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Invacare Typhoon Service Manual

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Invacare® Typhoon

SERVICE MANUAL

This document contains information on:
Troubleshooting
Maintenance
Repair
Version: 26.11.09

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Summary of Contents for Invacare Typhoon

  • Page 1: Service Manual

    Invacare® Typhoon SERVICE MANUAL This document contains information on: Troubleshooting Maintenance Repair Version: 26.11.09...
  • Page 2 +44 (0)1656 776 201 Pencoed uk@invacare.com eire@invacare.com Bridgend CF35 5HZ WWW: www.invacare.co.uk United Kingdom Invacare Mecc San s.r.l. +39 0445 38 00 59 Via Dei Pini, 62 Fax: +39 0445 38 00 34 italia@invacare.com I - 36016 Thiene (VI) WWW: www.invacare.it...
  • Page 3 Invacare Portugal, Lda +351 225 1059 46 +351 225 1059 47 Rua Estrada Velha, 949 P-4465-784 Leça do Balio Fax: +351 225 1057 39 portugal@invacare.com Portugal WWW: www.invacare.pt Återförsäljare: (Kundtjänst): +46 (0)8 761 70 90 Fax (Kundtjänst): +46 (0)8 761 81 08 Invacare®...

  • Page 4: Table Of Contents

    Before any inspection or repair work General safety information and notes on assembly / disassembly TIGHTENING TORQUES LAYOUT OF COMPONENTS AND MODULES SERVICE PLAN (1X ANNUALLY) TROUBLESHOOTING THE TYPHOON Troubleshooting the Typhoon with ACS 6.1.1 Diagnosing driving faults 6.1.2 Diagnosing problems with electric actuators 6.1.3...
  • Page 5 Checking the cables Replacing the ACS Remote Updating the driving program Testing an actuator motor 7.10 Adjusting and replacing the speed reduction switch 7.11 Replacing the steering head bearings on the front or rear castor wheels 7.11.1 Front Castor Wheels 7.11.2 Rear Castor Wheels 7.12...

  • Page 6: Introduction

    • Alterations to the electric vehicle which occur as a result of incorrectly or improperly executed maintenance or overhaul work lead to the exclusion of all liability on the part of INVACARE. • If you have any problems or questions please contact INVACARE SERVICE.
  • Page 7 READ WELL BEFORE OPERATION! This symbol advises you to read information carefully.

  • Page 8: Safety And Assembly Instructions

    • Invacare® supplies all electric vehicles from the factory with a standard drive programme. Invacare® can only assume a warranty for the safe vehicle handling of the electric vehicle – in particular tipping stability - for this standard drive programme!

  • Page 9: Tightening Torques

    Tightening torques The tightening torques stated in the following table are dependent on the thread diameters for the nuts and bolts for which no special values are determined. All values apply to dry and grease-free threads. Thread 3 Nm 6 Nm 10 Nm 25 Nm 49 Nm...

  • Page 10: Layout Of Components And Modules

    Layout of components and modules The following image shows the Typhoon from above rear, with the seat lifter raised and the rear cowling removed. Seat tilt actuator Seat-frame / rear cowling anti-collision switch Speed-reduction switch Power module CLAM (Combined Light and Actuator Module)

  • Page 11: Service Plan (1X Annually)

    Service plan (1x annually) Component Check Action Notes ⇒ Tighten screws, replace • Armrest damage and Armrests and fastening padding if damaged side panels ⇒ Tighten screws, replace • Side panel damage and fixing side panels if damaged ⇒ Replace covers / •...
  • Page 12 Component Check Action Notes ⇒ Clean contacts and • See "Replacing Check contacts and terminals for corrosion terminals the batteries" on page 33 for Safety Information on working with batteries ⇒ Evaluate flash code • Remote, Remote / status display blinking ⇒...

  • Page 13: Troubleshooting The Typhoon

    • Check the Status Display on the remote. Identify the error code if it is flashing. • Perform the necessary checks and repairs as recommended in the table below. Note For more information on troubleshooting the Typhoon with GB motors, please see the “Dynamic DX-GB-AS Power Module - Installation Manual”, Order Nr. 1441533 6.1.1...
  • Page 14 PROBLEM OTHER POSSIBLE SOLUTION REFERENCE SYMPTOMS CAUSE Status display Speed • See "Adjusting and Replace on remote reduction replacing the speed cable or flashes 2x, switch on the reduction switch" on switch drive mode lifter may be page 46 display shows defective or "U"...

