9 10 Back Element electrically adjustable in versions Standard and Comfort Back element disassembled Back element assembled p lt 24 me wv T 1 Back padding 2 8x Counters tapp screw 4 8x17 3 4x Clamping piece 4 Back belting 5 4x Counters tapp screw w cap 6 Back frame tube 7 2 Hexagon head screw M8x45 8
44. CA e 05 ie tating eian Wats 103 13 4 Disassembling assembling drive MOE att os SO tte ate has Ate ash hls 73 18 0 Cable and Plug cece eeeae 104 t81 General cates ie ol hii settee e ERES 104 14 0 Check and Repair Work 18 2 Testing procedure 104 on Actuators 000 cece eee eee 75 tAk General 250 oo 2 ce Re on Re onthe 75 19 0 Wheelchair Programming 105 14 2 Checking actuators 75 Aoo Lenaal ees p n E 105 14 3 Replacing legrest actuators 76 19 2 Programming atthe PC 105 14 4 Replacing seat adjustment actuator 77 19 2 Programming with the programming 14 5 Replacing actuator for backrest OE ints hit AI ah eer iad ene a 105 AGIUSUMENL deca tanh ices Ree acted 78 15 0 Check and Repair Work 20 0 Wheelchair Storage 0005 106 on Lighting System 000000as 79 15s 1 ENO CAUSES ee As Atea Poe et 79 15 2 Checking lighting system 79 15 3 Disassembling checking headlight 80 15 4 Disassembling checking flasher 81 15 5 Disassembling headlight flasher and lamp holder completely 82 15 6 Disassembling checking taillight flasher and rearlight 84 16 0 Check Work on the Driving Electronics Checking Modules 000005 85 16 1 General 00 00 eee 85 16 2 Checking joystick boxes 86 16 3 Checking main module 87 16 4 Checking lighting modules i e lighting
45. Inspection Remedy NOTE e Tyre losing air gt Repair or replace e The rear wheels can be mounted on inner tube standard hubs or on hubs with brake drum 7 oe Pa ene e The disassembly is identical in both foreign bodies instances e Outer cover damaged gt Replace outer cover It is recommended to remove the e Screws loose gt Tighten screws batteries before the disassembly to Rims damaged gt Replace rims reduce the wheelchair s weight Disassembly complete A CAUTION e Loosen countersunk screws 8 cross wise e The countersunk screws 8 Jack up wheelchair to clear the wheel are not allowed to be lubricated Unscrew countersunk screws 8 completely and detach the wheel 3 under any circumstances e The screws are inserted at the Deflate the wheel loosen Allen screws 11 cross wise and remove factory with Plasbolt They can Take apart rim bodies 4 and 5 be dismounted mounted up Withdraw the inner tube 7 from the outer cover 6 to 6 times e In the 7th mounting at the latest the screws must be cleaned and then inserted Repair inner tube or replace by new inner tube size 3 00 8 Assembly with Loctite e Tighten screws only hand tight nflate inner tube slightly until it takes the shape of a ring 7 a Aokoverri nsert inner tube 7 into the outer cover 6 and place the two rim halves into the cover from outside CAUTION nsert Allen screws 11 screw down cross wise and tighten by AN
46. OTE e The assembly is performed in the reverse order e When assembling always use new starlock caps 16 e During the assembly attention is to be paid to the correct location of the parts left right e Adjust legrests to equal length e Adapt locking screws 24 correctly and secure with nuts 28 For the assembly of the legrest elbow tube 9 and the legrest upper part 6 proceed as follows e Assemble the backlocking unit 89 insert guide rod 13 and screw on nut 12 e Place backlocking unit 39 with washers 15 on legrest elbow tube 9 and insert the release lever 14 e Insert starlock cap 16 into starlock tool and position tool correctly over the legrest elbow tube 9 and the release lever 14 e Fasten tool at first handtight and afterwards tighten with a ring spanner until cap 16 is completely pressed on e Loosen starlock tool and remove e Insert the upper end of the guide rod 13 into the legrest upper part 6 e Insert starlock cap 16 into the starlock tool and position tool correctly over the legrest upper part 6 and the guide rod 13 e Fasten tool at first handtight and afterwards tighten with a ring spanner until the cap 16 is completely pressed on e Loosen starlock tool and remove e Assemble bushing 10 legrest elbow tube 9 and legrest upper part 6 and screw together with the screw 11 and the nut 12 e The remaining assembly steps for the completion of the legrest are pe
47. S Remote right driving motor BE CEEE fe AV zu weiteren Modulen Location of the cable binders d Cable binders Removing the main module Fastening screw M5 x 20 SW 8 Detail Module Fastening Washer ES T Nut M5 SW 8 oe IA self locking Washe Screw M5 x 20 SW 8 101 17 7 Lighting Module Lighting and Adjustment Module CLAM and Voltage Transformer Preparation e Remove splash protection See chapter 11 7 in this respect e Remove cable binders at connection cables Removing the Modules e Remove all plugs from the socket board of the module to be replaced NOTE Press down plug locks as otherwise the plug will be damaged e Loosen the two fastening screws of the module SW 8 mm e Pull the module from the battery box retainer in downward direction Installing the Modules e Push the module into the battery box retainer from below and fasten it by means of the two fastening screws e Insert the plugs into the module s socket board The arrangement of the plugs can be seen from the connecting plan e Attach new cable binders e Mount the splash protection Connecting Plan Lighting Module and Lighting Adjustment Module CLAM Hauptmodul Bedienelemente Verstellmotoren Licht Remote actuators Light Power Module ojo ote ojo ojo ojo ojo ojo ololo Location of the cable bin
48. S plug while the switch is not being activated The measuring device must show continuity e Activate the switch and measure again on the contacts of the BUS plug The measuring device is not to show any continuity Malfunction Cause Remedy No continuity while switch Cable parted Replace microswitch is not activated Microswitch defective and cable Continuity while switch is Short Circuit in the Replace microswitch activated microswitch and cable 91 17 0 Repair Work on the Driving Electronics Replacing Modules 17 1 Standard Joystick Box Joystick box mounted to the standard seat Joystick box and fixing devices disassembled 1 Armrest Standard 4 BUS cable 7 Holder joystick box for attendant 10 Wing screw M6x10 13 Joystick box receptacle RECARO seat 16 Guide piece 2 19 1x Lever 2 21 4x Screw M5x40 24 2x Phillips screw 4 8x16 27 Holder for attendant RECARO 29 4x Lock nut M6 Inspection Remedy e Check electric functions See chapter 16 2 gt e BUS plug defective gt Replace BUS cable S e BUS cable damaged gt Replace BUS cable 10 e Joystick tight or damaged gt Replace joystick box e Screwings loose gt Tighten screws Rp e Parts or fixing device gt Replace screws replace parts completely defective or fixing device if necessary 2 Armrest RECARO 3 Joystick box 5 Joystick box holder Standard 6 Holder joystick box swivable 8 4x Screw M4x10 9 Jo
49. a pair of tongs Loosen nut M5 completely and detach together with bolt spring and locking lever from the seat frame 18 e Remove plastic discs from the hinge bolts 17 and 18 e Use a suitable sleeve such as a strip of leather and hold hinge bolts 17 and 18 with a pair of tongs e Loosen nuts 20 completely and detach hinge bolts 17 and 18 if appropriate together with stopper 19 from the seat frame 13 Montage e The assembly is performed in reverse order 48 Disassembly seat recline adjustment complete Only for electrical legrest adjustment Remove connection plug from the sockets front below at the battery box retainer Release legrest lock and detach legrests Release quick release bolt 29 at the upper part of the seat recline adjustment device not shown or at actuator 21 and remove if appropriate together with washers Only for actuator Remove connection plug from the socket front below an der at the battery box retainer Loosen nut 24 completely and remove together with washer 25 from the screw 23 Support actuator 21 or seat recline adjustment with your hand remove screw 23 together with washer 25 and detach actuator 21 or seat recline adjustment device from the seat frame 13 Only for actuator Loosen nut 28 at connecting rod and detach together with washer 27 Detach screw 26 together with washer 27 and remove the top of connecting rod
50. adjustment modules 88 16 5 Checking additional power supply of lighting module 12 V T V version 89 16 6 Checking voltage transformer for RECARO seat 00000 eee 90 16 7 Checking microswitch 91 1 0 Safety and assembly instructions The safety instructions are provided in the interests of working safety and must under all circumstances be complied with Prior to all inspection and repair work Read this service manual and the appertaining User s Manual e Ensure that minimum qualifications for performing relevant work are fulfilled see chapter entitled General information A CAUTION e Note that some components are heavy You should take this into account above all when removing the motors and or the batteries e The power supply for the wheelchair must be switched off before any conductive parts are removed Remove the batteries e When performing tests on conductive parts ensure that the contacts are not short circuited gt Danger of fire and injury from burns lt e Only use tools which are in perfect working order and are not damaged During disassembly and assembly e Mark the current settings of the wheelchair seat armrests back etc and the combination of cable connec tions before carrying out disassembly work This will make assembly easier afterwards CAUTION A e Support the raised wheelchair with suitable supports before you begin disasse
51. and turning by 1 8th rotation to the left e Pull the light bulb from the lamp base e Test by means of a multimeter the voltage existing between the contact in the casing pole and the lamp base pole Voltage in 6 km h wheelchair 10 km h wheelchair abroad 10 km h wheelchair Germany CAUTION N oa bridging the poles by all means gt Danger of Fire and Burning lt e Insert the new light bulb Type of flasher lamp 6 km h 10 km h 10 km h Type of rear ligh 6 km h 10 km h 10 km h whee whee whee amp whee whee whee cha cha cha cha cha cha ir ir ir ir ir ir aroad Germany abroad Germany 24V 24V 12V 24 V 21 watts 24 V 21 watts 12 V 21 watts 24 V 5 watts 24 V 5 watts 12 V 5 watts e Check whether the contact of the casing fits exactly to the positive pole of the light bulb NOTE The contact fits correctly if a slight pressure is to be applied when inserting the light bulb eLock the light bulb by slightly pressing down and turning by a 1 8th revolution to the right e Mount the rear light glass e Fix the rear light glass by means of the fastening screws Disassembling Rear Light AN e Remove rear light glass and lamps as described above e Mark plug and pull out e Loosen screws with nuts and washers completely e Remove rear light from the rear light board Montage e The assembly is
52. assembly Unscrew clamping lever 22 and remove headrest 1 with headrest support 2 from headrest holder 14 Remove headrest pad 6 from headrest shell 5 Velcro fastener Unscrew clamping lever with washer 13 completely and separate headrest shell 5 with headrest arm 3 from headrest support 2 Detach protecing caps 12 and separate nut 11 from screw 7 Detach screw 7 with bushings 8 and washers 9 plus headrest arm 3 from headrest shell 5 Loosen slotted head screw 10 and remove headrest arm bracket 4 from headrest shell 5 Take off protecting caps 21 detach nut 20 from screw 18 and remove screw with washers 19 Detach headrest holder 14 from clamp 15 Loosen Allen screws 16 and nuts 17 and detach clamp 15 from back frame tube 23 Assembly The assembly is performed in the reverse order 21 9 2 Armrests and Side Parts Side part disassembled d Side part disassembled 1 Side part complete 2 Side frame 3 Armrest pad 4 Side panel 5 Side pads 6 Hexagonal screw M4x35 7 Wing or Allen screw M5 8 Side part holder 9 Clamping lever M8x60 10 Crossbeam part of the seat frame 11 Clamping lever M8x60 12 2x Bore hole for compression rivets 13 Rearview mirror 14 Nut M8 with protecting cap 15 Bore hole for mirror 16 Parking brake 17 Standard joystick box 18 Hexagonal screws M5x20 with washers not shown 4x Inspection Remedy Armrest padding damaged Screws of armrest lo
53. attery box retainer e Prior to the testing make sure that the batteries are charged Status Display For a simple optical error determination the module is equipped with a green LED for status display Inspection of the status display e Switch the wheelchair on via the joystick box e Inspect LED see table below Main Module disassembled Inspection Remedy Bauer eenle e Status display glowing gt Module is all right e Status display off gt Check the voltage supply of the module Check programming e Status display flashing gt Replace module Testing Preparation e Remove batteries See chapter 12 1 in this respect e Remove splash protection See chapter 11 7 in this respect e Install battery boxes us display Testing Voltage Supply to Main Module e Remove the plug of the battery cable from the main module e Measure the voltage existing at the voltage supply contacts see drawing All combinations between the positive and the negative poles must be measured The voltage between the positive and the negative poles must each amount to at least 19 volts S NOTE Information on the use of the multimeters can be taken min 19 volts from the respective User s Manual CAUTION AN Avoid by all means a bridging of the voltage supply contacts gt Danger of Fire and Buring lt Malfunction Cause Remedy Chapter No voltage at the Externa
