Invacare HMV Zoom 300 Service Manual
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Invacare HMV Zoom 300 Service Manual

Highly maneuverable vehicle
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Service Manual
HMV™Highly
Maneuverable Vehicle
Zoom 300 and Zoom 400
DEALER: Keep this manual. The procedures
in this manual must be performed by a
qualified technician.
For more information regarding
Invacare products, parts, and services,
please visit www.invacare.com

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Summary of Contents for Invacare HMV Zoom 300

  • Page 1 Service Manual HMV™Highly Maneuverable Vehicle Zoom 300 and Zoom 400 DEALER: Keep this manual. The procedures in this manual must be performed by a qualified technician. For more information regarding Invacare products, parts, and services, please visit www.invacare.com...
  • Page 2 WARNINGS, CAUTIONS AND INSTRUCTIONS, CONTACT INVACARE TECHNICAL SUPPORT BEFORE ATTEMPTING TO SERVICE OR OPERATE THIS EQUIPMENT - OTHERWISE, INJURY OR DAMAGE MAY RESULT. NOTE: Updated versions of this manual are available on www.invacare.com. Zoom 300 and Zoom 400 Part No 1122167...

  • Page 3: Table Of Contents

    Removing ...............................20 Installing..............................20 Adjusting Seat Height..........................21 Removing/Installing the Seat Pivot......................21 Removing ...............................21 Installing..............................21 Adjusting Seat Depth ..........................22 90° Seat Swivel Adjustment ........................23 Removing/Installing the Seat Positioning Strap ..................24 SECTION 5—ARMS ................. 25 Part No 1122167 Zoom 300 and Zoom 400...
  • Page 4 Removing/Installing the Caster Assemblies ..................38 Removing ...............................38 Installing..............................38 Replacing Foam-Filled Tires Onto Wheel Rims ................39 SECTION 8—TILLER ................ 40 Removing/Installing the Tiller.........................40 Zoom 300 ..............................40 Zoom 400 ..............................41 Adjusting the Tiller Angle ........................43 Replacing Handgrips..........................43 Zoom 300 and Zoom 400 Part No 1122167...
  • Page 5 Programming Method .........................61 SECTION 9—SWINGARMS ............... 62 Removing/Installing the Swingarms.......................62 Removing ..............................62 Installing..............................62 SECTION 10—TRANSAXLE ............. 64 Removing/Installing the Transaxle ......................64 Removing ..............................64 Installing..............................64 Removing/Installing the Brake Release Lever..................65 Removing ...............................65 Installing..............................65 Part No 1122167 Zoom 300 and Zoom 400...
  • Page 6 Options Menu ............................82 Speed Lever in Neutral Menu ......................83 Controller Version Menu........................83 SECTION 12—BATTERIES AND CHARGER ........84 Recommended Battery Type .........................85 Removing/Installing the Batteries on Zoom 300................86 Removing ...............................86 Installing..............................86 Removing/Installing the Batteries on Zoom 400................88 Removing ...............................88 Installing..............................88 Connecting/Disconnecting the Battery Cables on the Zoom 400 ..........90...
  • Page 7 Suggested Maintenance Procedures .....................99 Lubrication Points..........................100 Electrical ..............................100 Controller ............................... 101 Error Codes............................102 SECTION 14—TRANSPORTING ............104 Disassembling/Assembling the Zoom 300 ..................104 Disassembling............................. 104 Assembling............................104 Disassembling/Assembling the Zoom 400 ..................105 Disassembling............................. 105 Assembling............................106 SECTION 15—SCOOTER ACCESSORIES ...........

  • Page 8: Special Notes

    It is Invacare’s position that users of powered scooters should be transferred into appropriate seating in vehicles for transportation and use be made of the restraints made available by the auto industry.

  • Page 9: Typical Product Parameters

    46 lbs TOTAL WEIGHT OF PRODUCT (Including Batteries): 120 lbs 185 lbs *NOTE: Zoom 300 parameters are based on an 18-inch wide seat. Zoom 400 parameters are based on a 20-inch wide seat. Part No 1122167 Zoom 300 and Zoom 400...

  • Page 10: Label Locations

    NOTE: Warning Label 1118359 is located under the rear shroud. Scooter Frame WARNING Pinch Point. 1079203 NOTE: Warning Label 1079203 is also located on the other swingarm. Part No 1122167 Zoom 300 and Zoom 400...

