Invacare Orion Service Manual
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Invacare Orion Service Manual

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Invacare
Orion
®

SERVICE MANUAL

Edition: 28.03.12

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Summary of Contents for Invacare Orion

  • Page 1: Service Manual

    Invacare Orion ® SERVICE MANUAL Edition: 28.03.12...
  • Page 2 ® SERVICE MANUAL Invacare - Orion These instructions contain information about: Testing work Repair Instructions This manual is part of the instructions for use. Service addresses Invacare Austria GmbH +43 6232 5 53 50 Herzog Odilostrasse 101 Fax: +43 6232 5 53 54 A-5310 Mondsee info@invacare-austria.com...
  • Page 3 +44 (0)1656 77 62 20 Pencoed Technology Park uk@invacare.com Pencoed WWW: www.invacare.co.uk Bridgend CF35 5HZ United Kingdom Invacare Mecc San s.r.l. +39 0445 38 00 59 Via dei Pini, 62 Fax: +39 0445 38 00 34 I - 36016 Thiene (VI) italia@invacare.com WWW: www.invacare.it...
  • Page 4 ® SERVICE MANUAL Invacare - Orion ( (Kundtjänst): +46 (0)8 761 70 90 Återförsäljare: Fax (Kundtjänst): +46 (0)8 761 81 08 Invacare® AB sweden@invacare.com Fagerstagatan 9 finland@invacare.com S-163 91 Spånga WWW: www.invacare.se Sverige MÖLNDAL Tillverkare: +46 (0)31 86 36 00 Invacare®...

  • Page 5: Table Of Contents

    ® Invacare - Orion SERVICE MANUAL 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...
  • Page 6 ® SERVICE MANUAL Invacare - Orion Replacing brakes Replacing brake cable Replacing steering linkage/steering rod 7.10 Replacing the seat suspension / spring 7.11 Replacing operating console 7.12 Replacing bend speed reducer 7.13 Replacing the potentiometer 7.14 Replacing front headlight (lamp) 7.15...

  • Page 7: 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 8: Definition And Representation Of Information And Safety Information In This Manual

    ® SERVICE MANUAL Invacare - Orion 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.

  • Page 9: Hazard Symbols And Symbols Used

    ® Invacare - Orion SERVICE MANUAL 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!

  • Page 10: Images In This Manual

    ® SERVICE MANUAL Invacare - Orion 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 11: Safety And Fitting Instructions

    ® Invacare - Orion SERVICE MANUAL Safety and fitting instructions These safety instructions are intended to prevent accidents at work, and it is imperative that they are observed. Before any inspection or repair work · Read and observe this repair manual and the associated operating manual! ·...
  • Page 12 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 13: Tightening Torques

    ® Invacare - Orion SERVICE MANUAL 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.

  • Page 14: Overview Electronic Modules

    ® SERVICE MANUAL Invacare - Orion Overview electronic modules Different electronic modules can be installed in the scooter. These are listed below: Electronic modules Designation Notes Rhino1 max. current: DS72KB01 70 A 110 A DS112KB02 Rhino2 max. current: DS90 90 A...

  • Page 15: Service Plan (1X Annually)

    ® Invacare - Orion SERVICE MANUAL Service plan (1x annually) ü Component Check Remedy Notes · Welded seams, · Tighten screws, Seat: fixings and replace parts if upholstery damaged · Seat suspension · Grease the spring See "Replacing generously, the seat...
  • Page 16 ® SERVICE MANUAL Invacare - Orion ü Component Check Remedy Notes · Status display · Evaluate blinking Drive electronic flashing code · Fixing · Tighten or replace · Cable, connecting fixing. · Replace cable, plug · Drive lever function connecting plug.

  • Page 17: Operational Faults

    ® Invacare - Orion SERVICE MANUAL Operational Faults Operational faults Please proceed as follows if you have any problems: · First assess the possible cause of the problem using the following table. · Check the drive console status display. Evaluate the blink error code.