54. ay how the correct passage is being signaled e g beeping sound depends on the kind of multimeter and the settings NOTE For information on the use of the multimeter please see the respective User s Manual 18 2 Testing Procedure e Set the multimeter to continuity test e Loosen all plug connections of the cable to be tested Connect one testing cable of the measuring instrument with a contact at the input plug and the other cable with the corresponding contact of the output plug ff NOTE Inpu plug and output plug can be determined freely However during the measuring they should not be changed output plug Measure the continuity at the contacts on the cable s input and e In the same way check all connections for short circuit or parted cables Multimeter with Digital Display Measuring Example Continuity test on BUS cable Input plug i Output plug tp Q 4 Malfunction Passage at varying contacts or cables No passage at corresponding contacts cables Cause Short circuit in cable or contact Parted cable Remedy Replace cable Replace cable 104 19 0 Wheelchair Programming 19 1 General For error diagnosis in the ACS electronics and for the setting of standard and custom made driving profiles the DYNAMIC Wizard PCD Software Version 2 0 should be employed Programming e C onfiguration e Diagnostics The programm
55. bleshooting 2005 17 Error Messages on Joystick Box 19 Error codes of the joystick box 19 Check and Repair Work on the Standard Seat System 21 Headrest saagama ace ant how PAK eal 21 Armrests and sides 22 Legrests with one piece foot plate 23 Legrests with one piece foot plate for short lower legs naana auaa aaa 24 Standard legrests and standard legrests with angle adjustment Chapter 9 6 9 7 9 8 9 9 10 0 10 1 10 2 10 3 10 4 11 0 Ana ackres ackres CH w5 gt ea Sea Standard and Comfor Standard and Comfor cushion apron with pocket and seat pla EN Wedge cushion comple frame comple Legrests with 73 and 90 degree angle adjustment Legrests with manual height adjustment Legrests with electrica height adjus omical backrest element Standard and Comfor MENET A oe a a cane aa version ically adjustable version t element manually adjustable quality t element elec Sy Sy SOR rc th eth hein sachets AAD EAE E E E Check and Repair Work on RECARO General Seat System Headrest safety belt and pushing bar Armrests and sides Seat module and seat frame Check and Repair Work on Chassis Front wheel suspension and wheels 3 00 4 Front wheel suspension and wheels 200x50 Rear wh Parking Rear wh eels and tyres brake and w
56. box and brake lever from the side parts e f necessary detach adjustments e Remove legrests 31 Detach connection cables a he electrical connections of the actuators legrest and backrest rom the cable clamps under the seat e Remove the quick release bolt 24 of the seat recline adjustment 19 or of the actuator 29 e Move the seating system forward and place on top of chassis 32 e Loosen nuts 9 loca ed on the upper part of the mounting plates 2 completely and detach together with the washers 8 from the screws 7 e Support seating system remove screws 7 with washers 8 and detach the seating system from the chassis 32 completely Disassembly assembly of seat cushions seat plate and apron with pocket e For disassembly assembly see chapter 9 12 Disassemblying legrest receptacle completely e f necessary detach the electrical connections for the actuators legrest adjustment e Release legrest locking 30 and detach legrests 31 e Use a suitable sleeve such as a leather strip and hold the locking bolt with a pair of tongs e Loosen nut M5 completely and detach together with bolt spring and locking lever from the seat frame 1 e Remove plastic discs 11 from the hinge bolts 3 and 4 e Use a suitable sleeve such as a leather strip and hold hinge bolts 3 and 4 respectively with a pair of tongs e Detach nuts 5 completely and remove hinge bol
57. cannot get pinched T1 14 5 Replacement of the Actuator Backrest Adjustment Disassembly Remove quick release bolt tilt seat frame upward and secure the seat e Pu the plug of the actuator out of the socket e Unhook the actuator cable from the clamps located under the seat plate e Remove the quick release bolt at the upper fastening of the actuator e Now detach the actuator by loosening the lower fastening screw SW 17 mm Assembly e Install the new actuator and fasten it by tightening the lower fastening screw e Insert the quick release bolt into the upper actuator fastening e Lead the actuator cable through the clamps under the seat to the socket board and put the plug into the socket e Conduct a performance test Fastening Points of Actuator Cable Connection cable of the electric backrest adjustment Actuator Backrest Quick release bolt Fastening screw M10 x 50 SW 17mm Actuator Lower Actuator Fastening NOTE Do not screw down the fastening screws too tightly The actuator must be able to move within its fastenings e Tightening too firmly can cause the fastening links to bend e Arrange the actuator cable in a manner where it cannot get pinched in Actuator Frame of backrest fastening w Nut M10 SW 17 mm Washer self locking Fastening Screw M10 x 50 SW 17 mm Quick release Bolt S Backrest frame Press 78
58. cure with nuts 24 25 9 5 Standard Legrests and Standard Legrests with Angle Adjustment Legrest receptacle left Mc 7 tal k 1 Legrest receptacle 2 4 Hinge bolt 7 8x35 mm 5 7 Slide piece SL22 8 10 Footplate large 11 13 Calf belt 14 16 Screw M6x45 17 19 Nut M6 Cap Stop 20 NOTE Items 14 to 20 are applicable for Seat frame Legrest lock spring weighed Legrest lower part Tapping screw 4 2x16 Insert tube Locking screw M6x40 Nut M6 standard legrests with angle adjustment only Inspection e Calf belt missing or damaged e Screwings loose e Weldment joints or legrest upper part defective e Footplate damaged e Weldment joints or legrest lower part defective e Weldment joints or insert tube defective e Weldment joints or footplate tube defective e Slide pieces or caps missing or damaged Legrest disassembled 3 Hinge bolt 7 8x30 mm 6 Legrest upper part 9 Screw M8x10 12 Cap A8 15 Footplate tube 18 2x Washer RD 6x17x2 5 Remedy Rep Tigh Rep Rep Rep Rep Rep Rep VV VV V VV OV ace exchange calf belt ten screwings ace legrest upper part ace footplate ace legrest lower part ace insert tube ace footplate tube ace exchange slide pieces or caps 26 Disassembly of Standard Legrests complete e Detach calf belt 13 from legrest lower part 8 e Release legrest lock 5 and lift legrest from hinge bolts 3 and 4 e Loosen
59. d pull the insert tube 8 out of the slide tube 7 Loosen clamp 18 and remove from the slide tube 7 together with screw 19 washer 20 and cap nut 21 The two following steps are applicable to the right legrest only e Release tapping screw 29 completely and pull the footboard receptacle 9 together with the width compensation 10 out of the footboard 11 e Remove leaf spring 81 from the footboard 11 The following steps are applicable to both legrests e Detach cap 17 release nut 26 from countersunk screw 25 and detach footboard receptacle 9 with bushing 14 from the width compensation 10 e f required unscrew locking screw 23 with counter nut 24 from the width compensation 10 e Remove cap 17 unscrew hexagon head screw 13 from the cone 16 and detach screw 13 with washer 15 bushing 14 and cone 16 from the upper part of the legrest 6 e Separate slide tube 7 from the upper part of the legrest 6 If necessary remove slide pieces 27 28 and 32 plus cap 30 NOTE The slide pieces are inserted They can be lifted by means of a suitable tool for instance a screw driver Assembly The assembly is performed in the reverse order WA NOTE e During the assembly please pay attention to the correct location of the parts left right e Insert leaf spring 31 correctly e Adjust legrests to equal length e Adjust locking screws 23 correctly and se
60. ders binders Remove Lighting and Lighting Adjustment Module CLAM Fastening screw M5 x 16 SW 8 Detail Fastening of the Module N L O 7 Washer gt WW I ug Screw M5 x 16 SW 8 102 17 8 Microswitch Disassembly Installing Position of the Microswitch Lift the seat and remove the splash protection See Chapter 11 7 R f Ad in this respect Remove the cable o Remove the cable o of the chassis Fold the rear light board upwards and detach the microswitch by loosening the fastening screws SW 7 the switch from the lightening module the microswitch from left frame tube vs Assembly Mount the new switch Lead the cable of the microswitch once again through the left Connecting Plan of the Microswitch frame tube of the chassis to the 12 V lightening module Insert the BUS plug into the module s socket board The arrangement of the plugs can be seen on the connecting plan Mount splash protection Fold the rear light board down again driving position Hauptmodul Power Module OJo ojo Oojo olo olo olo Bedienelemente Verstellmotoren Licht Remote actuators Light z B Mikroschalter 103 18 0 Testing Cables and Plugs 18 1 General All cables and plugs can be examined for defects such as parted cables by means of a continuity test This test is performed with the aid of a multimeter The w
61. e e Measure the voltage existing at the contacts of the feeder cable see drawing t must amount to at least 19 volts CAUTION AN Avoid by all means a bridging of the power supply contacts gt Danger of Fire and Burning lt min 19 volts Malfunction Cause Remedy Chapter No voltage at contacts Power supply to the plug of the main module interrupted Check replace cable 18 0 Check power supply 12 0 Test master fuse 50 A 12 0 Voltage below 19 V Battery fully discharged Pre charge battery 12 2 Replace battery 12 0 89 16 6 Testing Voltage Transformer for RECARO Seat Testing Preparations e Remove battery boxes See chapter 12 1 in this connection e Remove splash protection See chapter 11 7 in this connection e Install battery boxes Testing Voltage on Voltage Transformer for RECARO seat e Detach plug connection from the battery cable to the voltage transformer e Measure the voltage existing at the contacts of the feeder cable see drawing t must amount to at least 19 volts e Reconnect the plugs Detach the plug connection to the RECARO seat e Measure the output voltage Depending on the charging status of the batteries it must amount to between 2 5 and 4 volts Main Module and Voltage Transformer Fuse 15A Feeder Testing Voltage ECARO seat NOTE min 19 volts The voltage transformer provides an output voltage of 1
62. e plug Chapter 18 0 connection 5 x Flashing Right motor disengeaged Engage motor clutch L Defective right motor brake gt Check motor brake H Chapter 13 3 gt Replace motor __ Chapter 13 4 y 6 x Flashing gt Left motor disengaged Engage motor clutch gt Defective left motor brake m Check motor brake L Chapter 13 3 5 Replace motor Chapter 13 4 Yy The flashing code is also activated when both motors are disengaged The flashing code is only activated when the flasher is switched on too 19 y 7 x Flashing E Battery fully discharged Precharge charge battery Chapter 12 2 Check battery charger Chapter 12 3 Check modules and programming inform INVACARE Service Chapter 19 0 Check plug and socket connections plus BUS cable Chapter 18 0 Only in 10 km h T V version Fold rear light bar in driving position completely downwards Only in 10 km h TUV version Check microswitch replace if necessary Switch joystick box off and on again y 8 x Flashing ye Battery voltage too high y 9 x Flashing Error in data transfer 10x Flashing between modules T Drive motors 11x Flashing temporarily overloaded y C tibilit bl 12x Flashing ompatibility problem
63. e e Battery cable e Cable to actuators e Cable to control unit for actuators Only if control unit is available Actuators Lighting adjust ment module to Control Unit Power module P uk to P Joystick box Battery cable 12 5 4 Wheelchair Equipment with Lighting 24 V with Actuators Modules Cables e Main module Power Module e Lighting Adjustment module Combined lighting actuator modu e Joystick box e Control of actuators With older joystick boxes adjustment cannot be controlled via the the joysti e BUS cable to joystick box e BUS cable from power module to ligh actuator module e Battery cable e Cable to actuator motors lighting cab ay options ck box ting e Lighting Cable Actuators In rare instances two separate cables e Cable to control unit for actuators Only if control unit is available 5 5 Wheelchair Equipment with Lighting12 V T V version without actuator Motors Modules ain module power module e Lighting module 12 V e Joystick box Cables icroswitch e BUS cable to joystick box e BUS cable from power module to lighting module e Battery cable e Cable to microswitch e Cable for additional power supply e Lighting cable 12 V Additional Power Supply Serves to keep up the power supply of the lighting module 12 V via the ACS BUS cable in case of power failure thus ensuring full ser
64. e allows to perform diagnoses and settings by means of a commercially available PC starting from series 386 SX under operating systems DOS from version 3 1 upward and Windows from version 3 1 upward or Windows 95 Also an independant non PC related programmer can be employed The item numbers of the software and of the programmer can be found in chapter 2 0 List of Tools More detailed information on the PCD Software and the programmer can be obtained from the INVACARE SERVICE DEPARTMENT In this respect please see the service numbers indicated on page 2 19 2 Programming via PC Programming Socket and Version Number Connect the PC to the programming socket of the joystick box via the programming cable Switch the PC on and start the programme Dynamic Wizard Switch the wheelchair on via the joystick box The required programme version can be found on the programme version table Programming 4 socket a Number of software version For the programming of the wheelchair follow the programming description Software Manual Remove the connection cable Switch the wheelchair off and on again Test the driving functions WA NOTE e The version of the programme depends on the type of wheelchair The programme version tables are included in the programme description Software Manual or in the description of the programmer e The software version number is indicated on a sticker located on the joystick box e By