  • Page 11: On Zoom 400

    DO NOT lift scooter up by the front or rear shroud. Otherwise injury or damage to the scooter may occur. 1118373 Rev A Rear Frame Assembly WARNING Pinch Point. 1079203 Front Frame Assembly WARNING Pinch Point. 1079203 Part No 1122167 Zoom 300 and Zoom 400...

  • Page 12: Section 1-General Guidelines

    DO NOT service or adjust your powered scooter while occupied, unless otherwise noted. Operation Information Invacare products are specifically designed and manufactured for use in conjunction with Invacare accessories. Accessories designed by other manufacturers have not been tested by Invacare and are not recommended for use with Invacare products.

  • Page 13: Tire Pressure

    RED/ORANGE warning tags on some equipment. DO NOT remove these tags. Batteries The warranty and performance specifications contained in this manual are based on the use of deep cycle gel cell batteries. Invacare strongly recommends their use as the power source for this unit. Part No 1122167...

  • Page 14: Charging Batteries

    Rain Test Invacare has tested its powered scooters in accordance with ISO 7176 “Rain Test.” Passing this test means that the end user or his/her attendant should have sufficient time to remove his/her powered scooter from a rain storm and retain powered scooter operation.

  • Page 15: Section 2-Emi Information

    AM/FM radios, TV sets, CD players, cassette players, and small appliances, such as elec- tric shavers and hair dryers, so far as we know, are not likely to cause EMI problems to your powered wheelchair. Part No 1122167 Zoom 300 and Zoom 400...
  • Page 16 2) This device has been tested to a radiated immunity level of 20 volts per meter. Modification of any kind to the electronics of this wheelchair as manufactured by Invacare may adversely affect the RFI immunity levels. Zoom 300 and Zoom 400...

  • Page 17: Section 3-Safety Inspection

    Inspect front wheel/fork assembly for proper tension by spinning the wheel. The front wheel should come to a gradual stop. Check brake for binding or interference with travel. Check the front fork for damage or corrosion. Part No 1122167 Zoom 300 and Zoom 400...
  • Page 18 Inspect tires for flat spots and wear. Clean molded body shrouds. ® Lubricate the top of the seat post using a Teflon lubricant. Ensure that the anti-roll safety feature is working properly. The scooter should not free-wheel downhill. Zoom 300 and Zoom 400 Part No 1122167...

  • Page 19: Section 4-Seat

    3. Release seat lever and lift up on seat assembly to ensure the seat is secure. Seat Back Seat Seat Pivot Seat Lever (Located under the Seat) Seat Post FIGURE 4.1 Removing/Installing the Seat Part No 1122167 Zoom 300 and Zoom 400...

  • Page 20: Removing/Installing The Seat Post

    Locknut Washer Mounting Screw Frame Post Frame Post Mounting Hole NOTE: Seat post on Zoom 300 shown. Seat post on Zoom 400 installs the same way. FIGURE 4.2 Removing/Installing the Seat Post Zoom 300 and Zoom 400 Part No 1122167...

  • Page 21: Adjusting Seat Height

    Securely tighten. Washers 2. Install the seat. Refer to Removing/ Installing the Seat on page 19. Mounting Mounting Bolts Bolts FIGURE 4.4 Removing/Installing the Seat Pivot Part No 1122167 Zoom 300 and Zoom 400...

  • Page 22: Adjusting Seat Depth

    Depth - Assembly Seat Base Mounting Screws Back Depth - Assembly Medium Seat Base Mounting Screws Mounting Holes Back Back Assembly Depth - Assembly High Seat Base FIGURE 4.5 Adjusting Seat Depth Zoom 300 and Zoom 400 Part No 1122167...

  • Page 23: 90° Seat Swivel Adjustment

    9. Rotate the seat to the desired position. 10. Release seat lever to lock seat in desired position. Top View View From Back Seat Seat Seat Lever FIGURE 4.6 90° Seat Swivel Adjustment Part No 1122167 Zoom 300 and Zoom 400...

  • Page 24: Removing/Installing The Seat Positioning Strap

    Securely tighten. Arm Frame One Half (½) of Seat Positioning Strap One Half (½) of Seat Positioning Strap Washer Mounting Screw Mounting Screw Washer FIGURE 4.7 Removing/Installing the Seat Positioning Strap Zoom 300 and Zoom 400 Part No 1122167...

