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Invacare FDX Service Manual

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Invacare® FDX

SERVICE MANUAL

These instructions contain information about:
testing work
repair work
Edition:14.07.10

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Summary of Contents for Invacare FDX

  • Page 1: Service Manual

    Invacare® FDX SERVICE MANUAL These instructions contain information about: testing work repair work Edition:14.07.10...
  • Page 2 +34 - (0) 972 - 49 32 20 contactsp@invacare.com Poligon Industrial de Celrà 17460 Celrà (Girona) WWW: www.invacare.es ESPAÑA +33 - (0)247 - 62 64 66 Invacare® Poirier SAS Route de St Roch Fax: +33 - (0)247 - 42 12 24 contactfr@invacare.com F-37230 Fondettes WWW: www.invacare.fr France Invacare®...
  • Page 3 +39 - 0445 - 38 00 59 Invacare Mecc San s.r.l. Fax: +39 - 0445 - 38 00 34 Via Dei Pini, 62 italia@invacare.com I - 36016 Thiene (VI) WWW: www.invacare.it ITALIA Invacare Ireland Ltd. +353 - 18 10 70 84...
  • Page 4 S-163 91 Spånga WWW: www.invacare.se Sverige MÖLNDAL Tillverkare: +46 - (0) 31 – 86 36 00 Invacare Deutschland GmbH Fax: +46 - (0) 31 – 86 36 06 Kleiststraße 49 ginvacare@invacare.com D-32457 Porta Westfalica Deutschland LANDSKRONA +46 - (0) 418 – 285 40 Fax: +46 - (0) 418 –...

  • Page 5: Table Of Contents

    Table of contents Chapter Page INTRODUCTION General information Notes on transport Definition and representation of information and safety information in this manual Hazard symbols and symbols used Images in this manual SAFETY AND FITTING INSTRUCTIONS Before any inspection or repair work Personal safety equipment General safety information and information about fitting / removal TIGHTENING TORQUES...
  • Page 6 TEST PROCEDURES Testing the motor Testing the electro-mechanical parking brake REPAIR WORK Covers 8.1.1 Open front cover 8.1.2 Opening the rear cover 8.1.3 Opening the lateral cover 8.1.4 Opening the cover of the rear wheel cantilever arm Electronic modules 8.2.1 Replacing remotes 8.2.2 Replacing electronic modules...
  • Page 7 Centre-mounted legrest (electric & manual) 8.8.1 Replacing the manually operated centre-mounted legrest 8.8.2 Replacing the electrically operated centre-mounted legrest 8.8.3 Replacing an electric legrest actuator 8.8.4 Replacing the calf plate on the centre-mounted legrest (electric & manual) 8.8.5 Replacing the foot plate on the centre-mounted legrest (electric & manual) Replacing the restraining belt 8.10 Replacing the anti-tipper wheels...

  • Page 8: Introduction

    ● Alterations to the mobility aid which occur as a result of incorrectly or improperly executed maintenance or overhaul work lead to the exclusion of all liability on the side of INVACARE. ● If you have any problems or questions please contact Invacare® Service.

  • Page 9: Definition And Representation Of Information And Safety Information In This Manual

    1.3 Definition and representation of information and safety information in this manual Different types of information and signal words are used throughout this manual. HAZARD! The signal word "HAZARD!" refers to immediate hazards. ● The following lines in italics refer to actions which serve to avoid such hazards. WARNING! The signal word "WARNING!"...

  • Page 10: Hazard Symbols And Symbols Used

    1.4 Hazard symbols and symbols used Different types of hazard symbols and symbols are used throughout this manual. General hazards This symbol warns you of general hazards! ● Always follow the instructions to avoid injury to the user or damage to the product! BURN HAZARD! This symbol warns you of the danger of chemical burns, for example due to the discharge of battery acids!

  • Page 11: Images In This Manual

    1.5 Images in this manual The detailed images in this manual are given digits to identify various components. Component numbers in text and operational instructions always relate to the image directly above.

  • Page 12: Safety And Fitting Instructions

    2 Safety and fitting instructions These safety instructions are intended to prevent accidents at work, and it is imperative that they are observed. 2.1 Before any inspection or repair work ● Read and observe this repair manual and the associated operating manual! ●...
  • Page 13 Any changes to the drive program can affect the driving characteristics and the tipping stability of the vehicle! ● Changes to the drive program may only be carried out by trained Invacare® specialist dealers! ● Invacare® supplies all mobility aids with a standard drive program ex-works. Invacare® can...

  • Page 14: Tightening Torques

    3 Tightening torques The tightening torques stated in the following list are based on the thread diameter for the nuts and bolts for which no specific values have been determined. All values assume dry and de-greased threads. Thread Tightening torque 3 Nm 6 Nm 10 Nm...