65. e parts Screws loose Sa oS g e tight ke linings worn out defective Tighten screws Check brake drum linings replace if necessary Replace brake linings Backing plate or mounting parts damaged Replace parts 56 Disassembly Bowden Cable complete Lift seating system and lock if required NOTE Remove rear wheels 33 See chapter 11 3 in this respect e Itis recommended to remove the Release brake and write down the positions of the adjusting batteries before disassembling in order i to reduce the weight of the wheelchair screws 4 at the upper side of the brake lever 1 and on the Bowden cable holders 23 Loosen cable locking screws 21 and if necessary detach com pletely together with nut and washer Squeeze off caps 9 pull inner brake cable 8 out of the cable locking screws 21 and remove compression springs 25 e The wheelchair is to be jacked up Pull inner brake cable 8 together with the Bowden cable coverings 6 and 7 out of the adjusting screws 4 located at the lower part of the Bowden cable holders 23 Remove cable binders not shown from the Bowden cable coverings 6 and 7 and uncover both Bowden cable ends upwards toward the brake lever 1 Pull off Bowden cable coverings 6 and 7 Loosen wing or Allen screws 34 and detach the parking brake completely with brake housing holder 14 Remove Bowden cable coverings 6 and 7 from the inner brake cable 8 P
66. e piece Wing screw M6x10 Bushing PVC 2x Slide piece SL 22 2x Slide piece SL 18 2x Screw M8x45 2x Washer 8 4x17x1 6 2x Lock nut M8 Bushing RD 18x8x22 3x Washer 138x24x2 5 22 Lock nut M12x1 5 Cap SKS12 Clamping piece 22 mm Screw M8x25 Clamping lever M8 2x Cap SKS8 BUS cable 2 6m Switch box rod Plate Hinge Screw M6x40 Nut M6 Stop Switch box complete with cable 29 Actuator LA22 5E 75 24 30 2x Bushing RD 10x1x22 5 Holding pce chin control Recaro 32 4x Screw M6x40 33 4x Washer 6 4x12 5x1 6 Holding pce chin control Standard 35 4x Phillips screw 4 8x22 36 4x Plastic rosette Clamping piece 38 Screw M6x16 39 2x Pop rivet Connection cable for actuator and switch box NOTE e In the manual version the joystick box 1 is swiveled by means of the guide rod 4 e In the electric version the joystick box 1 is swiveled by means of the actuator 29 e Guide rod or actuator resp are connected to the backrest holder 2 and the swivel arm 3 e A large part of the components are used in both versions e In the electric version the switch box 28 with switch box rod 23 is employed additionally e The switch box 28 is riveted to the plate 24 and must be replaced completely together with the cable e For the Standard Comfort seat another holder is available besides the model 34 shown above It consists of two clamping halves with bushes and screw and is to be attached to the tube frame of OnNoOoBR WDM
67. eadlight casing Connection cable Spring finger connector NOOR WD Disassembling headlight and light bulb e Loosen tapping screw 2 and remove headlight glass 1 e Pull lamp holder 3 from the headlight glass 1 e Screw the light bulb 4 out of the lamp holder 3 Test Check Voltage e Test by means of a multimeter the voltage existing between the contact 7 of the headlight casing pole and the black cable pole at the lamp holder 8 Voltage in 6 km h wheelchair 24 V 10 km h wheelchair abroad 24 V 10 km h wheelchair Germany 12 V CAUTION Avoid bridging the poles by all means gt Danger of Fire and Burning lt e Insert the new light bulb 4 Type of bulb 6 km h wheelchair 24 V 3 watts 10 km h wheelchair abroad 24 V 3 Watt 10 km h wheelchair Germany 12 V 2 4 Watt mY NOTE J Make sure that the ground cable is located in the lamp holder and does not touch the positive pole of the light bulb 4 NOTE J e Test if appropriate whether the thread of the lamp holder is oxidized rusty For that detach headlight casing see chapt 15 5 clean thread if necessary and grease slightly Assembly Mounting the Headlight Glass Mount the headlight glass 1 Slot in the headlight casing NOTE The tab at the headlight glass 1 must interlock with the slot of the headlight casing 5 e Make sure that the contact 7 in the headlight casing 1 fits closel
68. eels for secure seat and wobble Check front wheels for free running and wobble Bearing of front wheel forks Check tyres Support castors with sup port plates gt Rep dam gt Tigh Rep gt Tigh pad gt Tighten screws 9 2 Rep Remedy Chapter J ace in case of age en screws 9 1 ace parts en Screws replace ace side parts gt Rep gt Tighten screws Replace parts 9 12 gt Replace ace gt Adjust or replace Bowden wire gt compression spring 9 9 gt Tighten screws Replace parts gt Replace gt Replace gt Replace motors gt Tighten screws 14 0 gt Replace seat if 10 0 necessary gt Tighten screws replace parts gt Rep gt Adju hub gt Adju ace 11 1 to st replace wheel 11 5 st or replace axle bolt wheel hub gt Adju gt Rem gt Adju st replace ount st or replace 15 Assembly Parking Brake Drive Units Legrests Batteries Driving Electronics Joystick Boxes Driving Electronics Main Module Lighting Adjustment Modules Lighting System Check Function Bowden wires loose Bowden wire covering damaged Wear damage of brake drums and brake linings Check functions for driving and pushing operation Check motors In models with clutch mechanism check check mechanism Weld seams locks screwings etc Check footplates Actuat
69. eft right e Adjust legrests to an equal length e Adapt locking screws 17 correctly and secure with nuts 20 27 9 6 7 z Tvs ae m 7 AA Legrests 73 and 90 degrees angle adjustable Legrest receptacle left 11 B 1 Legrest receptacle 2 Seat frame 4 Hinge bolt 7 8x35 mm 5 Legrest lock spring weighed 7 Insert tube conical 8 Legrest lower part 10 Footplate small 11 Slide piece SL22 13 Locking screw M6x40 14 2x washer RD 6x17x2 5 16 Nut M6 17 Screw M8x10 19 Cap A8 20 Calf belt 22 Screw M8x12 Inspection Calf belt missing or damaged Screwings loose Weldment joints or legrest upper part defective Footplate damaged Weldment joints or legrest lower part defective Weldment joints or insert tube defective Weldment joints or footplate tube defective Slide pieces or caps missing or damaged 6 Legrest Pa i disassembled N 3 Hinge bolt 7 8x30 mm 6 Legrest upper part 9 Footplate tube 12 Screw M6x45 15 Nut M6 Cap Stop 18 Tapping screw 4 2x13 21 Guard disc Remedy VV V VV VAa N Rep Tigh Rep Rep Rep Rep Rep Rep ace exchange calf belt ten screwings ace legrest upper part ace footplate ace legrest lower part ace insert tube ace footplate tube ace exchange slide pieces and caps 28 Disassembly complete Detach calf belt 20 from insert tube 7 Release legrest lock 5 and lift legrest from hinge bolts 3 and 4 Loosen screw 17 a
70. elcro fasteners 4 or cable clamps 6 from the seat plate 8 and replace glue Assembly e Proceed with the assembly in reverse order 40 9 13 Wedge cushion complete Wedge cushion disassembled DH J wo Inspection e Wedge cushion damaged e Insert tube damaged e Wedge cushion holder damaged e Screwings loose Disassembly complete Wedge cushion holder Insert tube A Insert tube B Insert tube C Wedge cushion 3x Wing screws M6x10 6x Screws NOOR WD Remedy gt Replace wedge cushion gt Replace insert tube gt Replace wedge cushion holder gt Tighten screwings e Loosen wing screws 6 and separate the insert tubes from each other e Loosen two screws 7 and detach the wedge cushion 5 from the insert tube C 4 e f required lift seating system electrically or manually and lock if appropriate e Loosen four screws 7 and detach the wedge cushion holder from the seat frame Assembly e Proceed with the assembly in reverse order 41 9 14 Seat frame complete Storm Comfort with seat frame assembled Legrest receptacle left For the seat recline adjustment also ao an cia can be 20 P installed oN 27 7 26 1 Seat frame 2 2x Mounting plate 3 2x Hinge bolt 7 8x30 4 2x Hinge bolt 7 8x35 5 4x Lock nut M6 6 2x Limit stop plate 7 4x Hexagonal head screw M8x50 8 8x Washer 16x8 3x1 5 9 4x Lock nut M8 10 Support bracket 11 4x Plastic disc 20x8x1 12
71. eldment joints or footplate tube defective Calfplate or calfplate rocker defective e Slide pieces or caps missing or damaged Check replace actuator Replace calfplate Tighten screwings Replace legrest upper part Replace footplate Replace legrest elbow tube Replace insert tube Replace footplate tube Replace parts Replace exchange slide pieces or caps gt gt gt gt gt gt gt gt gt gt 33 Disassembly complete Remove connection plug 42 from the socket in front at lower part of battery holder Remove caps 31 from screws 30 Loosen screws 30 at legrest upper part 6 and at legrest elbow tube 14 and detach the actuator 27 with bushings 28 and washers 29 completely Release legrest locking 5 and lift legrest off the hinge bolts 8 and 4 Loosen wing screw 25 and pull the insert tube 82 with footplate tube 33 and footplate 34 from the egrest elbow tube 14 Loosen screw 36 with washers 87 and nut 38 completely and separate insert tube 82 from foot plate tube 33 f required loosen locking screw 35 and nut 39 and detach from footplate tube 33 Loosen tapping screws 40 completely and detach footplate 34 from footplate tube 33 Loosen Phillips screws 19 completely and together with nuts 20 detach from clamping piece 15 Detach clamping piece 15 completely with calfplate 18 from the legrest elbow tube 14 Loosen t
72. ent Adjustmen Slide piece or caps missing or damaged mechanism defective 2 5 8 11 14 17 20 23 26 29 32 35 38 Seat frame Legrest lock spring weighed Legrest receptacle left 3 Hinge bolt 7 8x30 mm 6 Legrest upper partl Slide piece Y13x4x8 9 Legrest elbow tube Screw M6x35 12 2x Nut M6 Cap Stop Release lever RD 8x185 15 2x Washer 20x7 9x1 Clamp 22mm 18 Button headed screw Nut M8 Hut 21 Insert tube Footplate large 24 Tapping screw M6x40 2x Washer RD 6x17x2 5 27 Nut M6 Stop 2x Tapping screw 4 2x9 5 30 Calfplate joint Calfplate black Screw M8x80 Screw M5x16 33 Cap A8 36 Washer 8 4x17x1 6 housing release plate release block and spring oints or insert tube defective oints or footplate tube defective Remedy VV VV VV VV Rep Tigh Rep Rep Rep Rep Rep ace calfplate ten screwings ace legrest upper part ace footplate ace legrest elbow ace insert tube ace footplate tube Repair replace adjustment mechanism Rep ace exchange slide pieces or caps 30 Disassembly complete Release legrest lock 5 and lift legrest from the hinge bolts 3 and 4 Loosen nut 20 and pull insert tube 21 together with footplate tube 22 and footplate 23 from egrest elbow tube 9 Loosen screw 25 with washers 26 and nut 27 completely and separate insert tube 21 from footplate tube 22 f required release locking screw 24 and nut
73. ente Fax Service Apr s Vente 33 33 0 2 47 62 64 15 0 2 47 62 64 64 Bik INVACARE Deutschland GmbH Dehmer Str 66 D 32549 Bad Oeynhausen Deutschland T Kundendienst Fax Kundendienst INVACARE AB Avestagatan 29 16 353 Sp nga Sverige T Kundj nst Fax Kundj nst INVACARE UK Ltd South Road Bridgend Mid Glamorgan CF31 3PY United Kingdom T Customer Service Fax Customer Service 49 0 5731 754 210 49 0 5731 754 216 46 0 583 140 85 46 0 583 124 05 44 0 1656 647 372 44 0 1656 649 016 INVACARE NEDERLAND Fokkerstraat 36 3905 KV Veenendaal The Netherlands T Fax REHADAP SA c Areny s n Poligon Industrial de Celr 17460 Celr Girona ESPA A i Fax INVACARE PORTUGAL Lda Rua Senhora de Campanh 105 4369 001 Porto PORTUGAL T Fax Mecce San S R L Via Dei Pini 35 1 36016 Thiene VI ITALIA a Fax 31 0 318 550 056 31 0 318 555 054 34 0 972 49 32 00 34 0 972 49 32 20 352 0 2 51057 39 352 0 2 51050 20 39 0 445 380059 39 0 445 380034 107
74. er with washers 8 Assembly The assembly is performed in reverse order 44 10 0 Check and Repair Work on the Recaro Seating System 10 1 10 2 General Chapter 10 and its sub chapters are dedicated to the description of the special features of the Recaro seating system As to the disassembly assembly of the legrests the steps described in chapter 9 for the standard seating system are applicable Headrest Safety Belt and Push Handle Recaro seat assembled Recaro seat disassembled f 1 Back module 2 Headrest 3 Safety belt 4 Holder for push handle 5 Push bar 6 Handle 7 Clamping lever M6x10 8 4x Screws M6 9 4x Washers NOTE The Recaro seat can be designed as a complete seating module model DS with integrated control or or as model LX with detachable headrest and back module Inspection Remedy e Headrest damaged gt Replace headrest e Safety belt damaged gt Replace safety belt e Push handle damaged gt Replace individual parts e Screwings loose gt Tighten screwings Disassembly Pull headrest 2 upwards from WA NOTE back module 1 As arule when removing the headrests the clamps located under the guide tubes must be removed first e Unscrew four screws located at the rear of the back module 1 and detach the safety belt 8 e Release clamping lever 7 and detach push bar 5 with handle 6 from the holder 4 e f necessary pull handle 6 from the push bar 5 e Unscrew four
75. est holder 2 e Remove cap 16 loosen nut 15 and detach bolt 14 from the clamp 11 Recaro seat e Loosen 4 nuts 13 and detach together with washers 32 e Remove screws 27 and detach holder 31 from the seat Standard Comfort seat e Loosen Phillips screws 34 and detach holder 33 with rosettes 35 from the backrest e f necessary remove slide pieces 9 and 10 respectively Assembly e The assembly is performed in the reverse order 100 17 6 Main Module Preparation e Remove battery boxes See chapter 12 1 in this respect e Remove splash protection See chapter 11 7 in this repsct e Remove cable binders located at the main module Removing the Main Module e Remove all plugs from the socket board of the main module NOTE Press down plug lock as otherwise the plugs will be damaged e Loosen the two fastening screws of the main module SW 8 mm e Pull module out of the battery box retainer in downward direction Installing the Main Module e Push the main module into the battery box retainer from below und and fasten it by means of the two screws e Insert the plugs into the module s socket board The arrangement of the plugs can be seen from the connecting plan e Attach new cable binders e Mount the splash protection e Insert the battery boxes Connecting Plan Main Module linker Fahrmotor Batterie ACS Fahrpult rechter Fahrmotor left driving motor Battery AC