  • Page 25: Section 5-Arms

    2. Remove the arm from the arm support bracket. 3. If necessary, repeat STEPS 1-2 to remove the remaining arm. Arm Mounting Tube Adjustment Knobs Arm Support Bracket FIGURE 5.1 Removing/Installing/Adjusting Arms Part No 1122167 Zoom 300 and Zoom 400...

  • Page 26: Adjusting Arm Width

    5. To position the opposite arm at the same angle, count the exposed threads after the jam nut has been tightened. 6. Set the opposite arm to position determined in STEP 5. Zoom 300 and Zoom 400 Part No 1122167...

  • Page 27: Adjusting Arm Height

    3. Reinstall the lock knob that secures the arm to the arm mounting tube and tighten securely. 4. Repeat STEPS 1-3 for opposite arm, if necessary. Lock Knob Arm Mounting Tube FIGURE 5.3 Adjusting Arm Height Part No 1122167 Zoom 300 and Zoom 400...

  • Page 28: Replacing Armrest Pads

    Arms on page 25. 3. Turn the seat over and remove the six (6) mounting screws, washers and spacers that secure the arm support bracket to the seat assembly. 4. Remove the arm support bracket. Zoom 300 and Zoom 400 Part No 1122167...
  • Page 29 Side View Seat Assembly Spacers Arm Support Bracket Washers Mounting Screws Bottom View Arm Support Bracket Mounting Screws, Mounting Screws, Spacers, and Washers Spacers, and Washers FIGURE 5.5 Removing/Installing Arm Support Bracket Part No 1122167 Zoom 300 and Zoom 400...

  • Page 30: Section 6-Shrouds

    2. Place rear shroud on the frame and press down slightly to engage the hook-and-loop strips on the rear shroud (not shown) with those on the scooter frame. 3. Install the seat. Refer to Removing/Installing the Seat on page 19. DETAIL “B” - ZOOM 400 DETAIL “A” - ZOOM 300 Rear Rear Shroud Shroud...

  • Page 31: Removing/Installing The Front Shroud

    1. Remove the seat. Refer to Removing/Installing the Seat on page 19. 2. Remove the rear shroud. Refer to Removing/Installing the Rear Shroud on page 30. 3. Remove the batteries. Refer to Removing/Installing the Batteries on Zoom 300 on page 86.

  • Page 32: Zoom 400

    Mounting Screws Boot Assembly Front Basket Bracket goes through HERE Front Shroud NOTE: Floormat, tiller and fork assemblies, and scooter frame are not shown. FIGURE 6.3 Removing/Installing the Front Shroud - Zoom 400 Zoom 300 and Zoom 400 Part No 1122167...

  • Page 33: Removing/Installing The Boot Assembly

    Front Basket Front Basket Bracket Bracket Front Front Shroud Shroud NOTE: The Zoom 400 is shown. The Zoom 300 is the same without the front basket bracket. FIGURE 6.4 Removing/Installing the Boot Assembly Part No 1122167 Zoom 300 and Zoom 400...

  • Page 34: Section 7-Wheels And Casters

    4. Repeat STEPS 1-3 to install the other drive wheel. 5. Install the rear shroud. Refer to Removing/Installing the Rear Shroud on page 30. 6. Install the seat. Refer to Removing/Installing the Seat on page 19. Zoom 300 and Zoom 400 Part No 1122167...
  • Page 35 SECTION 7—WHEELS AND CASTERS DETAIL “A” - ZOOM 300 Keystock Warning: Pinch Point Drive Cutout Shaft Washer Scooter Frame Hex Nut Drive Wheel DETAIL “B” - ZOOM 400 Swingarm Scooter Frame Transaxle Assembly Keystock Washer Cutout Drive Shaft Hex Nut Drive Wheel FIGURE 7.1 Removing/Installing the Drive Wheels...

  • Page 36: Removing/Installing The Front Wheel

    Installing WARNING Front wheel MUST be mounted in the lower mounting holes for both the Zoom 300 and Zoom 400 - otherwise injury may result. NOTE: Before installing the front wheel, check the fork for bending. If bent, replace the fork. Refer to Removing/Installing the Fork on page 37.

  • Page 37: Removing/Installing The Fork

    2. Remove the rear shroud. Refer to Removing/Installing the Rear Shroud on page 30. 3. Disconnect the RED and BLACK battery connector from the wiring harness assembly. Refer to FIGURE 12.2 on page 87 for the Zoom 300 and FIGURE 12.3 on page 89 for the Zoom 400.