  • Page 15: Diagnosing Problems With Electric Actuators

    6.1.2 Diagnosing problems with electric actuators In case an electric actuator will not function, identify the source of the problem using the following table: PROBLEM OTHER POSSIBLE SOLUTION REFERENCE SYMPTOMS CAUSE Electric Remote CLAM is • See "Replacing Replace Actuator displays a defective the CLAM...

  • Page 16: Rem24 Error Codes And Diagnostic Codes

    6.1.3 REM24 Error Codes and Diagnostic Codes The drive electronics are capable of rectifying some errors automatically. In this case the status display will cease to flash. Please switch the remote on and off several times. Wait approx. 5 seconds each time before switching the remote on again. If this does not rectify the error, locate the error using the flash codes shown below.
  • Page 17 Flash code: Meaning: Solution: Notes 8 x flashes Battery voltage too • See User Manual of battery Switch lights on to lower high charger battery voltage • Check battery charger 9 or 10 x Faulty data Remove all electronic • transmission modules except the Power flashes...

  • Page 18: Repair Work

    Please install all shim rings in exactly the same positions they were in before dismantling. Replacing a conventional drive motor Find out here how to replace the conventional Typhoon drive units. CAUTION! Danger of tipping over and crushing! • Secure the vehicle with wedges and a jack-up device to prevent it rolling and tilting, as it tends to do this following removal of a drive wheel.
  • Page 19 Please note It is easy to lose the small uncoupling parts. It is wise to keep these in a safe place until they are required for reassembly. • Cut off the end cap on the Bowden cable (1) using diagonal-nosed cutting pliers. In doing so, please leave the Bowden cable as long as possible.
  • Page 20 Please note Make a note of the number of turns needed to loosen the nut. This number of turns determines the wheel camber. Incorrect wheel camber leads to one-sided wheel wear and can reduce driving power. • Insert a 17mm box wrench from the top through the opening in the chassis (1).
  • Page 21 Please note Only tighten the suspension nut using the noted number of turns. This sets the wheel camber. Incorrect wheel camber leads to one-sided wheel wear and can reduce driving power. • The drive unit is installed in the reverse order.

  • Page 22: Replacing And Calibrating A Gb Drive Motor

    Invacare's absolute discretion. This warranty does not include labour or shipping charges. Neither does the warranty apply to physical damage nor unauthorised repairs. Invacare's sole obligation and your exclusive remedy under this warranty is limited to such repair and/or replacement.

  • Page 23: Disassembling The Tyre And Rim On A Vehicle With Pneumatic Tyres

    Requirements: • Wooden block to prop up the vehicle • Allen key 6mm • Allen key 4mm • Small flat-bladed screwdriver • Circlip pliers • Loctite 243 • 2x combination wrench 13mm • Hammer • Chisel • Torque wrench • One new hexagonal dome headed bolt, M8, 20mm long, 5mm key size Additional parts and tools for working on puncture-proof tyres •...

  • Page 24: Disassembling The Rim And The Tyre On A Vehicle With Puncture-Proof Tyres

    • Unscrew valve cap. • Depressurise tyre by pressing in the pin in the valve (1). • Unscrew 5 screws (2) using the 6mm Allen key. • Remove the wheel rim half with the inner tube. 7.2.1.2 Disassembling the rim and the tyre on a vehicle with puncture-proof tyres WARNING! Danger of damage to the motor if the screws are not loosened and removed in the correct sequence! •...
  • Page 25 You will need to remove the entire upper half of the walking beam to replace the motor. To do this, you need to remove one of the pins (1) that hold the walking beam. The pins are secured with snap-rings from the inside. •...
  • Page 26 • The illustration at the right shows how to position the chisel (1) on the head of the screw (2) to get it started turning. • Use the small screwdriver to carefully remove the clip that holds the emergency declutching latch (2) in place. •...