  • Page 15: Arrangement Of Sub-Assemblies And Components

    Arrangement of sub-assemblies and components Overview In the rear under the seat: Electronic modules The electronic modules are located under the rear cover: (1) – Electronic module (2) – Actuator module (optional) (3) – Lighting circuit board (optional & not shown in the illustration) The electronic modules that are installed are described in chapter 4.2.
  • Page 16 On the right, next to the spring seat: (1) – G-Trac module (optional)

  • Page 17: Electronic Modules

    Electronic modules Various different types of electronic modules can be installed in the wheelchair. Before you connect components of the wheelchair such as adjustment motors or actuators to the electronic module, make sure you know exactly which electronic module is installed. The following table provides an overview.

  • Page 18: Acs Ii Pmb70 / Acs Ii Pmb70L Electronic Module

    4.2.1 ACS II PMB70 / ACS II PMB70L electronic module Connections 1) Battery 24V 2) Bus cable (to remote or ACT) 3) Bus cable (to remote or ACT) 4) Motor M1 5) Light 6) Motor M2 4.2.2 ACS II PMA90L electronic module Connections 1) Battery 24V 2) Cable to G-Trac module (GYRO)

  • Page 19: Actuator Module Act

    4.2.3.2 Actuator module ACT 4 Connections 1) ACI* 2) Bus cable (to remote or electronic module) 3) Bus cable (to remote or electronic module) 4) Actuator - channel 4 5) Actuator - channel 3 6) Actuator - channel 2 7) Actuator - channel 1 * The ACI connection serves to limit the movement of an actuator or to reduce velocity.

  • Page 20: Remotes

    Remotes Various types of remotes can be installed on the wheelchair. Before you connect components of the wheelchair such as adjustment motors or actuators, make sure you know exactly which remote is installed. The following table provides an overview. Remotes Designations Remarks REM G90A...
  • Page 21 Remotes Designations Remarks REM 550 Can be connected to - ACS II PMB70 - ACS II PMB70L - ACS PMA90LG power modules.

  • Page 22: Maintenance Plan (Once A Year)

    Maintenance plan (once a year) Component Check for Measures Remarks ● Damage to the ● If the belt is See chapter 8.9 Restraining belt restraining belt damaged, replace ● Function of the belt ● If the belt is See chapter 8.9 buckle damaged, replace ●...
  • Page 23 Component Check for Measures Remarks ● Motor brake check ● Check the motor See chapter 7.2 Brakes brake ● Check welding ● Tighten, replace if See chapter 8.8 & Legrests seams, locking necessary the User Guide devices, screws and foot plates ●...

  • Page 24: Operational Faults

    The tables for rectification of operational faults listed in the following chapters are only an excerpt from the original manufacturer's manuals. You can obtain the original manuals from Invacare®. If you have problems with the mobility aid, please proceed as follows: ●...

  • Page 25: Drive Fault Diagnosis

    6.1 Drive fault diagnosis PROBLEM OTHER POSSIBLE SOLUTION Documentation SYMPTOMS CAUSE Mobility aid The remote Drive motors Engage drive See operating manual will not status display disengaged motors start illuminates normally and displays blink code 5/6. Remote status Batteries Replace batteries See chapter 8.4.1.
  • Page 26 PROBLEM OTHER POSSIBLE SOLUTION Documentation SYMPTOMS CAUSE None High motor Stop journey and Motor runs but loses loading causes allow electronics electronics to cool down. power module to decrease voltage None High motor Leave mobility aid Motors stop and do not loading causes switched on and electronics...
  • Page 27 PROBLEM OTHER POSSIBLE SOLUTION Documentation SYMPTOMS CAUSE Motors do None Bad connections Check all cabling. See chapter 8.4.5. not run Fuse burnt out Check cabling and See chapters 8.4.5 and replace fuse 8.4.4 Batteries Replace batteries See chapter 8.4.1. defective Cabling to check cabling See chapter 8.4.5.
  • Page 28 PROBLEM OTHER POSSIBLE SOLUTION Documentation SYMPTOMS CAUSE None Drive shaft Check drive shaft, See chapters 8.13.1 and Irregular running movable or bent replace 8.13.3 transmission if defective. None Parts lost Reattach parts Parts lost once found. Batteries None Fuse burnt out, Check cabling and See chapters 8.4.5 and not being...

  • Page 29: Diagnosis Of Charging Device Faults

    Defective mains supply cable. Check the mains supply cable. Replace damaged cables or send the battery charger to Invacare® Service for repair. LEDs are burnt out Send the battery charger to Invacare® Service for repair. An internal fuse might be burnt Send the battery charger to out.