  • Page 38: Removing/Installing The Caster Assemblies

    Mounting Screws Scooter Frame Fork Stem Mount Front Fork NOTE: Zoom 300 frame is shown. Front fork mounts the same way to Zoom 400. FIGURE 7.3 Removing/Installing the Fork Removing/Installing the Caster Assemblies NOTE: For this procedure, refer to FIGURE 7.4.

  • Page 39: Replacing Foam-Filled Tires Onto Wheel Rims

    7. Install the drive wheel on the drive shaft. Refer to Removing/Installing the Drive Wheels on page 34. Washers Outer Rim Locknuts Wheel Hub Cutout Mounting Screws Inner Rim FIGURE 7.5 Replacing Foam-Filled Tires Onto Wheel Rims Part No 1122167 Zoom 300 and Zoom 400...

  • Page 40: Section 8-Tiller

    (Detail “D” of FIGURE 8.1.): A. Lift up the actuator wedge until the tiller angle adjustment cable is slack. B. Pull the tiller angle adjustment cable from the actuator wedge. 13. Remove the tiller. Zoom 300 and Zoom 400 Part No 1122167...

  • Page 41: Zoom 400

    (Detail “D” of FIGURE 8.1.): A. Lift up the actuator wedge until the tiller angle adjustment cable is slack. B. Pull the tiller angle adjustment cable weight from the actuator wedge. 16. Remove the tiller. Part No 1122167 Zoom 300 and Zoom 400...
  • Page 42 SECTION 8—TILLER DETAIL “A” - ZOOM 300 DETAIL “B” - ZOOM 400 Tiller Cable Tiller Coved Bracket Mounting Washers Coved Screws Mounting Washers Locknuts Screws Locknuts Cable Bracket Tiller Angle Adjustment Tiller Angle Assembly Adjustment Assembly DETAIL “C” - INTERIOR DETAIL “D”...

  • Page 43: Adjusting The Tiller Angle

    3. Spray the inside of the new handgrip with hairspray. 4. Slide the new handgrip onto the tiller handle. Tiller Handle (Under the Handgrip) 5. Repeat STEPS 1 and 4 for the other handgrip. FIGURE 8.3 Replacing Handgrips Part No 1122167 Zoom 300 and Zoom 400...

  • Page 44: Removing/Installing The Upper Tiller Shroud

    3. Remove the rear shroud. Refer to Removing/Installing the Rear Shroud on page 30. 4. Perform one (1) of the following: • On Zoom 300 - Disconnect the RED and BLACK controller connector from the RED and BLACK battery connector. Refer to FIGURE 12.2 on page 87.
  • Page 45 5. Perform one (1) of the following: • On Zoom 300 - Connect the RED and BLACK controller connector to the RED and BLACK battery connector. Refer to FIGURE 12.2 on page 87. • On Zoom 400 - Connect the two (2) BLACK battery connectors to the wiring harness connectors.

  • Page 46: Removing/Installing The Rear Tiller Shroud

    1. Secure the rear tiller shroud to the front tiller shroud using the four (4) mounting screws. Securely tighten. Mounting Screws Front Tiller Shroud Lower Tiller Shroud Mounting Screws FIGURE 8.5 Removing/Installing the Rear Tiller Shroud Zoom 300 and Zoom 400 Part No 1122167...

  • Page 47: Removing/Installing The Headlight

    DETAIL “A” DETAIL “B” Headlight Mounting Bracket Washer Headlight Locknut PC Board Hole in Upper Connector Tiller Shroud Headlight Connector Headlight Mounting Headlight Cable Bolt and Connector FIGURE 8.6 Removing/Installing the Headlight Part No 1122167 Zoom 300 and Zoom 400...

  • Page 48: Removing/Installing The Headlight Mounting Bracket/Front Tiller Shroud

    2. Secure the front tiller shroud and the headlight mounting bracket using the two (2) mounting screws. 3. Install the headlight. Refer to Removing/Installing the Headlight on page 47. 4. Install the rear shroud. Refer to Removing/Installing the Rear Tiller Shroud on page 46. Zoom 300 and Zoom 400 Part No 1122167...

  • Page 49: Replacing The Ignition Switch

    Bottom View of Ignition Top View of Locknut Switch and Attached Wiring Lower Tiller Ignition Shroud Switch Ignition Switch connects HERE Bottom View of PC Board Upper Tiller Shroud FIGURE 8.8 Replacing the Ignition Switch Part No 1122167 Zoom 300 and Zoom 400...