76. ews with washers 2 and 3 plus screws with washers and nuts 4 3 and 5 completey and detach battery box retainer 1 from the chassis e Loosen screws with washers and if appropriate with nuts 18 completely and detach modules Loosen screws with washers and nuts 8 9 and 10 completely and detach the connection socket with holder 15 from the battery box retainer 1 NOTE Assembly e Do not forget the cable binders e In TUV Version Do not forget spring steel sheet e The assembly is performed in reverse order for microswitch 62 11 8 Kerbstone Lifter Kerbstone lifter assembled Kerbstone lifter disassembled 1 Chassis 2 Kerbstone lifter support 3 4x Screw M8x20 4 4x Washer 5 Compression spring 6 2x Screw 7 4x Washer 8 2x Lock nut 9 Kerbstone lifter fork 10 2x Stopper 11 Screw 12 Washer 13 2x Bushing 14 2x Ball bearing 15 Lock nut 16 Lifter shoe Inspection Remedy e Lifter shoe damaged gt Replace lifter shoe e Screwings loose gt Tighten screws e Compression spring damaged gt Replace compression spring e Weldment joints or kerbstone lifter support damaged gt Replace kerbstone lifter support e Weldment joints or kerbstone lifter fork defective gt Replace kerbstone lifter fork Disassembly complete e Lift seating system and lock if necessary e If necessary remove lifter shoe 16 e Loosen nuts 8 completely and detach together with washers 7 e Remove screws 6 with washers 7
77. f the support bracket 30 Loosen nut 21 located at the upper part of the back frame tube 6 completely and detach together with washer 19 Support the compression spring 13 with your hand remove screw 18 with washer 19 and bushing 20 and detach compression spring together with the entire fork shaped piece 14 and put aside Loosen nuts 11 located at the lower part of the support bracket 30 and detach together with washers 10 om the back frame tube 6 with your hand and remove screws 7 with washers 8 and 10 from the support bracket 18 Then detach the back frame tube Detach safety belt 34 from the back frame tube 6 NOTE Press bushings 9 outwards from the bushing seats The bushings can only be removed from in the back frame tube the inside to the outside Loosen tapping screws with caps 5 completely and detach the back belt 4 from the back frame tube 6 or press the back padding 1 out of the back frame tube NOTE 6 The back padding can be removed even if the back frame tube is mounted If necessary remove the countersunk tapping screws 2 and detach the clamping pieces 3 Rotate the compression spring 13 out of the fork shaped piece 14 Loosen clamping screws 26 and nuts 27 to free the Bowden wire 22 Loosen counter nuts and locking screws 16 and detach the Bowden wire 22 with its covering 23 from he fork shaped piece 13 and the Bowden wire receptacle
78. g device 31 from the seat Standard Comfort seat e Loosen Phillips screws 35 and detach holding device 34 together with rosettes 36 from the backrest e f necessary remove slide pieces 9 and 10 respectively Assembly e The assembly is performed in reverse order 98 17 5 Chin Control Electrically Swivable in Vertical Direction Joystick box Backrest holder Swivel arm Receiving tube Switch box rod Plate Hinge Actuator LA22 5E Slide piece SL1 4x Slide piece S 2x Clamping piece Alu 4x Screw M6x25 5x Nut M6 Stop Bolt RD 16x88 M12x1 5 2x Nut M12x1 5 2x Cap SKS12 Locking ring A10 3x Washer 13x24x2 5 Screw M8x45 Bushing RD 10x1x22 5 3x Clamping piece 22 mm 2x Button head screw M8m25 3x Washer 8 4x17x1 6 Switch box complete Holding piece for Recaro seat Phillips screw 4 8x22 Lock nut M8 ONOoaAKRWBDY EAB e E E ot AUN CO 15 16 ilif 18 19 20 21 22 25 28 31 34 37 NOTE Chin Control and Holding Devices disassembled 23 26 29 32 35 38 24 27 30 33 36 3x Clamping lever M8 BUS cable 2 6 m Clamping piece Washer 6 4x12 5x1 6 Plastic rosette Connection cable for actuator and switch box 3x Wing Screw M6x10 5x Screw M6x40 Screw M6x16 Holding pce for Standard seat 2x Pop rivet e The joystick box 1 is swiveled by means of the actuator 8 e The actuator is borne by the bolt 14 and by the swivel arm 3 e The switch box
79. ge at the contacts indicated see drawing The voltage must amount to at least 19 V A CAUTION Do not bridge contacts Danger of Short Circuit Malfunction Cause e No voltage BUS cable defective gt Test replace BUS cable Chapter 18 0 BUS cable defective gt Test replace BUS cable Chapter 18 0 Main module defective gt Test main module Chapter 16 3 Test voltage supply to main module Chapter 16 3 e Voltage below 19 V Battery fully discharged gt Test battery Chapter 12 2 WA NOTE The following inspections are to be performed at the attendant s joystick box additional joystick box switchable e Check whether the control can be switched over by means of the flip switch e Check whether the final speed can be pre selected by means of the controller e Check whether the wheelchair con be controlled via the joystick e Check whether all other functions lighting and adjustment functions continue to be controllable via the main joystick box S NOTE e When ordering a replacement joystick box the part numbers and the number of the software version must be indicated e The software version number can be found on a sticker at the joystick box 86 16 3 Testing the Main Module NOTE Main Module assembled e The main module is maintenance free Only basic tests can be performed e The module is located in front under the splash protection at the b
80. h the actuator Loosen nuts 11 at lower part of support bracket 18 and detach together with washers 8 Support the back frame tube 6 with your hand and remove screws 7 with washers 8 and 10 from the support bracket 18 Then detach the back frame tube Detach safety belt 12 from back frame tube 6 Press bushings 9 outwards from the bush bearing in the back frame tube NOTE The bushings can only be removed from the inside to the outside Loosen tapping screws with caps 5 completely and remove back belting 4 from the back frame tube 6 or press the back padding 1 from the back frame tube 6 NOTE The back padding can be removed even if the back frame tube is assembled If required remove countersunk tapping screws 2 and detach the clamping piece 3 If required loosen nuts 21 completely and detach together with washers 20 If required hold the support bracket 18 with your hand remove screws 19 with washers 20 and detach support bracket 18 from the seat frame CAUTION Do not remove the support bracket 18 completely as otherwise the seat frame would be supported only by the threaded spindle and the actuator of the seat inclination adjustment and would thus become unstable As to the disassembly of the support bracket see chapter 9 14 Assembly The assembly is performed in the reverse order NOTE Insert the back padding 1 carefully in order not to damage the clampi
81. heel hubs eel suspension with shock absorbers support castors support plates a Drive un nd rear wheel link aaan it complete Splash guard for modules and bat Kerbstone lifter Transpo holder and reflectors Lighting ery box retainer rt bracket taxi bracket cane bar bumper bar Table of Contents Chapter Page Chapter Page 12 0 Check and Repair Work 17 0 Repair Work on the Driving Electronics on Electrical System 000000s 66 Replacing Modules 055 92 12 1 Checking batteries battery boxes and 17 1 Standard joystick box 92 battery potential 0 66 17 2 Joystick box for attendant 94 12 2 Charging batteries 68 17 3 Table control central control 95 12 3 Baileny charger rreeeruire seps hea 69 17 4 Chin control manually electrically swivable in horizontal direction 97 13 0 Check and Repair Work 17 5 Chin control electrically swivable on Drive Motors 22200000s 70 in vertical direction 0 004 99 131 General wed eae Se ee ee kee RDG 70 A736 Maninoa mo rre patted iaa oe 101 13 2 Checking and replacing carbon 17 7 Lighting module lighting and Brushes amp oeie ve ara E aas a ae ties 70 adjustment modules CLAM or 13 3 Checking motor magnetic brake and voltage transformer 102 free wheel switch 0 0 0 00048 71 TS MEGSI
82. hers from the lamp holder 1 Assembly e The assembly is performed in the reverse order 82 Disassembly Flasher LOO Turn con Pull con sen tapping screw 8 completely and detach flasher glass 16 Loosen screw 9 and detach flasher casing 17 slightly left right and carefully pull from the lampholder 1 nection cable 4 is released mirror with lamp base 11 carefully from the flasher casing 17 up to the poin nections at the lamp base become accessible Mar Pull connecting cables 4 from the flasher casing 17 and detach the casing Assembly e The assembly is performed in the reverse order Disassembly Lampholder Detach headlight 3 completely Detach flasher 2 completely Remove cable binder 10 f necessary remove washer and rubber bushing 6 from the chassis 12 Assembly e The assembly is performed in the reverse order NOTE e Do not forget the cable binder Press down flasher bulb 18 slightly turn by 1 8th revolution to the left and pull from the base 11 until where the k the connections unsolder from the lamp base and detach mirror with base 11 Loosen screw and washer 5 completely and detach together with lamp holder 1 83 15 6 Dissassembling Testing Taillight Flasher and Rear Light e Loosen fastening screws e Pull off rear light glass e Release the corresponding light bulb by slightly pressing down
83. in the User s Manual Testing the magnetic brake e Engage the motors e Set the multimeter to resistance measuring e Measure the resistance of the brake coils at the plug contacts shown in the drawing to the right t must amount to between 20 ohms and 200 ohms Testing the free wheel switch The free wheel switch switches the motors to pushing operation putting the magnetic brake out of function e Disengage motors e Set multimeter to resistance measuring e Measure the resistance of the brake coils at the plug contacts shown in the drawing to the right The resistance measured must amount to infinite Plug Contacts Motor Brake Contacts BER Motor Contacts Testing the Electric Circuit of the Motor Testing Magnetic Brake Resistance 20 ohms 200 ohms Malfunction Cause Solution Chapter No continuity of the electric Parted cable in the motor Replace motor 13 4 circuit of the motor Carbon brushes worn out Check replace carbon 13 2 brushes Resistance being 0 ohms Short circuit in magnetic brake Replace motor 13 4 Resistance clearly gt 200 Defective contact in the ohms but not infinite magnetic brake Replace motor 15 4 72 13 4 Disasembly Assembly of Drive Motor Disassembly of drive motor NOTE e The first two steps apply only to motors with a coupling mechanism e Loosen locking screw SW 8 mm at the disengaging lever of the mo
84. is respect Detach joystick box and if necessary brake lever from the side parts See chapter 9 2 in this respect Remove side parts from the seat frame 1 See Chapter 9 2 in this respect Remove back element entirely See in this respect chapters 9 9 to 9 11 depending on models f necessary remove the wedge cushion completely See chapter 9 13 in this respect Remove seat cushion seat plate and apron with pocket See chapter 9 12 in this respect f necessary detach the connection cables of the actuators and separate the connection cables from the cable clamps Release legrest lock 80 and detach legrests 81 Release quick release bolt 24 of the seat recline adjustment 19 or the actuator 29 and place the seat frame 1 forward on top of the chassis 82 Loosen nuts 9 at the upper part of the moun from the screws 7 Support the seat frame 1 remove screw 7 with washers 8 and lift the entire seat frame off the chassis 82 Remove screws 7 with washers 8 and nuts 9 completely and detach support bracket 10 from the seat frame 1 Remove four screws M6x20 with washers not shown completely and detach crossbeam 12 from the seat frame 1 f necessary remove clamping lever 13 f necessary loosen two screws M8x20 with washers not shown at the lower part of the mounting plate 2 completely and detach mounting plate from chassis 32 ing plates 2 completely and detach togeth
85. joystick box Should this not be the case pinpoint the errors by means of the flashing codes as follows e Switch joystick box off and on again e Determine flashing code by counting e Wait for flashing pause approx 2 3 seconds e Count code sequence again Flashing Codes of the Status Display on Joystick Box 7 Check status display of modules 1 x Flashing gt Electronic module defective Sng repce medde i necescary Chapter 16 0 y 4 2 x Flashing l Adjustment module defective Replace adjustment module Chapter 17 7 Defective loose cable plug gt Check replace cable plug Chapter 18 0 Defective ee gt Replace lighting adjustment module Chapter 17 7 Error in lighting system gt Check lighting system Chapter 15 0 Defective rear flasher Replace flasher Chapter 15 6 y 4 3 x Flashing ae Error in right motor y Check replace motor Chapter 13 0 loose defective motor _ysl Check replace cable plug Chapter 18 0 connection Y 4 4 x Flashing gt Error in left motor Oo Check replace motor Chapter 13 0 Loose defective motor _ 1 Check replace cabl
86. l battery contacts defective Check external contacts 12 1 contacts Master fuse defective Check master fuse 50 A 12 1 Voltage below 19 V Battery fully discharged Pre charge battery 12 2 Replace battery 12 0 87 16 4 Testing Lighting or Lighting Adjustment Modules NOTE Lighting Module and Adjustment Module assembled e The lighting adjustment modules are maintenance free Only basic tests can be performed e The modules are located in front under the splash protection at the battery box retainer e Prior to the inspection make sure that the batteries are charged ay a ae PE Status Display For a simple optical error diagnosis the modules are equipped with LEDs for status display Inspecting the status display e Switch on wheelchair at the joystick box Lighting Module and Adjustment Module e Inspect LEDs see table below BUS cable FR Inspection Remedy e Status display glowing gt Module all right e Status display off gt Test voltage supply of the module Test programmer e Status display flashing gt Replace module gt Testing Preparations e Remove battery boxes See chapter 12 1in this respect e Remove splash protection See chapter 11 7 in this respect nstall battery boxes Status display Checking Power Supply from the Main Module to the 24 V 12 V BUS plug Lighting Module or to the Lighting Adjustment Module e Remo