  • Page 18: Error Codes And Diagnostic Codes

    Switch the scooter off, wait a few minutes and then switch on again. · The electronic system has determined a motor short-circuit. Check the wiring harness for short-circuit and check the motor. · Contact your Invacare® dealer.
  • Page 19 · There is a defect in the braking coil or in the cabling. Check the magnetic brake and cabling for open or short-circuited circuitry. Contact your Invacare® dealer. · No neutral position Stops driving Drive lever is not in neutral when the when switching keyswitch was turned.

  • Page 20: Repair Work

    ® SERVICE MANUAL Invacare - Orion Repair Work General warning information on installation work CAUTION! Risk of damage to the vehicle! Collisions can be caused if shim rings are removed from the drive wheels during installation work! Shim rings are frequently placed between the drive shaft and the wheel hub to compensate tolerances.
  • Page 21 ® Invacare - Orion SERVICE MANUAL · Secure the scooter against rolling away. · Place supporting wooden block under the frames at battery holder height. · Remove the seat. · Remove motor cover. · Disconnect both battery plugs (1). ·...
  • Page 22 ® SERVICE MANUAL Invacare - Orion · Remove both screws (2) from the wheel cover (1). · Remove wheel cover (1). · Remove both screws (1) from the drive holder (2). · Remove drive holder (2). · Remove screws (1) on disengaging lever (2).

  • Page 23: Replacing Wheel Suspension

    ® Invacare - Orion SERVICE MANUAL Replacing wheel suspension ATTENTION! Risk of accident. Accidental rolling can lead to accidents. · Secure the scooter against rolling away. Note: When disassembling, note the position of small parts such as screws and washers. Put small parts down so that they can be reassembled in the right sequence.
  • Page 24 ® SERVICE MANUAL Invacare - Orion · Loosen wheel suspension screw (1). · Loosen knurled screw (2). · Replace wheel suspension · Reassembly takes place in the reverse order. · Adjust tracking (see chapter entitled "Replacing steering linkage/steering rod " on page 34).

  • Page 25: Replacing Shock Absorber

    ® Invacare - Orion SERVICE MANUAL Replacing shock absorber ATTENTION! Risk of accident. When parking the scooter on the scooters support wheels it is no longer slowed by the engine brake. The scooter can roll away out of control. · Place the scooter rear frame on a supporting wooden block before you remove the wheels.
  • Page 26 ® SERVICE MANUAL Invacare - Orion · Reassembly of the shock absorber takes place in reverse order. · Check function (trial run).

  • Page 27: Replacing Front Axle

    ® Invacare - Orion SERVICE MANUAL Replacing front axle ATTENTION! Risk of accident. Accidental rolling can lead to accidents. · Secure the scooter against rolling away. Note: When disassembling, note the position of small parts such as screws and washers. Put small parts down so that they can be reassembled in the right sequence.

  • Page 28: Replacing Steering Column/Fork 3-Wheel

    ® SERVICE MANUAL Invacare - Orion Replacing steering column/fork 3-wheel ATTENTION! Risk of accident. Accidental rolling can lead to accidents. · Secure the scooter against rolling away. Note: When disassembling, note the position of small parts such as screws and washers. Put small parts down so that they can be reassembled in the right sequence.
  • Page 29 ® Invacare - Orion SERVICE MANUAL · Remove screws (1) on rear steering column cladding. · Remove steering column cladding. · Loosen screws on front basket holder. · Remove basket holder. · Remove spacer bushes. · Disconnect cable (1, 2) from wiring harness.
  • Page 30 ® SERVICE MANUAL Invacare - Orion · Release brake cable (see chapter entitled "Replacing brakes" on page 31) · Unscrew screw at clamp (1). · Unscrew fixing bolt for steering column and remove. · Pull steering column out upwards. Replacing fork 3-wheel: ·...