  • Page 30: Test Procedures

    7 Test procedures 7.1 Testing the motor Requirements: ● Phillips screwdriver size 2 ● digital multimeter with resistance measurement ● Remove the rear panel as described in Chapter 8.1.2. ● Pull the motor plug (1) out of the electronics module. ●...

  • Page 31: Testing The Electro-Mechanical Parking Brake

    Pull the motor plug (1) out of the electronics module. ● Connect the digital multimeter to the adjacent central motor plug contacts (3) and measure the resistance between the contacts. ● If there is a defect, replace the motor and send it to Invacare® Service for inspection or repair.
  • Page 32 Note A resistance of between 40 and 80 ohms indicates an intact brake. A resistance of 0 ohms or a very high resistance (mega-ohms or infinity) indicates a short-circuit, a bad connection or a defective brake. CAUTION! Material damage can be caused to the electronics module due to short-circuits in the electro-mechanical brake.

  • Page 33: Repair Work

    Repair Work Covers 8.1.1 Open front cover Removing the front cover: ● Remove the legrests. ● Loosen and remove both of the knurled head screws (1). ● Press the front cover (2) slightly upward, then pull the cover forward and off. Installing the front cover: ●...

  • Page 34: Opening The Rear Cover

    8.1.2 Opening the rear cover Removing the rear cover: ● Loosen and remove both of the knurled head screws (1). ● Remove the rear cover (2). Installing the rear cover: ● Assemble the parts in reverse order. ● Tighten both knurled head screws hand-tight.

  • Page 35: Opening The Lateral Cover

    8.1.3 Opening the lateral cover Requirements: ● 10 mm socket wrench ● 6 mm Allen key ● Two oblong wooden blocks, at least 14 x 14 x 30 cm Removing the lateral cover: ● Remove the drive wheel, as described in chapter 8.12.1. ●...
  • Page 36 Installing the lateral cover: ● Connect the plug-in connections if there are tail lights installed in the lateral cover. Make sure that the markings (1 = red tail light) and (2 = yellow flasher) on the power supply cable and on the tail light plug-in connection are aligned with each other.
  • Page 37 ● Push the cover from the side between the seat and the chassis. ● Position both screws (1) including the washers and tighten the screws hand-tight.

  • Page 38: Opening The Cover Of The Rear Wheel Cantilever Arm

    8.1.4 Opening the cover of the rear wheel cantilever arm Requirements: ● 4 mm Allen key Removing the rear cover: ● Use the 4 mm Allen key to loosen and remove the hexagon socket head screw (1). ● Pull the cover up in the rear and remove it. The cover is held in place by additional Velcro fasteners.

  • Page 39: Electronic Modules

    Alterations to the drive programme must only be carried out by authorised Invacare® dealers! ● Invacare® can only assume a warranty for the safe vehicle handling of the wheelchair – in particular tipping stability - for this standard, unaltered drive programme! Note All electronic modules are supplied with a standard drive programme.
  • Page 40 Uninstalling electronic modules: ● Remove the rear cover, as described in chapter 8.1.2. ● Take exact note of the positions of all cables and the sockets that they are connected to. Mark the connectors and sockets or take a photograph with a digital camera. ●...
  • Page 41 ● Use the 8 mm socket wrench to loosen and remove the nuts (1). ● Remove the actuator module together with the mounting plate (2). ● If the actuator module is to be replaced: Use the 7 mm socket wrench and a Phillips screwdriver to loosen and remove the nuts (3). ●...

  • Page 42: Replacing The G-Trac Module

    8.2.3 Replacing the G-Trac module Requirements: ● 10 mm socket wrench ● Side cutting pliers ● Cable ties Uninstalling the G-Trac module: ● Switch the electronics of the wheelchair OFF. ● Remove the front, rear and right lateral covers, as described in chapter 8.1.1, 8.1.2 and 8.1.3. The G-Trac module is located on the spring-seat of the right-hand spring.
  • Page 43 ● Replace the G-Trac module. Installing the G-Trac module: ● Assemble the parts in reverse order. ● Reconnect all cable connectors to their former positions. ● The G-Trac module must be installed with the cable pointing upwards. ● The last step is to test all functions of the vehicle.

  • Page 44: Drive Program Selection After Component Replacement

    8.2.4 Drive program selection after component replacement The drive program is saved in the REM remote, and also in the DX, ACS or ACS II electronics module. If one of these two components is replaced, the system must be told which of the components has not been replaced so that it knows which contains the current controller profile.