87. left insert tube 4 Release legrest locking 19 and lift legrest 1 from the hinge bolts 16 and 17 Loosen cap nut 10 and pull the legrest upper part e g 2 from the insert tube 3 or 4 Loosen clamp 8 and detach from the legrest upper part 2 Unscrew tapping screw 15 completely and pull insert tube 3 ou Remove leaf spring 14 from the footboard 5 If necessary remove slide part 12 and caps 13 from the insert t t of the footboard 5 ubes 3 and 4 J NOTE Assembly e When assembling pay attention to the correct location The assembly is performed in the reverse order of the parts left right e Insert leaf spring 14 correctly e Adjust legrests to the same length 23 9 4 Legrest with One Piece Footboard for Short Lower Legs Legrest disassembled Legrest receptacle left 22 26 L o gt TOOK 11 Ans a 25 a An 27 24y ae 23 1 Legrest receptacle 2 Seat frame 3 Hinge bolt 7 8x30 mm 4 Hinge bolt 7 8x35 mm 5 Legrest lock spring weighed 6 Legrest upper part 7 Sliding tube 8 Insert tube 9 Footrest receptacle 10 Width compensation 11 Footrest ALU 12 Rubber mat glued 13 Hexagon head screw M8x120 14 Bushing 15x22x8 3 15 Washer 8 4x20x1 6 16 Cone 17 Cap SKS8 18 Clamp 22 mm 19 Button headed screw M8x25 20 Washer 8 4x20x1 6 21 Nut M8 Hut Stop 22 Wing screw M6x10 23 Locking screw M6x40 24 Nut M6 25 Countersunk screw M8x40 26 Nut M8 Stop 27 Slide piece 15x15
88. lt Battery Box Detail Terminal Terminal red cable NOTE Exact information on the condition of the batteries can be obtained by a capacity test which can only be performed by the manufacturer CAUTION Removal of Battery Boxes Swing up Rear Light Bar Battery Box Locking Belt Detail External Contacts of the Batteries Battery outside Battery inside f cea Guide Pins Contacts Contacts Terminal blue cable me gt Gory wer 2 Oo INVACARE O GA Sas j Battery For the replacement of batteries use exclusively gel batteries brand Sonnenschein Type Dryfit A 512 55A INVACAR Inspection Voltage decreasing heavily under strain driving operation hand brake applied and lights on Total voltage below 24 V Voltage of one battery below 9 5 V Precharging not possible or battery damaged No voltage at external contacts Contacts of batteries corroded or damaged Check all cables plugs and master fuses Battery box lid or battery box damaged Locking belt damaged Guide pins or external contacts damaged E Item No P50 992 Remedy gt Load batteries see chapter 12 2 gt Load batteries see chapter 12 2 gt Preload battery see chapter 12 2 gt Replace battery gt Replace master fuse 50A or cable gt Clean contacts replace if necessary gt Replace if necessary gt Replace if necessary gt Replace locking belt
89. m 4 one piece 11 Rim part 1 12 Rim part 2 13 Hex head screw M8x50 14 2x Washer 8 4x17x1 6 15 Lock nut M8 16 5x Screw M6x50 17 5x Lock nut M6 Inspection Remedy e Wheel losing air gt Repair or replace inner tube e Outer cover damaged gt Replace outer cover e Rim damaged gt Replace rim e Screws loose gt Tighten screws e Wheel bearing tight or worn out gt Adjust or replace wheel bearing e Front wheel fork tight or too slack gt Adjust clean slide bearing or replace fork e Front wheel fork damaged gt Replace fork Disassembly front wheels e Use suitable support e g wooden block and jack up wheelchair e Loosen nut 15 completely and detach together with washer 14 from the screw 13 e Pull out screw 13 and detach together with washer 14 from the front wheel 7 e Remove front wheel 7 from the fork 2 Assembly e The assembly is performed in reverse order 53 Disassembly 1 piece rims and tyres Remove front wheel 7 completely See in this respect Disassembly Assembly Front Wheels Remove valve cap not shown and deflate tyre by pressing on the spring pin of the valve Pull outer cover 8 sideways from the rim 10 with the aid of a tyre puller Remove inner tube 9 from the outer cover 8 and from the rim 10 f required repair inner tube or replace inner tube size 200x50 Detach outer cover 8 completely from the rim 10 f required press out wheel bearing
90. mbly or re assembly e Never use normal nuts instead of self locking nuts e Always use correctly sized washers or separators NOTE J e All plug connections are fitted with clips that prevent them from accidentally slipping apart when the wheelchair is in operation e To release connectors the clips must be pressed in e When carrying out assembly work make sure that the clips latch in securely Prior to initial use after repair work A CAUTION e Check to make sure all screws are securely tightened e Check that all parts are properly locked in place e Make sure the tyre pressure is at the recommended 2 5 bar before driving the powerchair e Always perform a test drive after repair work 2 0 List of tools A standard toolkit comprising the following minimum inventory is required Combination ring and open end spanner SW 6 7 8 10 11 12 13 17 19 Allan key 2 5 MM 3mm 4mm 5mm 6 mm 8mm 10mm Torque wrench commercially available Socket spanner set Screwdrivers for slotted screws various Crosstip screwdriver No 1 No 2 and No 3 Side cutting pliers Flat pliers Round pliers Pointed pliers Waterpump pliers Cable lug pliers Wooden or plastic hammer Tyre repair set commercially available Tyre gauge Removing tool for valves Ejecting tool for tyre bearing Multimeter with testing spikes and different cable clamps Jumper cable Soldering iron 30W Wheel hub puller for front wheels Mounting pliers for
91. means of the programming software also driving profiles that are individually tailored to the user s needs can be programmed 19 2 Programming by Means of the Programming Device Programmer Connect the transmission cable of the programming device to the programming socket of the joystick box e Switch the wheelchair on Select the programming parameters that you want to change and proceed to programme the wheelchair For this purpose follow the description of the programming device Remove the transmission cable Switch the joystick box off and on again e Check the driving functions CAUTION After every change of the programming parameters check the driving functions by test drives 105 20 0 Storing the Wheelchair Whenever a storage of the wheelchair for a prolonged period of time is required the following steps should be taken e Check tyre pressure and inflate to the nominal value if necessary See chapter 11 0 in this respect e Charge battery for 36 hours by means of the INVACARE charger See chapter 12 0 in this respect e Detach the batteries See chapter 10 1 in this respect e Store batteries in a cool place remove and store separately if necessary See chapter 12 0 in this respect Before a renewed operation check tyre pressure and battery voltage once more and inflate recharge if required 106 POIRIER Groupe INVACARE Les Roches F 37230 Fondettes France T Service Apr s V
92. ment e Actuator for chin control The control of the actuators is performed via the joystick box and if required via an additional control box The socket boards for the connection of the actuators are located in front under the seat of the wheelchair The occupancy of the individual plug connections is marked by symbols Right Legrest Seat angle adjust ment The STORM Recaro usually has only an actuator for the seat angle adjustment which is controlled by the ACS The remaining adjustment options are integrated in the seat and are a part of the Recaro seat The control panel is located in the surface of the seat That is why the entire seat must be replaced when the adjustment options are faulty 14 2 Testing the actuators The following tests can be performed on the actuator motors Performance test by voltage application Continuity test of the motor coils by means of a multimeter Window mek I eg D Q feb eg D Visual test of the plug connections Check whether the contacts of the plug are pushed back or oxidized N brown cable Continuity test Continuity test e Pull the plug of the actuator to be tested out of the socket board e Set the multimeter to continuity test e Measure the continuity of the electric circuit of the actuator at the inspection windows shown in the drawing at the right Performance Test e Pull the plug of the
93. n such a way that the cutout is ocated over the valve nsert cheese head screws 21 and tighten cross wise nflate tyre to the prescribed pressure of 2 5 bar und screw on valve cap 23 Then mount wheel 7 into the front wheel fork 2 See in this respect Disassembly Assembly Front Wheels Disassembly Remove front wheel 7 completely See in this respect Disassembly Assembly Front Wheels Loosen slide piece 3 for example with a screwdriver and detach Hold front wheel fork 2 loosen nut 4 completely and detach together with washer 5 Remove front wheel fork 2 with adjusting washer 6 from the slide bearing downward in the chassis 1 Assembly The assembly is performed in reverse order CAUTION e The front wheel forks rest on slide bearings which give way after the first operating hours and must be tightened e Check and tighten nut 4 after 5 operating hours and once again after another 10 hours e The nut 4 must be tightened to a degree where the forks turn freely without any vertical play 52 11 2 Front Wheel Suspension and 200x50 Wheels Front wheels assembled Front wheels disassembled a NOTE The front wheels can be equipped with 1 piece or 2 piece rims 1 Chassis 2 Front wheel fork f wheel 200x50 3 Slide piece DA 42 4 Hex head nut M12x1 5 Stop 5 Washer 13x24x2 5 6 Adjusting washer 16x22x1 0 7 Front wheel 8 Outer cover 200x50 9 Inner tube 200x50 10 Ri
94. nd pull legrest upper part 6 from the insert tube 7 Loosen nut 15 and together with washer 14 separate from screw 1 f required loosen nut 16 and remove together with locking screw 13 f required remove slide piece 11 and caps 19 NOTE The slide pieces are inserted They can be lifted up with a suitable tool such as a screwdriver If necessary loosen screw 22 and detach guard disc 21 from footplate 10 Assembly The assembly is performed in the reverse order S MS During the assembly pay attention to the correct location of the parts left right e Adjust legrests to an equal length e Adapt locking screws 17 correctly and secure with nuts 20 Loosen tapping screw 18 completely and detach footplate 10 from the footplate tube 9 Detach screw 12 and washer 14 and separate footplate tube 9 from the insert tube 7 29 9 7 Legrests manually height adjustable Legrest disassembled 12 1 Legrest receptacle 4 Hinge bolt 7 8x35 mm 7 3x slide piece SL22 10 Bushing RD 18x6x22 13 Guide rod 16 2x Starlock cap 8mm 19 Washer 8 4x17x1 6 22 Footplate tube 25 Screw M6x45 28 Nut M6 31 Calfplate holder 34 Bushing RD 15x3 35x22 37 Nut M8 Stop 39 Back locking unit consisting of Inspection Calfplate damaged Screwings loose Weldment joints or legrest upper part defective Footplate damaged Legrest elbow tube defective Weldment Weldm
95. ng pieces plastic 37 9 11 Back Element Manually Adjustable in Standard and Comfort Versions Back element disassembled 26 18 1 Back padding Back belting 8x Counters tapp screw 4 8x17 4x Tapping screw with cap 6 2x Washer 16x8 3x1 5 g 2x Lock nut M8 12 Fork shaped piece M10x1 15 Screw 18 Bushing 21 Bowden wire covering 24 Clamping screw 27 Cylinder shaped button 30 4x Hexagon head screw M8x50 33 35 Starlock cap 3 4x Clamping piece Back frame tube 2x Bus hing 12x8 5x23 Quick release bolt Flat lin for fork shaped pce Hexagon head screw M10x50 Lock n 2x End Nut for Suppo ut M10 cap for Bowden wire clamping screw t bracket 4x Loc The back element can be equipped with back padding 1 or with back belt 4 7 2x Hexagon head screws M8x45 8 10 4x Washers 24x8 3x2 11 13 Compression spring 14 16 2x Locking screw counter nut 17 19 2x Washer 19 5x10 5x2 1 20 22 Bowden wire 23 25 Bowden wire receptacle 26 28 Adjusting lever 29 31 8x Washer 16x8 3x1 5 32 34 Safety belt NOTE Inspection Back padding damaged Remedy Replace back padding nut M8 Stop Back belting damaged Replace back belting Safety belt damaged Replace safety belt Screwings loose Tighten screws Weldment joints or back frame tube defective Replace back frame tube Support bracket damaged Check compression spring and Bowden wire Bowden wire defective Bowden
96. ng screw 21 Disengage motor and check while the brake is being released whether the wheel hubs 22 turn freely Turn wheel hubs 22 slowly one after the other on each side while simultaneously pulling the brake lever 1 steadily until the hub is slowed down NOTE e Up to the point of slowing down both hubs must have made approximately the same rotation If necessary adjust brakes to a uniform pull by adjusting the inner brake cable 8 or by means of the adjusting screws 4 Mount rear wheels 33 See in this respect chapter 11 3 Make wheelchair ready to start 57 Disassembly brake housing with brake lever complete Disassemble Bowden cable completey See disassembly Bowden cable Loosen counter nuts and remove adjusting screws 4 at brake housing 10 and 11 Loosen tapping screws 5 completely and detach brake housing from its holder 14 Pull off Knob 3 from brake lever 13 and remove cover 2 from the brake housing 10 and 11 Loosen screws 12 completely take apart the brake housing parts 10 and 11 and remove the brake lever 13 Assembly The assembly is performed in the reverse order For the assembly of the Bowden cable see Assembly Bowden cable For the adjustment of the brakes see Adjusting Brakes Disassembly Wheel Hub with Brake Drum complete Remove rear wheel 33 See in this respect chapter 11 3 Remove slide piece 30 loosen nut 81 completely and detach together
97. not tighten the fastening screws too tightly bushings A V The actuator must be able to move within for legrests gt a its fastenings De e Install the cable in a way where it cannot get pinched O Washer Fastening screw M8 x 35 SW 13 mm Lower Actuator Fastening 76 14 4 Replacement of Actuator Seat Adjustment Actuator Seat Adjustment Disassembly taema to 2a ato e Remove the quick release bolt fold the seat frame upward and secure the seat Pull the plug of the actuator out of the socket e Now detach the actuator by removing the lower fastening t i Jf screw SW 17 mm Ali i Fastening Screw e Detach the top of the motor s connecting rod M10 x 50 SW 17 mm See chapter 14 4 in this respect wo 5 Assembly Actuator Lower Actuator Fastening e First mount the top of the connecting rod e Install the new actuator and fasten it by tightening he lower fastening screw e Lead the motor cable to the socket board and put the plug in to the socket e Fold the seat frame downward again and fasten the motor o the seat by means of the quick release bolt Nut M10 SW 17 mm self locking Conduct a performance test Washer NOTE Do not screw down the fastening screws too tightly Fastening Screw M10 The actuator must be able to move within its x 50 SW 17 mm fastenings e With too much tightening the fastening clips can bend e Place the cable in a way where it