  • Page 50: Replacing The Horn

    Switch and Wires out in this direction Top View of Lower Tiller Horn Switch Shroud connects Horn Switch and Wiring HERE Bottom View of Upper Tiller Shroud FIGURE 8.9 Replacing the Horn Zoom 300 and Zoom 400 Part No 1122167...

  • Page 51: Replacing The Headlight Switch

    Upper Tiller against Upper Tiller Shroud Shroud Headlight Headlight Switch Switch connects HERE Top View of Lower Tiller Headlight Bottom View of Upper Shroud Switch Tiller Shroud FIGURE 8.10 Replacing the Headlight Switch Part No 1122167 Zoom 300 and Zoom 400...

  • Page 52: Replacing The Pc Board

    NOTE: For this procedure, refer to FIGURE 8.11. 1. Disconnect the RED and BLACK controller connector from the RED and BLACK battery connector. Refer to FIGURE 12.2 on page 87 for the Zoom 300 and FIGURE 12.3 on page 89 for the Zoom 400.
  • Page 53 Top View of Lower Tiller Shroud Controller connects HERE Headlight connects HERE Horn connects Headlight Switch (Zoom 400 Only) HERE connects HERE (Zoom 400 Only) PC Board FIGURE 8.11 Replacing the PC Board Part No 1122167 Zoom 300 and Zoom 400...

  • Page 54: Removing/Installing The Tiller Angle Adjustment Assembly

    2. Install the tiller. Refer to Removing/Installing the Tiller on page 40. Mounting Bolts Tiller Angle Adjustment Assembly Front Fork NOTE: Zoom 300 shown. Zoom 400 is the same. FIGURE 8.12 Removing/Installing the Tiller Angle Adjustment Assembly Zoom 300 and Zoom 400 Part No 1122167...

  • Page 55: Replacing The Tiller Wiring Harness

    4. Perform one (1) of the following to remove the batteries: • For Zoom 300 - Refer to Removing/Installing the Batteries on Zoom 300 on page 86. • For Zoom 400 - Refer to Removing/Installing the Batteries on Zoom 400 on page 88.
  • Page 56 Top of Batteries Tie-Wraps Tie-Wraps Top View - Rear Top of Batteries Tiller Wiring Harness Connector Rear Wiring Harness Connector Rear Wiring Harness FIGURE 8.13 Replacing the Tiller Wiring Harness - 300 Zoom 300 and Zoom 400 Part No 1122167...
  • Page 57 Tie-Wraps Tiller Wiring Harness Top of Batteries Top View - Rear Tiller Wiring Harness Connector Rear Wiring Harness Rear Wiring Harness Connector FIGURE 8.14 Replacing the Tiller Wiring Harness - Zoom 400 Part No 1122167 Zoom 300 and Zoom 400...

  • Page 58: Changing To Left-Handed Operation

    2. Perform one (1) of the following to remove the batteries: • For Zoom 300 - refer to Removing/Installing the Batteries on Zoom 300 on page 86. • For Zoom 400 - refer to Removing/Installing the Batteries on Zoom 400 on page 88.

  • Page 59: Calibrating Throttle Potentiometer

    [6] or seven [7] times). 1. Turn power off and remove the key from the ignition. 2. Disengage the brake release lever. Refer to Disengaging/Engaging the Brake Release Lever on page 66. Part No 1122167 Zoom 300 and Zoom 400...
  • Page 60 15. Test drive the scooter. NOTE: If the scooter does not drive, repeat this procedure. If the scooter still does not drive, call Invacare at the number listed on the back cover of this manual. Zoom 300 and Zoom 400...

  • Page 61: Programming Method

    4. Rotate the throttle shaft slowly until the buzzer sounds. NOTE: If the controller version is 2.46 or higher, the Status LED will also glow. 5. Press ENTER to confirm the value when finished. Part No 1122167 Zoom 300 and Zoom 400...

  • Page 62: Section 9-Swingarms

    2. Remove the seat. Refer to Removing/Installing the Seat on page 19. 3. Remove the rear shroud. Refer to Removing/Installing the Rear Shroud on page 30. 4. Remove the batteries. Refer to Removing/Installing the Batteries on Zoom 300 on page 86 and Removing/Installing the Batteries on Zoom 400 on page 88.
  • Page 63 Washer Viscous Element Cotter Pin Transaxle Drive Assembly Wheel Base Frame Viscous Element NOTE: Swingarm on Zoom 300 shown. Swingarm on Zoom 400 removes/installs the same way. FIGURE 9.1 Removing/Installing the Swingarms Part No 1122167 Zoom 300 and Zoom 400...