  • Page 45: Profile Selection With Remote Rem A Or Rem B

    8.2.4.2 Profile selection with remote REM A or REM B ● Plug the plug into the remote or the ACS II controller. ● LEDs (1) and (4) blink. ● Use the bottom rocker switch (5) to select where the required controller profile is saved. LED 1 = remote LED 4 = ACS II control system ●...

  • Page 46: Profile Selection With Remote Rem 550

    8.2.4.3 Profile selection with remote REM 550 ● Plug the plug into the remote or the ACS II controller. ● The display (2) shows that you need to select a profile. ● Use the bottom rocker switch (3) to select where the required controller profile is saved. I = remote II = electronics module ●...

  • Page 47: Updating The Driving Program

    ● Alterations to the drive program must only be carried out by trained Invacare®-dealers! ● Invacare® can only assume a warranty for the safe vehicle handling of the wheelchair – in particular tipping stability - for unaltered standard drive programs! Requirements: ●...

  • Page 48: Batteries, Cables & Battery Chargers

    Batteries, cables & battery chargers 8.4.1 Removing the batteries CAUTION: Danger of injury and danger of damage to property if the batteries are handled incorrectly! ● The installation of new batteries may only be performed by authorised technicians. ● Pay attention to the warning notes on the batteries. ●...
  • Page 49 ● Disconnect the plug-in connection (1) of the front battery (2). ● Remove the rear cover, as described in chapter 8.1.2. ● Take exact note of the positions of all cables and the sockets that they are connected to. Mark the connectors and sockets or take a photograph with a digital camera.
  • Page 50 ● Disconnect the plug-in connection (1) of the rear battery (2). ● Disconnect the battery cable from the electronic module. ● Lift the electronic module bracket up and remove it. Pull the bracket towards the rear and let it hang over the back end of the wheelchair. ●...

  • Page 51: Replacing Batteries / Replacing Battery Cables

    8.4.2 Replacing batteries / replacing battery cables Note To replace the fuse, the battery cable with the fuse attached to it must be replaced. CAUTION: Danger of injury and danger of damage to property if the batteries are handled incorrectly! ●...
  • Page 52 Uninstalling batteries/battery cables: ● Remove the batteries, as described in chapter 8.4.1. Positive terminal (+): ● Remove the cable ties (1) with side cutting pliers. ● Lift the battery terminal cap (2) off and move it up the cable and out of the way. ●...

  • Page 53: How To Handle Damaged Batteries Correctly

    Only ever transport damaged batteries in an appropriate acid-resistant container. ● Wash all objects that have come into contact with acid with lots of water. Disposing of dead or damaged batteries correctly Dead or damaged batteries can be given back to your dealer or directly to Invacare®.

  • Page 54: Replacing The Main Fuse

    8.4.4 Replacing the main fuse Note To replace the fuse, the battery cable with the fuse attached to it must be replaced. ● Replace the battery cables, as described in chapter 8.4.2.

  • Page 55: Checking The Cables

    8.4.5 Checking the cables Requirements: ● Side cutting pliers ● Cable ties ● Remove the covers, disconnect the battery plug connections and pull the batteries out of the battery compartment, as described in chapter 8.4.1. ● Check the fuse cable (1), the battery cable (2) and the battery connections (3) for visible damage and pinches.
  • Page 56 ● Check all cables for visible damage and crushing. Replace damaged cables. ● Pull on each plug (1) carefully. The plug must not come out of the socket. ● If a plug is loose, apply slight pressure to push the plug into the socket. The plug must snap in place securely.

  • Page 57: Lighting System

    Lighting system 8.5.1 Replacing light bulbs in the front (conventional lighting system) Requirements: ● Phillips screwdriver size 2 ● Loosen the concealed Phillips head screw on the back of the head lamp / turn indicator combination. ● Remove the transparent plastic cover. ●...

  • Page 58: Replacing The Complete Head Lamp Assembly (Conventional Lighting System)

    8.5.3 Replacing the complete head lamp assembly (conventional lighting system) Requirements: ● Phillips screwdriver size 2 ● Side cutting pliers ● Cable ties Uninstalling head lamps: ● Remove the rear cover, as described in chapter 8.1.2. ● Take exact note of the positions of all cables and the sockets (1) that they are connected to. Mark the connectors and sockets or take a photograph with a digital camera.
  • Page 59 ● Loosen both of the cap nuts (1) with an 8 mm open-end wrench and remove the head lamp with the bracket from the rubber mounting. ● Not shown in the illustration are two Phillips head screws, with which the head lamp is secured to the bracket.