  • Page 27: Reassembling The Rim And The Tyre On A Vehicle With Pneumatic Tyres

    7.2.1.4 Reassembling the rim and the tyre on a vehicle with pneumatic tyres • Re-position the inner-tube in the tyre. • Re-fit the rim-half. • Position the screws and tighten them a little. • Fill the inner-tube with a little air. •...
  • Page 28 • Position the rim-half in the tyre. The holes for the screws in the rim-half and the ones in the rotor casing need to be aligned with each other. It can be helpful to align the notch in the rim-half and the one in the rotor casing where the valve would usually be, using them as a positioning guide.

  • Page 29: Calibrating Gb Motors

    7.2.2 Calibrating GB motors The following sections explain the calibration process with the handheld programming device. Injury hazard! The wheelchair starts to move in an uncontrolled manner if one or both of the drive wheels is touching the ground during calibration! •...
  • Page 30 The programming device You should enter this: shows the following: "YES" (if drive wheels have been raised) GB MOTOR CALIBRATION Wheels will move! Drive wheels raised? EXIT "YES" (if drive wheels have been raised) GB MOTOR CALIBRATION Chair will drive! Are wheels raised? EXIT "BEGIN"...

  • Page 31: Replacing Components Of The Electronics

    Replacing components of the electronics Find out here how to replace the Typhoon electronic components. Pre-requisites: • Large and small crosstip screwdrivers • 8 mm open-jawed or ring wrench • Press in the retaining clips (1) and in doing so pull the electronic panelling upward and to the rear applying slight pressure to the handle (2).
  • Page 32 • Press in the retaining clip (1) using a small crosstip screwdriver and slide the Clam from the electronic carrier in the direction of the arrow. • The drive unit is installed in reverse order. • To allow the electronic carrier to lock into place correctly, increase the distance between the chassis and the battery using a large crosstip screwdriver.

  • Page 33: Replacing The Batteries

    Replacing the batteries Find out here how to replace the Typhoon batteries. CAUTION! Risk of chemical burns! • Please look out for damaged batteries or ensure that you do not damage the batteries. Leaking acid can cause chemical burns to the skin and eyes.
  • Page 34 CAUTION! Cables can pull off! • Remove the front panelling carefully on vehicles with a lighting system, as the light circuit board is attached to it. Hold on to the panelling until you have marked and released all connectors. • Unscrew the screws (1) and (2) on both sides of the vehicle using a 5 or 6mm hexagon socket.
  • Page 35 • Press in the retaining clips (1) and in doing so pull the electronic panelling upward and to the rear applying slight pressure to the handle (2). CAUTION! Electronics can be damaged! • Disconnect all electronic components from the batteries before commencing work on the batteries.
  • Page 36 • Pull the battieres out to the front using the carrying belt • Remove the battery inserter and carrying belt from the battery. CAUTION! Fire hazard! Cables can be pinched and chafed. • Please ensure correct cable layout! They may not protrude into the lifter area. Use cable binders if necessary.
  • Page 37 • Assemble in accordance with this installation sequence: • Push the batteries (3) together with the carrying belt (5) and battery inserter (4) into the chassis. • Push the regulating motor (2) together with the nest into the chassis and allow to lock into place in the bottom plate.
  • Page 38 • Raise the lifter slightly and unlock the retaining mechanism (1). The entire lifter load is now on the regulating motor again. • Test all vehicle functions. • Check the charge status of the new batteries and charge fully if necessary.

  • Page 39: Replacing The Main Fuse

    Replacing the main fuse CAUTION! Fire hazard! • Only ever use an original strip fuse and permissible strength of current. • In the event that the main fuse has burnt out, remedy the cause before fitting a new fuse. Pre-requisites: •...
  • Page 40 • Open the cover on the fuse holder. • If the strip fuse (2) has burnt out, look for the cause and remedy. The main fuse may only be replaced when the fault has been remedied. • Use an 8mm open-jawed or ring wrench to unscrew the nuts (1) on the strip fuse (2).

  • Page 41: Checking The Cables

    Checking the cables Find out here how you can check the plug connections on the Typhoon electronics. Pre-requisites: • None • Move the lifter to the uppermost position. • Press in the retaining clips (1) and in doing so pull the electronic panelling upward and to the rear applying slight pressure to the handle (2).