98. ogether with bushing 18 or 20 from the front wheel 7 e Remove front wheel 7 from the fork 2 Assembly e The assembly is performed in reverse order CAUTION The screws 16 were mounted at the factory with Plasbolt They can be dismounted mounted up to 6 times At the 7th time at the latest the screws must be cleaned and then reinserted with Loctite In 2 piece rims make sure before inserting the axle bolts 14 that the bushing 19 is correctly centered Disassembly 1 piece Rims and Tyres e Remove the front wheel 7 completely See in this respect Disassembly Assembly Front Wheels e Remove valve cap 23 and deflate tyre completely by pressing the spring pin of the valve e Pull off outer cover 8 sideways from the rim 10 by means of a tyre puller e Remove inner tube 9 from the outer cover 8 and from the rim 10 If necessary repair inner tube or replace inner tube size 260x85 e Detach outer cover 8 completely from the rim 10 If necessary press wheel bearing 15 out and bushing 17 Assembly e Press first wheel bearing 15 into the rim 10 until it closes even with the rim e Insert bushing 17 into the rim 10 e Press second wheel bearing 15 into the rim 10 until it closes even with the rim e Mount outer cover 8 sideways onto the rim 10 e Insert inner tube 9 correctly and inflate until the inner tube has taken the shape of a ring e Mount outer cover
99. omplete inside Parking brake complete Gear for driving units Shock absorber Support wheels Actuator for backrest Quick release bolt Storm Comfort i nr a View from below li i i Storm Recaro View from the right Recaro seat complete Side part complete Mounting kit for joystick box swiveling Special joystick box Legrests complete Foot plates Kerbstone lifter complete Front wheel complete Reflector 0 Declutching leber 11 Driving motor right 12 Rear wheel complete 13 Support wheel 14 Rear light assembly bar complete 15 Chassis 16 Seat frame 17 Taxi bracket OMAN ODOAKRWBNDN 4 Storm Recaro Seat tilted Storm Recaro Front view Actuator at Recaro seat Splash protection for module Chassis Support bar for kerbstone lifter fork Kerbstone lifter Front wheel fork Seat support for Recaro Seat angle adjustment manual os Pocket for side part Recaro Side part complete Mirror for Recaro complete Headlight and flasher Calf belt BUS cable for joystick box Protection for joystick box NOOR WDM OnNOoaKR WDM 4 0 4 1 Components of the Electronic Control ACS General The wheelchair s electronic control Action Control System ACS Main Module Lighting Module consists of individual components modules According to each type of wheelchair the wheelchairs are equipped with different modules ACS Modules
100. on with pocket 4 Velcro fastener strips glued 5 4x Tapping screw 4 8x18 7 Quick release bolt 8 Connection cable NOTE Seat plate mounted near i Seat plate from below lifted 4 N Skal m ex ep i ba y M 3 Seat plate 6 Cable clamps glued e The seat plate can be provided with different types of seat cushions e The Velcro fastener strips under the seat cushion are clamped Inspection e Seat cushion damaged e Apron with pocket damaged e Velcro fastener damaged e Screwings loose e Seat plate damaged e Cable clamps damaged Disassembly complete gt Replace seat cushion gt Replace apron with pocket gt Replace Velcro fastener gt Tighten screwings gt Straighten replace seat plate gt Replace cable clamps e Lift seat cushion 1 slightly at the front and pull upwards from the seat plate 3 e Remove apron with pocket 2 from the seat plate e f necessary lift seating system electrically or manually and lock if appropriate NOTE Nar J A Tw 7 For a mechanical seat recline adjustment loosen first the quick release bolt 7 After that the seat 3 can be lifted completely The seat should be supported by means of a suitable object e f required press connector cable 8 for the actuator out of the cable clamps 6 e Remove tapping screws 5 entirely and lift the seat plate 3 from the seat frame 9 e f required remove defective V
101. ool e g a pipe wrench driving position e Now mount the disengaging lever and fasten it by tightening the locking screw SW 8 mm The locking screw M 5 x 10 must contact exactly the flattened part of the shaft see drawing Disengaging Locking Screw Lever M5 x 10 SW 8mm NOTE J Following the assembly make sure that no moving parts such as rods or screw connections are sliding against the motor casing Conduct a performance test e Lead the motor cable to the main module Connection Plan Motor Plug and plug the connection plug into the socket board linker Fahrmotor Batterie ACS Fahrpult rechter Fahrmotor left driving motor Battery ACS Remote right driving motor ERE CEEE tele CRE AV zu weiteren Modulen e Secure the cables by means of cable binders Position of the Cable Binders e Mount the splash protection CAUTION Following the assembly the correct operating of the disengaging lever as well as the driving functions must be tested gt Make a test drive lt 74 14 0 Check and Repair Work on the Actuators 14 1 General In the STORM Standard and Comfort qualities the actuator motors are activated by the ACS via an actuator module Depending on each type the STORM Standard or Comfort aN can be equipped with the following actuators z e Actuator for seat angle adjustment fen e Actuator for backrest adjustment e Actuators for legrest adjust
102. ors if necessary Damage of batteries and boxes corrosion on contacts Check contacts terminals Check battery voltage Joystick boxes status display flashing Fastening Cable plug connection Function of joystick Power supply Status display flashing Power supply Functions of lighting and adjustment modules Power supply Damage of lights Function of lamps Remedy gt Adjust replace gt Tighten adjust replace gt Replace gt Replace gear or motor if necessary gt Replace carbon brushes or motor gt Tighten screws nuts and replace parts if necessary gt Tighten replace gt Tighten replace gt Replace gt Clean contacts replace batteries or boxes gt Tighten replace gt Charge batteries replace gt Evaluate flashing codes gt Tighten replace gt Replace gt Replace joystick box gt Replace cable plug or joystick box gt Replace module gt Replace cable plug or module gt Check status displays on modules gt Replace cable plug or module gt Replace lights gt Replace lamps Chapter 11 6 13 0 9 3 to 9 8 16 2 17 1 to 17 5 16 3 17 6 16 4 16 7 17 7 17 8 15 0 16 7 0 Operation Troubles 7 1 General Note In case of malfunctions of the lighting system actuators or power supply proceed as follows e First evaluate the causes of malfunction specified in chapter 7 2 e
103. ose Side part padding damaged Side part covering damaged Side part frame damaged Side part holder damaged Clamping lever damaged Mirror damaged Replace armrest padding Tighten screws Replace side part padding Replace side part covering Replace side part frame Replace side part Replace clamping lever Replace mirror VV VV VV VV NOTE The steps for disassembly and assembly of the standard joystick box and the parking brake are only applicable to the respective types of wheelchair Complete Dissassembly A Lift seating system electrically or manually and lock if necessary Unscrew wing or Allen screws 7 and remove joystick box 17 or parking brake 16 together with the holding device from the armrest 1 Remove cap if necessary loosen nut 14 and pull the mirror 13 out of the side part frame 2 Loosen clamping lever 11 and remove side part 1 in upward direction Unscrew clamp lever 9 completely and pull side part holder 8 out of the crossbeam 10 Loosen screws and washers 18 and detach the crossbeam 10 from the seat frame Remove side part padding 5 from the side panel 4 Velcro fastener Rebore carefully the compression rivets 12 located on the lower part of the side panel 4 by means of a twist drill 3 5 to 4 mm and detach the side panel 4 from the side panel frame 2 Loosen screws and washers 6 and remove the armrest padding 8 from the side panel frame 2
104. place BUS cable 1 with holder 3 is attached to the BUS cable damaged gt Replace BUS cable push handle epyslien tight or damaged gt BER ace joystick box e In the remaining models the joystick e Screwings loose gt Tighten screws box 1 with clamping piece 4 is e Parts or holding device gt Replace screws replace directly attached to the backrest completely defective parts or holder if required Disassembly joystick box e Detach BUS cable 2 from the joystick box 1 e Loosen wing screws 11 and detach joystick box 1 Assembly e The assembly is performed in the reverse order Disassembly joystick box holder e Detach joystick box 1 as described above e Loosen nut 9 and detach together with washer 8 screw 7 and holding plate 13 from the mounting 12 angle e Loosen 4 nuts 6 and detach together with screws 7 mounting angle 12 and clamping pieces 4 from he holder 3 or from the backrest respectively e In the Recaro seat loosen screw and detach holder 3 from the push handle e If necessary remove slide piece 10 Assembly e The assembly is performed in the reverse order 94 17 3 Table Control Central Control 14 eai 1 Joystick box 4 Holding plate for central control 7 Support arm 10 2x Phillips screw M5x12 13 2x Lock nut M8 16 2x Washer 13x24x2 5 19 2x Slide piece SL 22 22 Swivel arm part 2 25 Wing screw M6x10 28 4x Cap lock nut M6 31
105. r with washer 25 e Support actuator 8 remove screw 19 and detach the actuator from the swivel arm 8 Assembly e The assembly is performed in the reverse order Disassembly Switch Box e Detach connection cable 38 from the wheelchair and put aside e Loosen nut 13 completely and detach together with screw 27 e Detach switch box 28 from the switch box rod 5 e If necessary loosen wing screw 24 and detach switch box rod 5 Assembly e The assembly is performed in the reverse order Disassembly Holder complete e Remove joystick box 1 as described above e Remove actuator 8 as described above e Remove switch box 28 and switch box rod 5 as described above e Loosen clamping lever 23 and remove together with screw 22 and washer from the receiving tube 4 e Detach receiving tube 4 together with clamps 21 carefully from the swivel arm 3 and clear the BUS cable 26 in the process e Remove the BUS cable 26 completely from the swivel arm 8 and detach from the wheelchair e Remove cap 16 loosen nut 15 and detach the swivel arm 3 with bushing 20 and washers 18 from he backrest holder 2 e Detach swivel arm 3 from the backrest holder 2 e Loosen wing screws 24 and clamping lever 23 respectively and detach backrest holder 2 from the holding pieces 31 and 33 respectively e Loosen nuts 13 together with screws 12 and detach clamping piece 11 from the backr
106. re serious repairs always use the original packaging for transportation e Please include a detailed account of the fault You will find the following symbols in this repair manual NOTE This symbol indicates general information concerning special features and helpful advice for disassembly and assembly CAUTION Please pay special attention to this symbol It indicates gt Safety instructions lt Chapter 1 0 2 0 3 0 4 0 4 1 4 2 4 3 4 4 5 0 7 0 71 7 2 8 0 8 1 9 0 9 1 9 2 9 3 9 4 9 5 Table of Contents Page Safety and Assembly Instructions List of Tools Arrangement of Subassemblies Components and Operating Elements 7 Components of the Electronic Control System ACS 000ceeae 10 General l ou ee 10 Connection cables of modules 10 Status display error display 14 Microswitch 0 0 00002008 14 Modules ince tease maiaa aai 12 Wheelchair equipment without lighting without actuators 12 with lighting 24 V without actuators 12 without lighting with actuators 12 with lighting 24 V with actuators 13 with lighting 12 V without actuators 13 with lighting 12 V with actuators 14 with electronically adjustable RECARO seat 000 14 Inspection Plan 2 1 cece eee eee eee 15 Operation Troubles 0000us 17 Geral state Se oo Cleat ney chase A aR 17 Trou
107. reconnect the mains plug Green LED FULL CHARGE will light up for approx 3 seconds and will then change to the yellow LED CHARGE e Pull mains plug INVACARE Charger SS aa MAINS ON CHARGE FULL CHARGE 4 J S Remedy Malfunction Cause Red LED MAINS ON Supply voltage 230 V missing not illuminated Charger defective Yellow LED CHARGE Batteries fully discharged not illuminated Charger defective Green LED Excess voltage in batteries FULL CHARGE Status display blinking not illuminated Charger defective gt Test 230 V mains gt Replace charger gt Test battery voltage gt Replace charger gt Test charging voltage gt Test batteries gt Replace charger 69 13 0 Check and Repair Work on Drive Motors 13 1 General Drive motor assembled Drive unit assembled oa Chassis Drive motor 2x Stopper for carbon brush 2x Coupling lever Motor plug Main module 2x Allen screw M6x30 with lock washer Gear NOTE 9 Coupling mechanism e Depending on type the motors can be equipped with a coupling mechanism or with separate coupling levers pr NOORA ON ee Inspection Remedy e Motor vibrating emitting running noises gt Test motor replace if necessary e Motor won t start gt Test motor replace if necessary e Power brake not reacting g
108. rformed in reverse order 49 11 0 11 1 Check and Repair Work on the Chassis Front wheel suspension and wheels 3 00 4 Front wheels assembled Z A NOTE The front wheels can be equipped with 1 piece or Front wheels disassembled 2 piece rims 1 Chassis 2 Front wheel fork f wheel 3 00 4 3 Slide piece DA 42 4 Hexag head locknut M12x1 5 5 Washer 13x24x2 5 6 Adjusting washer 16x22x1 0 7 Front wheel 8 Tyre outer cover 260x85 9 Inner tube 260x85 10 Plastic rim 4 one piece 11 Rim part 1 12 Rim part 2 13 Axle bolt for one piece rim 14 Axle bolt for 2 piece rim 15 2x Ball bearing 6001 16 2x Screw M8x16 17 Bushing 16x1 75x51 2 18 Bushing 16x1 75x19 19 Bushing 15x1 2x59 1 20 Bushing 16x2x12 5 21 5x Cheese head screw M6x60 22 5x Hexagon head cap lock nut M6 23 Valve cap Inspection Wheel losing air Tyre damaged Rim damaged Screws loose Wheel bearing tight or worn out Front wheel tight or too loose Front wheel fork damaged Remedy gt Repair or replace tube gt Replace tyre gt Replace rim gt Tighten screws gt Adjust or replace wheel bearing gt Adjust clean slide bearing or replace fork if necessary gt Replace fork 50 Disassembly Front Wheels e Use suitable support e g wooden block and jack up wheelchair e Hold axle bolt 13 or 14 with a jaw spanner SW 13 and loosen 2 screws 16 completely e Pull out axle bolt 13 or 14 and detach t