  • Page 60: Replacing The Head Lamps Completely (Led Lighting System)

    8.5.4 Replacing the head lamps completely (LED lighting system) Requirements: ● 3 mm Allen key ● Side cutting pliers ● Cable ties Uninstalling head lamps: ● Remove the rear cover, as described in chapter 8.1.2. ● Take exact note of the positions of all cables and the sockets (1) that they are connected to. Mark the connectors and sockets or take a photograph with a digital camera.
  • Page 61 Installing head lamps: ● Assemble all parts again in reverse order. ● Install the cables carefully and secure them with cable ties. Make sure that the cables not are not pinched or stretched. ● Tighten both screws hand-tight. ● Check all vehicle functions. ●...

  • Page 62: Replacing The Head Lamp Bracket (Conventional Lighting System)

    8.5.5 Replacing the head lamp bracket (conventional lighting system) Requirements: ● Phillips screwdriver size 2 ● 8 mm socket wrench Uninstalling the head lamp bracket: ● Loosen both of the cap nuts (1) with an 8 mm socket wrench and remove the head lamp with the bracket from the rubber mounting.

  • Page 63: Replacing A Light Bulb In The Rear (Conventional Lighting System)

    8.5.6 Replacing a light bulb in the rear (conventional lighting system) Requirements: ● Phillips screwdriver size 2 ● Loosen the Phillips head screw in the transparent cover of the tail lamp / turn indicator combination. ● Remove the transparent plastic cover. ●...

  • Page 64: Replacing The Complete Tail Lamp Assembly (Conventional Lighting System)

    8.5.8 Replacing the complete tail lamp assembly (conventional lighting system) Requirements: ● 8 mm socket wrench Uninstalling the tail lamp: ● Remove the front cover and the rear covers, as described in chapters 8.1.1 and 8.1.2. ● Take exact note of the positions of all cables and the sockets (1) that they are connected to. Mark the connectors and sockets or take a photograph with a digital camera.
  • Page 65 ● Remove the nuts together with the washers. ● Pull the tail lamp (1) towards the rear and remove from the tail lamp bracket (3). Installing the tail lamp: ● Assemble all parts again in reverse order. ● Tighten both screws hand-tight. ●...

  • Page 66: Replacing The Tail Lamp Bracket (Conventional Lighting System)

    8.5.9 Replacing the tail lamp bracket (conventional lighting system) Requirements: ● 3 mm Allen key Uninstalling the head lamp bracket: ● Remove the front, rear and lateral covers, as described in chapter 8.1.1, 8.1.2 and 8.1.3. ● Uninstall the complete tail lamp assembly, as described in chapter 8.5.8. ●...

  • Page 67: Replacing The Tail Lamps Completely (Led Lighting System)

    8.5.10 Replacing the tail lamps completely (LED lighting system) Note Individual LEDs are not intended to be replaced. The LEDs are replaced along with the complete bracket assembly. This means that the complete red or yellow tail lamp is replaced. Requirements: ●...

  • Page 68: Seat / Seat Frame (Without Lifter)

    Seat / seat frame (without lifter) Note This chapter describes how to replace the seat frame on a wheelchair without a lifter or tilt module. To replace a lifter or tilt module, please follow the procedures explained in chapter 8.7. WARNING: Danger of crushing! The seat is very heavy.
  • Page 69 ● Insert a suitable wooden block (2) between the seat (1) and the chassis (3). This will prevent the seat from falling down when you loosen and remove the screws. WARNING: Danger of crushing! The seat is very heavy. Danger of injury to hands and feet! ●...
  • Page 70 Uninstalling the seat frame: A – front seat frame B – rear seat frame ● Use a 6 mm Allen key to loosen the hexagon socket head screws (2). ● Pull the seat frame (1) up and off. Installing the seat and seat frame: ●...

  • Page 71: Replacing The Tilt Module / Lifter Module

    Replacing the tilt module / lifter module 8.7.1 Replacing the tilt module (without lifter) Note This chapter describes how to replace the tilt module on a wheelchair without a lifter. Similar tasks are described In the following chapters: ● Replacing the seat frame alone – chapter 8.6 ●...
  • Page 72 ● Completely remove both knurled head screws (1) including the washers. ● Remove the cover (2). ● Disconnect the plug from the actuator module. ● Open the cable clips on the underside of the seat. ● Free up all cables so that you can lift the seat off. WARNING: Danger of crushing! The seat is very heavy.
  • Page 73 ● Use the 6 mm Allen key to loosen and remove the four hexagon socket head screws (3) on both sides of the wheelchair. ● Remove the screws and the washers. ● Lift the tilt module (1) up off of its brackets (2). ●...