  • Page 64: Section 10-Transaxle

    5. On Zoom 400 only - disassemble the scooter. Refer to Disassembling/Assembling the Zoom 400 on page 105. 6. Remove the batteries. Refer to Removing/Installing the Batteries on Zoom 300 on page 86 or Removing/Installing the Batteries on Zoom 400 on page 88.

  • Page 65: Removing/Installing The Brake Release Lever

    Zoom 400 on page 105. 8. Install the rear shroud. Refer to Removing/Installing the Rear Shroud on page 30. 9. Install the seat. Refer to Removing/Installing the Seat on page 19. NOTE: Zoom 300 shown. Zoom Washer 400 transaxle removes/installs Drive the same way.

  • Page 66: Disengaging/Engaging The Brake Release Lever

    Bracket Release Cotter Pin Lever NOTE: Zoom 300 shown. Zoom 400 brake release lever removes/installs the same way. FIGURE 10.2 Removing/Installing the Brake Release Lever Disengaging/Engaging the Brake Release Lever WARNING Ensure that the brake-release lever is in the engaged position before driving. There should be an audible "click"...
  • Page 67 Transaxle Engaged (Push Lever In) Disengaged (Pull Lever Out) Brake Release NOTE: Zoom 300 shown. Zoom 400 brake Lever release lever engages the same way. FIGURE 10.3 Disengaging/Engaging the Brake Release Lever Part No 1122167 Zoom 300 and Zoom 400...

  • Page 68: Section 11-Controller

    3. Remove the rear shroud. Refer to Removing/Installing the Rear Shroud on page 30. 4. Perform one (1) of the following: • On Zoom 300 - Disconnect the RED and BLACK controller connector from the RED and BLACK battery connector. Refer to FIGURE 12.2 on page 87.

  • Page 69: Installing

    SECTION 11—CONTROLLER DETAIL “B” - ZOOM 400 DETAIL “A” - ZOOM 300 Locknuts Mounting Controller Screws Controller Base Frame Controller Tray Mounting Screws Controller Locknuts Tray Locknut Scooter Frame DETAIL “C” - LOCATION OF CONNECTORS 6-way Rear Harness 4-way Motor Connector...

  • Page 70: Replacing The Controller Tray

    86 and Removing/Installing the Batteries on Zoom 400 on page 88. 6. Perform one (1) of the following: • On Zoom 300 - Connect the RED and BLACK controller connector to the RED and BLACK battery connector. Refer to FIGURE 12.2 on page 87.
  • Page 71 19. Connect the tiller wiring harness to the rear wiring harness (refer to FIGURE 8.13). 20. Install the batteries. Refer to Removing/Installing the Batteries on Zoom 300 on page 86 or Removing/Installing the Batteries on Zoom 400 on page 88.

  • Page 72: Zoom 400

    18. Install the rear wiring harness. Refer to Removing/Installing Rear Wiring Harness on page 74. 19. Connect the tiller wiring harness to the rear wiring harness. Refer to FIGURE 8.14. 20. Assemble the scooter. Refer to Disassembling/Assembling the Zoom 400 on page 105. Zoom 300 and Zoom 400 Part No 1122167...
  • Page 73 DETAIL “A” - REMOVE/INSTALL WIRING HARNESS CONNECTORS Mounting Bolts Connector Controller Tray Connector Locknuts Circuit Breaker NOTE: Charger, Controller and Wiring harness shown removed. FIGURE 11.3 Replacing the Controller Tray - Zoom 400 Part No 1122167 Zoom 300 and Zoom 400...

  • Page 74: Removing/Installing Rear Wiring Harness

    • 8-way rear harness connector • 4-way motor connector 2. Disconnect the batteries. Refer to Removing/Installing the Batteries on Zoom 300 on page 86 or refer to Removing/Installing the Batteries on Zoom 400 on page 88. 3. Disconnect the circuit breaker. Refer to Replacing/Resetting the Circuit Breaker on page 76.
  • Page 75 Connector Circuit Breaker Screws Controller Tray Charger Connector Rear Harness Connector 4-Way 8-Way 6-Way Locknuts Connector Connector Connector DETAIL “B” - ZOOM 300 Screws Battery Connector 6-Way Connector Charger Connector 4-Way Connector Rear Harness Connector 8-Way Connector Controller Locknuts Tray Circuit Breaker FIGURE 11.4 Removing/Installing Rear Wiring Harness...