109. rformed in reverse order of the disas sembly Starlock tool with caps Insertion of the caps a De gt w 2 a 32 9 8 Legrests with electrical height adjustment Legrest disassembled Legrest receptacle left Le al a 11 12 E Dy Actuator motor assembled 14 om 4 30 gt se 31 17 30 31 _ 1 Legrest receptacle 2 Seat frame 3 Hinge bolt 7 8x30 mm 4 Hinge bolt 7 8x35 mm 5 Legrest locking 6 Legrest upper part 7 Slide piece F 30x15 8 2x Washer 20x7 9x1 9 Joint plate 10 Joint plate 11 2x Screw M6x30 12 Phillips screw M6x40 13 3x Cap lock nut M6 14 Legrest elbow tube 15 Clamping piece 16 Calfplate rocker 17 Calfplate holder 18 Calfplate 19 2x Phillips screw M5x25 20 2x Nut M5 Stop 21 Dowel pin 5x20 22 Washer 8 4x17x1 6 23 Nut M8 Stop 24 Phillips screw M5x16 25 Wing screw M6x10 26 Cap SKS8 27 Actuator cpl LA22 5E 28 2x Bushing RD 10x1x22 5 29 4x Washer 8 4x17x1 6 30 2x Screw M8x35 31 2x Cap SKS8 32 Insert tube 33 Footplate tube 34 Footplate large 35 Locking screw M6x45 36 Screw M6x40 37 2x Washer RD 6x17x2 5 38 Nut M6 Hut Stop 39 Nut M6 40 2x Tapping screw 4 2x13 41 2x Slide piece SL22 42 Connection plug Inspection Remedy e Actuator motor plug or cable defective e Calfplate damaged e Screwings loose e Weldment joints or legrest upper part defective e Footplate damaged Legrest elbow tube defective e Weldment joints or insert tube defective W
110. ring 25 Remove inner brake cable 8 with covering 6 from the adjusting screw 4 Loosen counter nut and remove the adjusting screw 4 from the Bowden cable holder 23 Support the drive unit 15 loosen screws with washers 24 completely and detach Bowden cable holder 23 from the drive unit Assembly The assembly is performed in reverse order For the assembly of the inner brake cable see Assembly Bowden cable For the adjustment of the brakes see Adjusting Brakes 58 11 5 Wheel Suspension in the Rear with Shock Absorbers Support Castors Support Plates and Rear Wheel Link Wheel suspension disassembled 1 Chassis 4 Support castor 7 Washer 8 4x25x2 10 4x Lock nut M8 13 Bushing RD 12x1 8x18 16 4x Screw M6x30 with washer 19 Metal link bushing 22 Bushing RD 19x18 25 Stopper POP 1093 Inspection Support wheel damaged Support plate deformed damaged Shock absorber too soft damaged Screws loose Rear reflector damaged Rear wheel link damaged Disassembly support wheels Remove rear battery box 2 Drive unit complete 5 Shock absorber 11 11x Washer 8 4 3 Support plate short 6 Screw M8x50 8 Bushing RD 22x12 ALU 9 4x Screw M8x75 12 Bushing RD 10x0 95x31 5 14 Rear reflector not shown 15 Disengaging mechanism 17 Bowden cable holder 20 Screw M12x160 23 Nut M12 Stop 26 Washer 18 Rear wheel link 21 Support disc RD 25x4 24 Bushing RD 18x2 5x49 4 Remedy
111. ror Displays Status displays are LEDs which by blinking point to errors in the Status Displays of the Joystick Boxes wheelchair s electric system Standard The following joystick boxes have a status display e Standard joystick box e Chin control e Table and central control Table and Central Joystick Box Control Die ON OFF LEDs of these joystick boxes are arranged as status displays The causes of the errors are displayed by a flashing interval flashing code of these LEDs The remaining modules are also equipped with status displays Chin Control A flashing of these displays calls the attention to an error in the module 4 k 4 NOTE J The ACS is equipped with an error memory which can be evaluated by means of a commercially available PC The additionally required hard and software can be ordered from INVACARE Deutschland GmbH under Part No P10 076 4 4 Microswitch The microswitch is only mounted in connection with lighting module 12V Mikroswitch TUV version The switch is attached to the rear light assembly bar It switches the wheelchair off as soon as the rear light assembly bar is opened thus preventing that the wheelchair is driven with a rear light assembly bar that is not correctly closed Installing position of the microswitch 11 5 0 Modules The equipment with modules depends on the type of wheelchair The basic equipment consists of the main module with its respective joystick box
112. s between modules Requires repair by INVACARE Service Chapter 16 7 When the joystick box has just been switched on the driving mode and the status display will flash additionally Error Message 10 km h version only Emergency flasher continuously flashing Loose or defective plug connection to lighting module Chapter 18 0 Defective lighting module Defective microswitch Chapter 16 4 Chapter 16 7 20 9 0 Testing and Repair Work on the Standard Seat System 9 1 Headrest Headrest disassembled Headrest assembled 17 Na 1 Headrest complete 2 Headrest support 3 Headrest arm 4 Headrest arm bracket 5 Headrest shell 6 Headrest pad 7 Hexagon head screw M8x50 8 2x Bushing 8 5x13 9 2x Washer 8 5 10 2x Slotted head screw M4x15 11 Nut M8 self locking 12 2x Protecting caps 13 Clamping lever M6 with washer 6 5 14 Headrest holder 15 Clamp 16 4x Allen screw M5x25 17 4x Nut M5 self locking 18 Hexagon head screw M8x55 19 2x Washer 8 5 20 Nut M8 self locking 21 2x Protecting cap 22 Clamping lever M5x10 23 Backrest frame tube Inspection Remedy e Headrest pad damaged gt Replace pad e Headrest shell damaged gt Replace headrest shell e Clamping lever damaged gt Replace clamping lever e Individual parts damaged gt Replace parts e Screwings loose gt Tighten screwings Complete Dis
113. screws 8 with washers 9 completely and detach holder 4 from the back module 1 Assembly e Proceed with the assembly in reverse order 45 10 3 Armrests and side parts Side parts assembled Side part disassembled Armrest holder Clamping lever Slide piece Armrest receptacle Wing screw Receiver of armrest pad 2x Screws Side part pocket Armrest pad 10 Adapter 11 Wing Allen screws 12 Mirror 13 Mirror holder 14 Clamp with clamping screw washers and nut M6 15 Seat frame 16 Cap 17 Joystick box Inspection Remedy OMNOOAKR WD e Mirror damaged gt Replace mirror e Side part pocket damaged gt Replace side part pocket e Armrest padding damaged gt Replace armrest pad e Screwings loose gt Tighten screwings e Slide pieces or caps damaged gt Replace slide parts or caps gt e Holders or receptacles damaged Replace individual parts Disassembly complete e Detach connection plug unscrew wing or Allen screws 11 and detach joystick box 17 plus mirror 12 with holder 13 from the adapters 10 e If necessary detach cap 16 loosen nut M6 completely and detach mirror 12 with fastener clamping screw and washers 14 from the mirror holder 13 e Loosen wing screw 5 and clamping lever 2 and detach receptacle 6 with pocket 8 and pad 9 plus receptacle 4 completely from the holder 1 e f necessary loosen screws 7 and separate pad 9 with pocket
114. t Test brake replace motor if necessary e Gear emitting running noises or being gt Replace drive unit or gear blocked See chapter 11 6 13 2 Testing or replacing carbon brushes NOTE Removing carbon brushes e Worn out carbon brushes lead to a deterioration of the TN motor performance e Each motor is equipped with two carbon brushes They are located behind the lateral stoppers 4 of the motors Removing carbon brushes e Remove the stopper 4 NOTE Make sure that while you loosen the stopper same is being subjected to a slight spring pressure e Pull carbon brush from its guide 70 Testing carbon brushes e Testing length Measure the length of the carbon brush Orginal length 13 mm Wear limit 11 mm Once the carbon brush has reached the wear limit of 11 mm it must be replaced Testing the bearing surface Perform a visual inspection of the running surface t must show only slight running traces f the running surface shows deep grooves the motor collector is damaged Any further repair of the motor can only be performed by the NVACARE Service Department Installing carbon brushes e Place carbon brush into its guide see drawing NOTE Make sure that the carbon brush is not canted when introduced It must be able to move smoothly within the guide e Introduce the solder cap of the carbon brush into the guide as shown in the drawing e Screw in the stopper ff NOTE
115. tely and remove together with washer 7 and bushing 8 Detach shock absorber 5 from the chassis 1 and from the support plate 8 Remove rear reflector with holder from the shock absorber 5 Assembly The assembly is performed in reverse order NOTE e The shock absorbers are distinguished by versions 1500 Nm up to 75 kgs user s weight and 2300 Nm over 75 kgs user s weight e The rear reflectors are glued Disassembly rear wheel link Lift seating system and lock if necessary or detach seating system entirely from the chassis 1 Remove battery boxes and jack up wheelchair f necessary loosen screws washers and nuts completely and remove disengaging mechanism 15 from he motor Remove drive unit See chapter 11 6 in this respect Remove stopper 25 Loosen nut 23 completely and remove with bushings 21 and 22 Remove screw 20 with washer 26 and bushing 21 Detach rear wheel link 18 from the chassis 1 f necessary remove bushings 19 and 24 from the link Assembly The assembly is performed in reverse order 60 11 6 Driving Unit complete Driving unit assembled Driving unit disassembled 1 Chassis 2 Driving unit complete 3 Rear wheel link 4 Gear 5 Drive motor 6 Connection plug 7 2x Screw M6x30 8 4x Screw M6x30 and washer 9 Bowden cable holder 10 Wheel hub 11 Lock nut M12x1 5 12 Disc 13 13 Feather key 6x6x40 14 Screw M8x75 with washer 15 Lock nut M8 with
116. the joystick box will flash additionally The voltage of an individual battery at full charge and room temperature must amount to approx 20 22 C 14 0 2 V 68 Charging fully discharged batteries If the voltage of a battery measures less than 9 5 V the battery is fully discharged For charging fully discharged batteries proceed as follows e Remove battery boxes and open See chapter 12 1 in this respect e Precharge each battery individually while simultaneously measuring the charging voltage e Precharge up to 10 V with an unregulated charger After that stop charging with the unregulated charger A CAUTION e The batteries are not permitted to lie on their sides or up end during the charging process e Do not fully charge batteries with the unregulated charger This could destroy the batteries gt Danger of Explosion lt Close battery boxes and re install e Fully charge battery with the INVACARE charger via the charging socket of the joystick box The charging process should last at least 48 hours 12 3 Battery Charger NOTE Also observe the instructions for charging the batteries e inthe User s Manual of the charger e on the front and back of the charger Performance Test e Plug in the charger mains plug Red LED MAINS ON illuminated e Disconnect again the mains plug from the mains e Plug the charging plug into the charging socket of the joystick box and then
117. tor to be replaced e Remove the disengaging lever e Support drive motor with your hand loosen completely two fastening screws hexagon socket SW 5 mm with lock washers and detach drive motor NOTE e Do not damage lose plastic bushing and starting damper Assembly drive motor e Push plastic bushing on the motor output shaft e Place starting damper on the gear input shaft Make sure that the driver of the starting damper interlocks with the gear input shaft e Fasten the motor to the gear by means of the two fastening screws hexagon socket SW 5mm and the two lock washers The following is to be observed The motor cables must point upwards to the frame of the chassis The slot of the motor output shaft must be in alignment with the driver of the starting damper NOTE e If key and slot are not aligned exactly turn the driving wheel gear output shaft until the slot locks into place and the motor is located exactly in front of the gear e Fasten screws hand tight Do not overturn Motor fastening Locking screw M5 x 10 SW 8 mm Disengaging Lever D Fastening Screw Hexagon Socket M6 x 30 SW 5 mm Motor Output Shaft a Plastic Bushing Gear Input Shaft J Starting Damper Driver 73 NOTE Position of Disengaging Lever e The following two steps apply only to motors with a coupling mechanism e Lock the motor by turning the shaft left by means of a suitable t
118. ts 8 and 4 respectively if appropriate together with limit stop plate 6 from the seat frame 1 Assembly e The assembly is performed in reverse order 43 Disassembly Seat Recline Adjustment complete Only in electrical legrest adjustment Remove connection plugs from the sockets in front below at the battery box retainer 28 Release legrest locking device 30 and detach legrests 31 Release quick release bolt 24 above at the seat recline adjustment 19 or at the actuator 29 and remove ogether with washers 23 if necessary Only in actuator Remove connection plug in front below at the battery box retainer 28 Loosen nut 27 completely and remove together with washer 26 from the screw 25 Support the actuator 29 or the seat recline adjustment device 19 with your hand remove screw 25 with washer 26 and detach actuator 29 or adjustment device 19 from the seat frame 1 Only in actuator Loosen nut M8 at the connecting rod and detach together with washer Detach screw M8 together with washer and remove the top of the connecting rod from the connecting rod of the actuator Only in manual adjustment Unscrew threaded rods 20 and 21 from the adjustment device 19 If necessary press bushing 22 out of the threaded rod 21 Assembly The assembly is performed in reverse order Disassembly Seat Frame complete f necessary remove headrest See chapter 9 1 in th