  • Page 74: Replacing The Lifter / Tilt Module

    8.7.2 Replacing the lifter / tilt module Note This chapter describes how to replace the seat frame on a wheelchair with a lifter / tilt module. Similar tasks are described In the following chapters: ● Replacing the seat frame alone – chapter 8.6 ●...
  • Page 75 ● Completely remove both knurled head screws (1) including the washers. ● Remove the cover (2). ● Disconnect the plug from the actuator module. ● Open the cable clips on the underside of the seat. ● Free up all cables so that you can lift the seat off. WARNING: Danger of crushing! The seat is very heavy.
  • Page 76 ● Open the power supply chain of the lifter: - Flip the cover (1) up. - Pull the flap (2) out of the cover. - Repeat this procedure link by link. ● Remove both cable ties that secure the cable at the ends of the power supply chain. ●...
  • Page 77 ● Use the 6 mm Allen key to loosen and remove the four hexagon socket head screws (3) on both sides of the wheelchair. ● Remove the screws and the washers. ● Lift the tilt module (1) up off of its brackets (2). ●...

  • Page 78: Replacing The Tilt Actuator

    8.7.3 Replacing the tilt actuator Note This chapter only describes how to replace the tilt actuator. To replace the complete tilt module, please proceed as described in chapters 8.7.1 and 8.7.2. WARNING: Danger of crushing! The seat is very heavy. Danger of injury to the hands if the seat falls down unintentionally! ●...
  • Page 79 WARNING: Danger of crushing! The seat is very heavy. Danger of injury to the hands if the seat falls down unintentionally! ● Let a second person help you. ● Carefully secure the seat against falling down unintentionally before removing the actuator. If there is no means to secure the seat from falling down, remove it entirely.

  • Page 80: Replacing The Lifter Actuator

    8.7.4 Replacing the lifter actuator Note This chapter only describes how to replace the lifter actuator. To replace the complete lifter module, please follow the procedures explained in chapter 8.7.2. Possible methods: The lifter actuator is very easy to replace when the lifter is in a raised position. It is a little more complicated to replace when the lifter is in a lowered position and cannot be raised due to a fault.
  • Page 81 ● Completely remove both knurled head screws (1) including the washers. ● Remove the cover (2). ● Disconnect the plug from the actuator module. ● Open the cable clips on the underside of the seat. ● Free up the actuator cable so it can be removed from the lifter module later along with the actuator.

  • Page 82: Method 2 - Uninstalling The Lifter Actuator With The Lifter Lowered

    8.7.4.2 Method 2 - uninstalling the lifter actuator with the lifter lowered WARNING: Danger of crushing! The seat is very heavy. Danger of injury to hands and feet! ● Let a second person help you. Requirements: ● Spring-ring pliers ● Side cutting pliers ●...
  • Page 83 ● Loosen and remove the hexagon socket head screw (1) of the seat frame on the left and on the right side of the wheelchair. WARNING: Danger of crushing! The seat is very heavy. Danger of injury to hands and feet! ●...
  • Page 84 ● Swing the tilt lever arm (1) forwards. ● Remove the retaining rings (1) from the front bolt (4) of the lifter actuator (2) with the spring- ring pliers. ● Pull the bolt out of the guide with a pair of bent-nose pliers, until the bolt almost touches the tilt actuator (5).
  • Page 85 ● Lift the tilt actuator (5) up a little. ● Pull the bolt (4) of the lifter actuator under the tilt actuator and out of the guide. ● Remove the retaining rings (1) from the rear bolt (3) of the lifter actuator (2) with the spring- ring pliers.

  • Page 86: Centre-Mounted Legrest (Electric & Manual)

    Centre-mounted legrest (electric & manual) Note The centre-mounted legrest is the only part of the wheelchair, in which screw sizes are indicated in inches. 8.8.1 Replacing the manually operated centre-mounted legrest WARNING: Danger of crushing! The legrest is very heavy. Danger of injury to hands and feet! ●...
  • Page 87 Installing the manually operated centre-mounted legrest: ● Assemble the parts in reverse order. ● Test all functions of the wheelchair.

  • Page 88: Replacing The Electrically Operated Centre-Mounted Legrest

    8.8.2 Replacing the electrically operated centre-mounted legrest WARNING: Danger of crushing! The legrest is very heavy. Danger of injury to hands and feet! ● Pay attention to the heavy weight. Requirements: ● 6 mm Allen key ● Side cutting pliers ●...
  • Page 89 ● Use the 6 mm Allen key to loosen and remove the two hexagon socket head screws (2) on both sides of the wheelchair. ● Completely remove both hexagon socket head screws, including the washers. ● Pull the entire legrest forwards out of the seat. ●...