  • Page 76: Replacing/Resetting The Circuit Breaker

    3. Remove the rear shroud. Refer to Removing/Installing the Rear Shroud on page 30. 4. Perform one (1) of the following: • On Zoom 300 - Disconnect the controller from the batteries by pulling the RED and BLACK controller connector from the RED and BLACK battery connector. Refer to FIGURE 12.2.
  • Page 77 SECTION 11—CONTROLLER YELLOW Metal Connectors DETAIL “A” - ZOOM 300 from Wiring Harness Locknuts Circuit Breaker Controller Tray Circuit Breaker Mounting Hole YELLOW Metal Connectors from Wiring Harness DETAIL “B” - ZOOM 400 Controller Tray Circuit Breaker Locknuts Circuit Breaker Mounting Hole FIGURE 11.5 Replacing/Resetting the Circuit Breaker - Replacing...

  • Page 78: Resetting Circuit Breaker

    3. To reset, do one (1) of the following: • For Zoom 300 - Press circuit breaker button located at rear of the controller tray. • For Zoom 400 - Press circuit breaker button located at front of controller tray.

  • Page 79: Replacing The Fuse

    3. Pull fuse out and install new fuse (Detail “A” of FIGURE 11.7). 4. Reverse STEPS 1-4 to reassemble the powered scooter. Rear Wiring Fuse Holder Harness DETAIL “A” Batteries Fuse Fuse Holder Fuse Holder Controller FIGURE 11.7 Replacing the Fuse Part No 1122167 Zoom 300 and Zoom 400...

  • Page 80: Changing To Left-Handed Operation

    NOTE: After a few seconds, if a fault is indicated on the display, refer to the back of the programming card (provided with the programmer) for details. 7. Press the MENU key to scroll through all of the menus available with the programmer. Zoom 300 and Zoom 400 Part No 1122167...

  • Page 81: Main Menu

    SECTION 11—CONTROLLER DETAIL “A” - ZOOM 300 Front of Scooter Top View of Controller Scooter Programmer Port with Protective End Cap Rear of Scooter Programmer Port with DETAIL “B” - ZOOM 400 Protective End Cap Controller Rear View of Scooter FIGURE 11.8 Changing to Left-Handed Operation - Programming the Controller...

  • Page 82: Options Menu

    SETTING Polarity of the Throttle Potentiometer is reversed (Left Hand Drive) POT REVERSE Normal polarity of the Throttle Potentiometer (Right Hand Drive) Sleep time is enabled. ENABLE SLEEP Sleep time is disabled. Zoom 300 and Zoom 400 Part No 1122167...

  • Page 83: Speed Lever In Neutral Menu

    NOTE: If the controller version is 2.46 or higher, the Status LED will also glow. 4. Press ENTER to confirm the value when finished. Controller Version Menu This menu is used to display the current version of the Controller software. Part No 1122167 Zoom 300 and Zoom 400...

  • Page 84: Section 12-Batteries And Charger

    DO NOT tip the batteries. Keep the batteries in an upright position. Invacare strongly recommends that battery installation and battery replacement always be done by a qualified technician. All battery terminals caps (two [2] on the LEFT battery and two [2] on the RIGHT battery) MUST be installed prior to use.

  • Page 85: Recommended Battery Type

    When connecting the battery cables to the batteries, the battery cables MUST be connected to the battery terminals/posts as shown in FIGURE 12.2 for Zoom 300 and FIGURE 12.5 for Zoom 400 - otherwise damage to the battery may result.

  • Page 86: Removing/Installing The Batteries On Zoom 300

    SECTION 12—BATTERIES AND CHARGER Removing/Installing the Batteries on Zoom 300 NOTE: When removing or installing batteries, ensure that the battery harness connectors completely grip the terminals of the battery. Connection should be tight and secure. Pliers can be used to gently crimp the contact to strengthen the connection.
  • Page 87 NEGATIVE (-) BLACK Battery Cable POSITIVE (+) RED Battery Terminal NEGATIVE (-) BLACK Battery Terminal NEGATIVE (-) BLACK POSITIVE (+) RED Battery Terminal Battery Terminal FIGURE 12.2 Removing/Installing the Batteries on Zoom 300 Part No 1122167 Zoom 300 and Zoom 400...