  • Page 31: Replacing Brakes

    ® Invacare - Orion SERVICE MANUAL Replacing brakes ATTENTION! Risk of accident. Accidental rolling can lead to accidents. · Secure the scooter against rolling away. Note: When disassembling, note the position of small parts such as screws and washers. Put small parts down so that they can be reassembled in the right sequence.
  • Page 32 ® SERVICE MANUAL Invacare - Orion · Pull brake out of brake drum. · Replace brake lining or complete brake. · Reassemble wheel and brake. · Push wheel and brake onto shaft, or push axle through. · Operate brake and hold, tighten axle bolts at same time.

  • Page 33: Replacing Brake Cable

    ® Invacare - Orion SERVICE MANUAL Replacing brake cable ATTENTION! Risk of accident. Accidental rolling can lead to accidents. · Secure the scooter against rolling away. Note: When disassembling, note the position of small parts such as screws and washers. Put small parts down so that they can be reassembled in the right sequence.

  • Page 34: Replacing Steering Linkage/Steering Rod

    ® SERVICE MANUAL Invacare - Orion Replacing steering linkage/steering rod ATTENTION! Risk of accident. Accidental rolling can lead to accidents. · Secure the scooter against rolling away. Note: When disassembling, note the position of small parts such as screws and washers. Put small parts down so that they can be reassembled in the right sequence.
  • Page 35 ® Invacare - Orion SERVICE MANUAL Replacing steering link: · Remove circlip (1) on steering link (2). · Replace steering link. · Adjust length of steering link using setting screws (3). Replacing steering rod: · Remove circlip (4) on steering rod (5).

  • Page 36: Replacing The Seat Suspension / Spring

    ® SERVICE MANUAL Invacare - Orion 7.10 Replacing the seat suspension / spring ATTENTION! Risk of accident. Accidental rolling can lead to accidents. · Secure the scooter against rolling away. Note: When disassembling, note the position of small parts such as screws and washers. Put small parts down so that they can be reassembled in the right sequence.
  • Page 37 ® Invacare - Orion SERVICE MANUAL · Remove the bolt (7), nut and washers. · Remove the seat support tube (2) from the receptacle tube (1). · Remove the concertina type cover (3) including the spring (5) and the plastic end pieces (4 and 6).

  • Page 38: Replacing Operating Console

    ® SERVICE MANUAL Invacare - Orion 7.11 Replacing operating console ATTENTION! Burn and scald hazard if power cable is short-circuited! · Turn off the power completely before removing any power supply components of the electric vehicle! Therefore take out the batteries.
  • Page 39 ® Invacare - Orion SERVICE MANUAL · Disconnect plug from operating console circuit board. · Replace operating console. · Reconnect plug with circuit board on new operating console. · Reassembly of the operating console takes place in reverse order ·...

  • Page 40: Replacing Bend Speed Reducer

    ® SERVICE MANUAL Invacare - Orion 7.12 Replacing bend speed reducer ATTENTION! Risk of accident. Accidental rolling can lead to accidents. · Secure the scooter against rolling away. Note: When disassembling, note the position of small parts such as screws and washers. Put small parts down so that they can be reassembled in the right sequence.
  • Page 41 ® Invacare - Orion SERVICE MANUAL Adjusting: · Set steering to straight ahead. · Align sensor straight using regulating unit. · Take hold of the sensor and tighten the fork screw. Check: · Turn the steering completely to the right and then the left.

  • Page 42: Replacing The Potentiometer

    ® SERVICE MANUAL Invacare - Orion 7.13 Replacing the potentiometer ATTENTION! Burn and scald hazard if power cable is short-circuited! · Turn off the power completely before removing any power supply components of the electric vehicle! Therefore take out the batteries.
  • Page 43 ® Invacare - Orion SERVICE MANUAL · Remove screws (1) on potentiometer. · Replace potentiometer · Reconnect potentiometer plug (1) with operating console. Setting the potentiometer to the middle position: · Loosen the bolts (1) on the drive lever mounting.