  • Page 90: Replacing An Electric Legrest Actuator

    8.8.3 Replacing an electric legrest actuator WARNING: Danger of crushing! The legrest is very heavy. Danger of injury to hands and feet! ● Pay attention to the heavy weight. Requirements: ● 1/2" socket wrench ● 3/8" Allen key ● Side cutting pliers ●...
  • Page 91 ● Use the 3/8" Allen key and a 1/2" socket wrench to loosen the screw (3). ● Use the 3/8" Allen key and a 1/2" socket wrench to loosen the screw (1). ● Remove the nuts including the washers, but leave the screw inserted in the screw hole, do not pull it completely out.

  • Page 92: Replacing The Calf Plate On The Centre-Mounted Legrest (Electric & Manual)

    8.8.4 Replacing the calf plate on the centre-mounted legrest (electric & manual) Requirements: ● 1/64" Allen key A manual legrest can be seen in the illustration. The method of fixation to the seat is almost identical with both legrests. Uninstalling the calf plate: ●...

  • Page 93: Replacing The Foot Plate On The Centre-Mounted Legrest (Electric & Manual)

    8.8.5 Replacing the foot plate on the centre-mounted legrest (electric & manual) Requirements: ● 1/64" Allen key ● 1/4" Allen key A manual legrest can be seen in the illustration. The method of fixation to the seat is almost identical with both legrests. Uninstalling the footplate ●...

  • Page 94: Replacing The Restraining Belt

    Replacing the restraining belt Requirements: ● 10 mm socket wrench ● 4 mm Allen key Uninstalling the restraining belt: ● Loosen the screw (3) and the corresponding nut (not shown in the illustration) with a 4 mm Allen key and a 10 mm socket wrench. ●...

  • Page 95: Replacing The Anti-Tipper Wheels

    8.10 Replacing the anti-tipper wheels Requirements: ● Small flat screwdriver ● Two 13 mm socket wrenches Uninstalling an anti-tipper wheel: ● Carefully remove the black plastic cap (3) from the middle of the anti-tipper wheel (2) with a small flat screwdriver. ●...

  • Page 96: Rear Wheels

    8.11 Rear wheels 8.11.1 Replacing a rear wheel Requirements: ● Small flat screwdriver ● 16 mm socket wrench ● Two oblong wooden blocks, at least 14 x 14 x 30 cm WARNING: Danger of crushing! The wheelchair is very heavy. Danger of injury to the hands and feet! ●...

  • Page 97: Replacing A Rear Wheel Fork

    8.11.2 Replacing a rear wheel fork WARNING: Danger of crushing! The wheelchair is very heavy. Danger of injury to the hands and feet! ● Let a second person help you. Danger of injury due to uncontrolled movement of the wheelchair! ●...
  • Page 98 ● Prop up the wheelchair on multiple wooden blocks with the help of a second person. ● Use the 22 mm socket wrench to loosen and remove the self-securing nut (2). ● Pull the wheel fork (4) downwards out of the rear wheel cantilever arm (1). Pay attention to the washers (3), spacer washers and the separable ball bearings (not visible in the illustration).

  • Page 99: Adjusting The Wheel Fork

    8.11.3 Adjusting the wheel fork WARNING: Danger of crushing! The wheelchair is very heavy. Danger of injury to the hands and feet! ● Let a second person help you. Requirements: ● 22 mm socket wrench ● Use the 4 mm Allen key to loosen and remove the hexagon socket head screw (1). ●...
  • Page 100 ● Let a second person tilt the wheelchair forward over the drive wheels, until the anti-tipper wheels prevent it from tipping any farther. ● Swivel the wheels (5) so that they point upward. ● Release the wheels, so that they can swing downwards. ●...

  • Page 101: Drive Wheels

    8.12 Drive wheels 8.12.1 Replacing a drive wheel WARNING: Danger of crushing! The wheelchair is very heavy. Danger of injury to the hands and feet! ● Let a second person help you. Danger of injury due to uncontrolled movement of the wheelchair! ●...

  • Page 102: Replacing A Tyre

    8.12.2 Replacing a tyre Requirements: ● 5 mm Allen key ● Two oblong wooden blocks, at least 14 x 14 x 30 cm ● Three c-clamps with plastic caps ● Torque wrench 5 – 30 Nm (or similar) ● Talcum powder Uninstalling a tyre: ●...

  • Page 103: Replacing A Drive Wheel Hub

    8.12.3 Replacing a drive wheel hub WARNING! Danger of damage to the wheelchair! Collisions can be caused if shim rings are removed from the drive wheels during installation work! ● Shim rings are frequently placed between the drive shaft and the wheel hub to compensate tolerances.
  • Page 104 ● Assemble the parts of the wheel hub in reverse order. ● Between the wheel and the motor / drive unit, distance rings of various widths are inserted to adjust the clearance between the wheel and the motor. Select the correct width for the distance rings.