  • Page 42: Replacing The Acs Remote

    • Alterations to the drive programme must only be carried out by trained Invacare®-dealers! • Invacare® can only assume a warranty for the safe vehicle handling of the wheelchair – in particular tipping stability - for unaltered standard drive programmes! •...
  • Page 43 • Installation of the remote is carried out in reverse order. • Update the software, in case a newer version is available. • Customise the driving programme with the programming software, if required. • Check all vehicle functions.

  • Page 44: 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! Pre-requisites: •...

  • Page 45: Testing An Actuator Motor

    Testing an actuator motor Requirements: • Multimeter • Check the electrical resistance of the actuator. If it is close to infinite, then the motor is likely to be burnt out. If it is less than 1Ω, then motor has a short-circuit. In either case, the motor needs to be replaced.

  • Page 46: Adjusting And Replacing The Speed Reduction Switch

    7.10 Adjusting and replacing the speed reduction switch Find out here how you can adjust and replace the switch that reduces the speed when in the upper lifter position. Pre-requisites: • Small pliers • Move the lifter to the upper and lower position several times.

  • Page 47: Replacing The Steering Head Bearings On The Front Or Rear Castor Wheels

    7.11 Replacing the steering head bearings on the front or rear castor wheels CAUTION! Incorrect reassembly can damage the bearings or cause the steering wheels to fall out! • The single-row angular ball bearing races are not the same on both sides! For this reason there is only one correct way to fit them! It is imperative that you observe the reassembly information! Requirements:...

  • Page 48: 7.11.2 Rear Castor Wheels

    • Loosen and remove the 19 mm nut using the socket wrench. Hold the wheel so it does not rotate while removing the nut. • Pull the steering head shaft down and out of the steering head tube. • Remove the washer and the bearing race from the top of the tube.
  • Page 49 • Carefully remove the black plastic cap (1) that covers the end of the steering head tube, using the small flat-bladed screwdriver. • Loosen and remove the 19 mm nut using the socket wrench. Hold the wheel so it does not rotate while removing the nut.

  • Page 50: Replacing The Anti-Dive Spring

    7.12 Replacing the Anti-Dive Spring CAUTION! Danger of the wheelchair tipping over or rolling away! • Secure the wheelchair from tipping over by propping it up with a wooden block under the battery box that is long and wide enough! Using a wooden block that is too short or too high could cause the wheelchair to tip over! •...
  • Page 51 • Push the lower half of the walking beam down so that the tension on the spring (1) is released. • Remove the upper end of the spring from the hole in walking beam. • Use the Allen key 5mm to remove the bolt (1) that holds the retainer plate that secures the lower end of the spring.

  • Page 52: Repairing A Flat Tyre (Conventional Motor)

    7.13 Repairing a flat tyre (conventional motor) CAUTION! Danger of the wheelchair tipping over or rolling away! • Secure the wheelchair from tipping over by propping it up with a wooden block under the battery box that is long and wide enough! Using a wooden block that is too short or too high could cause the wheelchair to tip over! •...
  • Page 53 • Unscrew valve cap. • Let the air out of the tyre completely by pressing the pin in the centre of the valve in. • Remove the 5 cylinder head screws (back of the wheel, 2. • Remove the rim halves from the tyre. •...

  • Page 54: Repairing A Flat Tyre (Gb Motor)

    7.14 Repairing a flat tyre (GB motor) CAUTION! Danger of the wheelchair tipping over or rolling away! • Secure the wheelchair from tipping over by propping it up with a wooden block under the battery box that is long and wide enough! Using a wooden block that is too short or too high could cause the wheelchair to tip over! •...

  • Page 55: Replacing A Drive Wheel

    Screw the valve cap back on. 7.15 Replacing a drive wheel Note For information on how to remove a drive wheel on a Typhoon with either standard or GB motors, please see the sections on repairing flat tyres. 7.16 Replacing the safety belt Requirements: •...
  • Page 56 Dismantling the safety belt: • Remove the plastic cap (5). • Loosen the bolt (3) and the associated nut (in the figure this is covered) with a 4 mm Allen key and a 10 mm socket spanner. • Remove the nut incl. the washer. •...

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