  • Page 44: Replacing Front Headlight (Lamp)

    ® SERVICE MANUAL Invacare - Orion 7.14 Replacing front headlight (lamp) Requirements: · Phillips screwdriver · Remove the seat. · Remove motor cover. · Separate battery cable. 3-wheel version · Remove screw (1) on front headlight under front cladding. 4-wheel version ·...
  • Page 45 ® Invacare - Orion SERVICE MANUAL · Reassembly of the headlight takes place in reverse order. · Check function...

  • Page 46: Replacing The Front Direction Indicators

    ® SERVICE MANUAL Invacare - Orion 7.15 Replacing the front direction indicators Requirements: · Phillips screwdriver. · Remove the seat. · Remove motor cover. · Separate battery cable. 3-wheel version · Remove direction indicator screw (1). · Disconnect direction indicator cable (2) from wiring harness.

  • Page 47: Replacing Centre Brake Light

    ® Invacare - Orion SERVICE MANUAL 7.16 Replacing centre brake light ATTENTION! Burn and scald hazard if power cable is short-circuited! · Turn off the power completely before removing any power supply components of the electric vehicle! Therefore take out the batteries.
  • Page 48 ® SERVICE MANUAL Invacare - Orion · Remove the bolt (1) on the rear panelling. · Lift the rear panelling upwards. · Remove screws (1) on brake light. · Replace brake light. · Reassembly of the brake light takes place in reverse order.

  • Page 49: Replacing Rear Lights/Direction Indicators

    ® Invacare - Orion SERVICE MANUAL 7.17 Replacing rear lights/direction indicators ATTENTION! Burn and scald hazard if power cable is short-circuited! · Turn off the power completely before removing any power supply components of the electric vehicle! Therefore take out the batteries.
  • Page 50 ® SERVICE MANUAL Invacare - Orion · Remove rear light. · Remove screws (1) on rear light glass. · Remove rear light glass (1). · Replace lightbulb (2). · Reassembly of the rear light/direction indicator takes place in reverse order.

  • Page 51: Replacing The Electronic Module

    · Changes to the drive program may only be carried out by trained Invacare® specialist dealers! · Invacare® can only give a warranty for safe mobility aid driving behaviour - especially tipping stability - for unaltered standard drive programs! ATTENTION! Risk of accident.
  • Page 52 ® SERVICE MANUAL Invacare - Orion · Secure the scooter against rolling away. · Place supporting wooden block under the frames at battery holder height. · Remove the seat. · Remove motor cover. · Disconnect both battery plugs (1). From the operating manual: ·...
  • Page 53 ® Invacare - Orion SERVICE MANUAL · Remove screws (1) on electronic module. · Replace electronic module (2). · Reassembly of the drive and the electronic module takes place in reverse order. · Load drive program onto electronic module. See electronic software description.

  • Page 54: Updating Software

    · Changes to the drive program may only be carried out by trained Invacare® specialist dealers! · Invacare® can only give a warranty for safe mobility aid driving behaviour - especially tipping stability - for unaltered standard drive programs! Requirements: ·...

  • Page 55: Installing The Windshield

    ® Invacare - Orion SERVICE MANUAL Accessories Installing the windshield Requirements: · 13 mm open-ended wrench · 14 mm open-ended wrench · Remove the rear view mirror and the stoppers of the plastic cover on the handlebars. · Remove the threaded bolts of the rear view mirror holder.
  • Page 56 ® SERVICE MANUAL Invacare - Orion · Insert the threads of the windshield mounting brackets (3) through the bracket holders (1). · Secure the windshield mounting brackets with the self-locking nuts (2). · Adjust the windshield using the nuts (2) and (4) on both sides so that it is perpendicular to the direction of travel .

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