  • Page 105: Drive Unit

    8.13 Drive unit 8.13.1 Replacing the motor / gearbox unit WARNING: Danger of crushing! The wheelchair is very heavy. Danger of injury to the hands and feet! ● Let a second person help you. Danger of injury due to uncontrolled movement of the wheelchair! ●...
  • Page 106 ● Use the 13 mm socket wrench to loosen the four screws (1). ● Hold the motor / gearbox unit with one hand. ● Completely remove the four screws, including the washers. ● Remove the motor / gearbox unit. Installing the motor / gearbox unit: ●...

  • Page 107: Replacing Or Rotating The Motor / Gearbox Unit Sealing Ring

    8.13.2 Replacing or rotating the motor / gearbox unit sealing ring CAUTION: Danger of crushing! The motor / gearbox unit is very heavy. Danger of injury to the hands! ● Pay attention to the heavy weight. Requirements: ● 10 mm socket wrench Uninstalling the sealing ring: ●...

  • Page 108: Replacing The Motor / Gearbox Coupling

    8.13.3 Replacing the motor / gearbox coupling CAUTION: Danger of crushing! The motor / gearbox unit is very heavy. Danger of injury to the hands! ● Pay attention to the heavy weight. Requirements: ● 10 mm socket wrench Uninstalling the motor / gearbox coupling: ●...
  • Page 109 Installing the motor / gearbox coupling: ● Place the new coupling (2) on the motor axle (3). Pay attention to the position of the groove. ● Carefully insert the motor into the gearbox. Pay attention to the position of the groove in the axle of the gearbox (4).

  • Page 110: Replacing The Carbon Brushes

    8.13.4 Replacing the carbon brushes Note Always replace all carbon brushes on both motors at the same time. WARNING: Danger of crushing! The wheelchair is very heavy. Danger of injury to the hands and feet! ● Let a second person help you. Requirements: ●...
  • Page 111 ● Loosen all four plastic caps (3) with a flat screwdriver and remove the caps. ● Pull the carbon brushes (4) out of their holders slightly. Take note of the installation position and orientation of the carbon brushes. Note If the carbon brushes are just to be checked and not replaced, then you must take note of the position and orientation of the brushes.

  • Page 112: Running The Motor In

    8.13.5 Running the motor in Note The following procedure is necessary to run in the motor after replacing the carbon brushes to guarantee maximum performance. WARNING: Danger of accidents! Danger to people, the surroundings and wheelchair! ● Never leave the wheelchair unattended during the following procedure! ●...

  • Page 113: Replacing The Motor / Gearbox Fixation And Rear Wheel Cantilever Arm

    8.14 Replacing the motor / gearbox fixation and rear wheel cantilever WARNING: Danger of crushing! The wheelchair is very heavy. Danger of injury to the hands and feet! ● Let a second person help you. Danger of injury due to uncontrolled movement of the wheelchair! ●...
  • Page 114 ● Use the 22 mm socket wrench to loosen and remove the self-securing nut (2). ● Remove the washer. ● Pull the motor / gearbox fixation and rear wheel cantilever arm off of the pivot point. Assembling the motor / gearbox fixation and rear wheel cantilever arm: ●...

  • Page 115: Replacing The Spring In The Rear

    8.15 Replacing the spring in the rear Note Invacare® recommends always replacing both springs to ensure optimum performance of the wheelchair. WARNING: Danger of crushing! The wheelchair is very heavy. Danger of injury to the hands and feet! ● Let a second person help you.
  • Page 116 Installing the suspension: ● Assemble the parts in reverse order.

  • Page 117: Fixation Rings

    8.16 Fixation rings 8.16.1 Replacing a front fixation ring Requirements: ● 13 mm socket wrenches (two of them) ● Torque wrench 0 – 30 Nm (or similar) Removing a front fixation ring: ● Switch the wheelchair off. ● Remove the front cover and the rear covers, as described in chapters 8.1.1 and 8.1.2. ●...

  • Page 118: Replacing A Rear Fixation Ring

    8.16.2 Replacing a rear fixation ring Requirements: ● 13 mm socket wrenches (two of them) ● Torque wrench 0 – 30 Nm (or similar) Removing a rear fixation ring: ● Switch the wheelchair off. ● Remove the front cover and the rear covers, as described in chapters 8.1.1 and 8.1.2. ●...

  • Page 119: Replacing The Battery Boxes

    8.17 Replacing the battery boxes Requirements: ● 7 mm socket wrench ● 8 mm socket wrench ● 10 mm socket wrench ● 13 mm socket wrench ● 16 mm socket wrench ● 22 mm socket wrench ● 13 mm open-ended wrench ●...

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