119. ull inner brake cable 8 out of the brake housing 10 and 11 and detach from the brake lever 13 Assembly Place inner brake cable 8 over the brake lever 13 in the brake housing 10 and 11 and pull through the adjusting screws 4 in such a way that the free length to the left rear wheel amounts to approx 700 mm and o the right rear wheel to approx 1000 mm Pull Bowden cable covering 6 over the inner brake cable 8 until it ends level with the adjusting screw 4 at e brake housing 10 and 11 h Pull Bowden cable covering 7 over the inner brake cable 8 until it ends level with the adjusting screw 4 at he brake housing 10 and 11 ount brake housing with brake housing holder 14 to the armrest Pull inner brake cable 8 through the adjusting screws 4 at the lower part of the Bowden cable holders 23 in such a way that the coverings 6 and 7 end level with the adjusting screws Attach compression springs 25 pull inner brake cable 8 through the cable locking screws 21 and for the present tighten both locking screws Squeeze caps 9 onto both ends of the inner brake cable 8 Adjusting the brakes Loosen locking screws 21 slightly on each side one after the other and pull inner brake cable up to the point where the distance between the locking screw 21 and the adjusting screw 4 at the Bowden cable holder 23 amounts to approx 85 mm Fasten the inner brake cable 8 with the locki
120. unting Flasher Glass Flasher glass Slot in flasher casing 81 15 5 Disassembling Completely Headlight Flasher and Lamp Holder Front Lighting assembled Headlight Front Lighting disassembled 6 lt 4 1 Lamp holder 2 Flasher complete 3 Flasher complete 4 Connection and ground cable resp 5 Screw M6x25 with washer 6 Rubber bushing with washer 7 Tapping screw 2 9x15 8 Tapping screw 3 5x10 9 Screw M5x8 10 Cable binder 11 Mirror with lamp base 12 Chassis 13 Headlight glass with mirror 14 Headlight casing 15 Lock nut M6 and washers 16 Flasher glass 17 Flasher casing 18 Flasher bulb NOTE e The headlight lamp is provided with voltage via the lampholder positive pole and a separate ground cable The lamp holder contacts the contact spring in the headlight casing The ground cable is clamped into the lamp base e The flasher lamp is provided with voltage via a twin wire cable The wires are soldered to the lamp base CAUTION AN When disassembling the headlight flasher and lamp holder the batteries must be removed first gt Danger of Short Circuit Fire and Burning lt Disassembling headlight e Loosen tapping screw 7 completely and detach headlight glass 13 e Remove lamp base not shown from the headlight glass 13 and unscrew the lamp not shown f required pull ground cable 4 from the lamp base and remove base e Loosen nut 15 completely and detach headlight casing 14 with was
121. uts 22 detach screw 21 and four levers 18 19 and 20 from the brackets 17 e Loosen two Phillips screws 24 and remove guide pieces 15 and 16 from the brackets 17 e f necessary remove slide pieces 11 from the guide pieces 15 and 16 by means a screwdriver Assembly e The assembly is performed in the reverse order NOTE When assembling make sure that the lever with the pressure piece 20 is installed in such a way that the guide piece 16 can lock into place when swivelled Disassembly joystick box holder for attendant e Detach joystick box 3 as described above Recaro seat e Loosen screw at push handle and detach holder 27 Standard Comfort seats e Loosen nuts 30 and detach holder 26 completely with clamps 28 and screws 29 from the backrest e f necessary remove slide piece 11 by means of a Screw driver Assembly e The assembly is performed in the reverse order 93 17 2 Joystick Box for Attendant Joystick Box with Fixing Devices disassembled Joystick box for attendant BUS cable Holder for RECARO seat 2x Clamping piece 4x Screw M6x35 4x Lock nut M6 Screw M6x16 Washer 6 4x12 5x1 6 9 Cap lock nut M6 10 Slide piece SL 22 11 2x Wing screw M6x10 12 Mounting angle 13 Holding plate ON OAR WDY 6 Na 10 s Inspection Remedy S NOTE e Check electrical functions See chapter 16 2 e In the Recaro seat the joystick box BUS plug defective gt Re
122. ve the BUS plug of the connection cable from the main module to the 24 V 12 V lighting module or to the lighting adjustment module respectively e Measure the voltage existing at the contacts of the power supply see drawing It must amount to at least 19 volts min 19 volts CAUTION AN Avoid by all means to bridge the contacts of the voltage supply gt Danger of Fire and Burning lt Malfunction Chapter No voltage at the Fuse in main module blown contacts Interrupt testing and resume testing after a few seconds BUS cable defective Check replace BUS cable 18 0 Main module defective Check replace main module 16 3 17 0 Power supply to main module Check power supply 12 0 interrupted Check master fuse 50 A 12 0 Voltage below 19 V Battery fully discharged Pre charge battery 12 2 Replace battery 12 0 88 16 5 Testing Additional Power Supply of the 12 V Lighting Module TUV Version Main Module and 12 V Lighting Module NOTE Plug vonnection e f required test model first according to the description given gt in chapter 16 4 Testing Preparations e Remove battery boxes See chapter 12 1 in this respect e Remove splash protection See chapter 11 7 in this respect e Install battery boxes Additional Cable Testing Voltage e Detach the plug connection from the battery cable to the a mm 9 12 V lighting modul
123. verse order NOTE e The reflectors are fastened with double sided adhesive tape e Before attaching new reflectors remove first the old adhesive tape completely A CAUTION Do not use any solvents that might attack the paintwork 64 11 10 Lighting Bar Bumping Bar Lighting bar assembled Lighting bar bumper bar disassembled Chassis Rear covering Lighting bar Rear lights Incandescent bulbs Cable harness Cable clips Plug assembly with anti interference capacitors 4x Tapping screw 3 9x15 5 4x Phillips screw M5x20 with lock nut M5 11 2x Screws M6x20 with lock nuts M6 and 4 washers 18x6 4x1 5 DOAN DAA WD I 12 2x Screws M8x20 with washers 13 Bumper bar 14 Microswitch Inspection Remedy e Bumper bar damaged gt Replace bumper bar e Screwings loose gt Tighten screws e Rear covering damaged gt Replace rear covering e Lighting bar damaged gt Replace lighting bar Disassembly bumping bar with rear covering e Remove rear battery and fold rear covering 2 upward e Loosen screws with washers 11 completely and detach together with bumper bar 13 e Loosen screws with washers 12 completely and detach together with rear covering 2 Assembly e The assembly is performed in the reverse order Disassembly lighting bar with rear covering e Remove rear battery and fold rear covering 2 upward e Separate plug connections 8 and release cable harness 6 from the cable
124. vice of lighting system and warning flashers Module and Cable Equipment to control unit Power Module mo Lighting Actuator E aic R a lt Y Joystick Box a p 0 hs a Battery Cable Module and Cable Equipment to Joystick Box Power Module f Lighting Module 12 V Ps aan KK 2 Micro ee switch Lighting Cable 12V Additional Power Supply 13 5 6 Wheelchair Equipment with 12 V Lighting T V version with Actuators Module and Cable Equipment Modules e Main module power module eee Main Moduleer 12 V Lighting Module e Lighting actuator module to to combined lighting actuator module Control Unit Joystick Bo e 12 V lighting module t e Joystick box e Control unit for actuators Va in older joystick boxes adjustment options cannot be controlled via the joystick box e Microswitch Cables e BUS cable to joystick box EUS Cable Om power Maule Actuators Battery 12V Gn lighting actuator module Cable QNung Sich BUS cable to lighting module i Cable Battery cable Additional Power Supply e Cable to microswitch e Cable for additional power supply e 12V lighting cable e Cable for actuators Additional Power Supply Serves to keep up the power supply of the lighting module 12 V via the ACS BUS cable in case of power failure thus ensuring full service of lighting system and warning flashers 5 7 Wheelchair Equipment with electrically adjustable REC
125. wire covering defective Compression spring defective Flat link in fork shaped pce tight or defective Fork shaped piece defective Quick release bolt defective Adjusting lever defective Rep Rep Rep Rep Rep Rep Rep gt gt gt gt gt gt gt gt gt gt gt gt gt gt ace Bowden wire ace support bracket Readjust Bowden wire ace Bowden wire covering ace compression spring Loosen or replace flat link ace fork shaped piece ace quick release bolt ace adjusting lever 38 Disassembly complete NOTE e It is not absolutely necessary to follow each and every operational step indicated here The compression spring and the Bowden wire for instance can be mounted or dismounted without having first to remove the entire backframe e Mark or write down the exact locations of the locking screws and counter nuts 16 before detaching the Bowden wire 22 the Bowden covering 23 e The Bowden wire 22 is provided with final caps 24 on both ends 24 which might have to be pinched off before the disassembly The adjusting lever 28 is housed in the seat frame and locked with a starlock cap 35 To detach the lever the seat cushion and the seat plate should be removed first See chapt 9 12 in this respect lf there is a headrest then remove the headrest first See chapter 9 1 in this respect Remove quick release bolt 12 at the lower part o
126. wo Phillips screws 24 and separate calfplate holder 17 from calfplate 18 Remove cap 26 loosen nut 23 and detach together with washer 22 Detach calfplate holder 17 f Remove dowel pin 21 and detach calfplate rocker 16 from clamping piece 15 Loosen Phillios screw 12 and nut 13 completely and detach legrest elbow tube 14 with washers 8 from joint plates 9 and 10 Loosen two screws 11 and nuts 13 completely and detach joint plates 9 and 10 from legrest upper part 6 If necessary remove slide pieces 7 and 41 om the calfplate rocker 16 NOTE The slide pieces are inserted They can be lifted up with a suitable tool such as a screwdriver Assembly The assembly is performed in the reverse order 34 9 9 Inspection Back Element anatomical in Standard and Comfort versions Back element disassembled Back element assembled 5 e am EA i K b D Aaa J Nove The back element can be equipped with back padding 1 or with back belting 8 1 Back padding anatomical 2 Tapping screw with cap 3 Back belting 4 Tapping screw with cap 5 Back frame tube 6 Back element holder 7 Clamping lever M8x10 8 2x Hexagon screw M8x50 9 4x Washer 21x8 3x1 5 10 Lock nut M8 11 4x Caps SKS8 12 Safety belt 13 Seat frame Remedy Back padding damaged Back belt damaged Safety belt damaged Screwings loose Weldment joints oder back frame tube defective
127. y e Grip lighting bar at its center and turn upwards e Hold battery boxes one after the other by the locking belt 9 support with your other hand and pull backwards from the battery frame e Loosen the locking belt 9 and take off the lid 1 e Loosen the screwings first the negative pole of the pole binders 6 and 7 and detach binders with fuse plus the lid from the battery and the box e Loosen the nuts and washers at the external 2 and internal contacts 5 inside the lid 1 and detach the cable harness completely from the lid 1 e Lift battery 8 from the box with the aid of the locking belt 9 e Pull the locking belt 9 out of the box Assembly e Follow the steps in reverse order 12 2 Charging the Batteries A CAUTION INVACARE Charger e Careful when testing charging Do not bridge the battery poles gt Danger of Short Circuit lt NOTE Also observe the information on battery charging provided e in the User s Manual of the STORM e inthe User s Manual of the charger e on the front and back of the charger S d Charging Cable J For care and maintenance of the battery s mechanical Mains Cable J i A components see chapter 12 1 s p Inspection Remedy Joystick Box e Status display at joystick box blinking 7x fully discharged gt Measure voltage of battery Charging Plug e Status display at joystick box 2
128. y to the positive pole of the light bulb 4 e Fix the headlight glass by means of the tapping screw 2 NOTE The contact fits correctly if a slight pressure must be applied when inserting the headlight glass 1 80 15 4 Disassembly Test of Front Flasher Disassembly e Loosen the fastening screw and remove the flasher glass e Unlock the light bulb by pressuring down slightly and turning by 1 8th rotation to the left e Pull the light bulb from the base Testing e Test by means of a multimeter the voltage existing between the contact in the flasher casing pole and the lamp base pole Voltage in 6 km h wheelchair 24V 10 km h wheelchair abroad 24V 10 km h wheelchair Germany 12V CAUTION Nro bridging the poles by all means gt Danger of Fire and Buring lt Montage e Insert the new light bulb Type of bulb 6 km h wheelchair 10 km h wheelchair abroad 10 km h wheelchair Germany 24 V 10 watts 24 V 10 watts 12 V 10 watts e Lock the light bulb by pressing down slightly and turning by 1 8th rotation to the right e Mount the flasher glass e Fix the flasher glass by means of the fastening screw NOTE J Make sure when mounting the flasher glass that the tab on the side of the glass interlocks with the slot of the flasher casing Removing Flasher Glass Bn Fastening screw Removing Light Bulb Testing Voltage Flasher casing Lamp base Mo
129. ystick box support bar 11 Slide piece 15x15 12 Guard bow ACS joystick box 14 Joystick box swivable 15 Guide piece 1 17 2x Bracket 18 2x lever 1 20 1x Lever 2 with pressure piece resilient 8mm 22 4x Lock nut M5 23 2x Set screw M6x6 25 Magnetic key 26 Holder for attendant 28 2x Clamping piece 29 4x Screw M6x35 Joystick box holding devices for attendant 92 Disassembly joystick box Detach BUS cable from 4 joystick box 3 e Loosen set screw 23 at joystick box holder 14 and wing screw 10 at joystick box stay bar 9 and detach joystick box 3 e Loosen four screws 8 completely and remove together with holder 5 6 or 7 from the joystick box 8 f required loosen two screws and detach guard bow 12 from the joystick box 3 Assembly e The assembly is performed in reverse order Disassembly joystick box support bar and joystick box receptacle e Detach joystick box 3 as described above e Loosen set screw 23 at the armrest 1 and 2 respect and detach joystick box support bar e f necessary remove slide piece 11 by means of a screwdriver Only in RECARO seat e Loosen wing screw 10 at armrest 2 and detach joystick box receptacle 13 Assembly e For the assembly proceed in the reverse order Disassembly joystick box holder swivable Detach joystick box 3 as described above e Loosen set screw 23 at the armrest 1 and 2 respect and detach joystick box holder e Loosen four n

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