  • Page 88: Removing/Installing The Batteries On Zoom 400

    When battery is in proper position, remove lifting strap (Detail “A” of FIGURE 12.3). 7. Connect the two (2) BLACK battery connectors to the wiring harness connectors (Detail “C” of FIGURE 12.3). Zoom 300 and Zoom 400 Part No 1122167...
  • Page 89 DETAIL “D” - REMOVING/INSTALLING THE BATTERIES Batteries Batteries Removed Installed Battery Tray Battery Tray Battery Strap NOTE: Seat and Rear Shroud not shown for clarity. FIGURE 12.3 Removing/Installing the Batteries on Zoom 400 Part No 1122167 Zoom 300 and Zoom 400...

  • Page 90: Connecting/Disconnecting The Battery Cables On The Zoom 400

    Battery Terminal Cap NOTE: Only battery cable and terminal cap shown. Both caps install in the same manner. FIGURE 12.4 Connecting/Disconnecting the Battery Cables on the Zoom 400 - Installing Battery Terminal Caps Zoom 300 and Zoom 400 Part No 1122167...

  • Page 91: Disconnecting

    1. Remove the seat. Refer to Removing/Installing the Seat on page 34. 2. Remove the rear shroud. Refer to Removing/Installing the Rear Shroud on page 44. 3. Remove the batteries. Refer to Removing/Installing the Batteries on Zoom 400 on page 88. Part No 1122167 Zoom 300 and Zoom 400...

  • Page 92: Replacing The Charger

    Work should be performed in an area without risking damage to carpeting or floor covering. 2. Turn power off and remove the key from the ignition. 3. Remove the seat. Refer to Removing/Installing the Seat on page 19. Zoom 300 and Zoom 400 Part No 1122167...
  • Page 93 19. Install the rear shroud. Refer to Removing/Installing the Rear Shroud on page 30. 20. Install the seat. Refer to Removing/Installing the Seat on page 19. 21. Insert the key into the ignition and turn the power on to drive the scooter. Part No 1122167 Zoom 300 and Zoom 400...
  • Page 94 Tie-Wrap DC Charger Cable Charger Cable to AC Receptacle DC Charger Connector AC Receptacle to Charger NOTE: Connectors to Controller not shown for clarity. FIGURE 12.6 Replacing the Charger - Zoom 300 Zoom 300 and Zoom 400 Part No 1122167...

  • Page 95: Zoom 400

    17. Install the rear shroud. Refer to Removing/Installing the Rear Shroud on page 30. 18. Install the seat. Refer to Removing/Installing the Seat on page 19. 19. Insert the key into the ignition and turn the power on to drive the scooter. Part No 1122167 Zoom 300 and Zoom 400...
  • Page 96 Tray Mounting Tie-Wraps Screws Charger Connector Tie- Wrap Controller Tray Charger Port Charger (hidden from view) NOTE: Connectors to Controller not shown for clarity. FIGURE 12.7 Replacing the Charger - Zoom 400 Zoom 300 and Zoom 400 Part No 1122167...

  • Page 97: Charging The Batteries

    3. Refer to Battery Charger Operation - Charger Indicator Light on Tiller on page 98. AC Power Cord Rear Shroud Rear Shroud Rear Shroud Charger Port NOTE: Charger port on Zoom 300 shown. Charger port on Zoom 400 is similar. FIGURE 12.8 Charging the Batteries Part No 1122167 Zoom 300 and Zoom 400...

  • Page 98: Battery Charger Operation - Charger Indicator Light On Tiller

    Check that all connections are secure. If Charge LED indicator is still OFF, unplug AC power cord from the on-board battery charger and wall outlet. Contact dealer or a qualified technician. DETAIL “A” - ZOOM 300 CONTROL PANEL DETAIL “B” - ZOOM 400 CONTROL PANEL BATTERY LEVEL...

  • Page 99: Section 13-Maintenance And Troubleshooting

    1. Before storing the scooter for prolonged periods of time, perform the following. A. Charge the batteries. Refer to Charging the Batteries on page 97. B. Remove the batteries. Refer to Removing/Installing the Batteries on Zoom 300 on page 86 or refer to Removing/Installing the Batteries on Zoom 400 on page 88.

  • Page 100: Lubrication Points

    Contact Invacare for Service. lar. Powered scooter does not Poor battery terminal con- Clean terminals. respond to commands. nection. Power indicator off - even after Electrical malfunction. Contact Invacare for Service. recharging. Zoom 300 and Zoom 400 Part No 1122167...

  • Page 101: Controller

    • If the voltage is 0V, check that an inhibit switch is not engaged (e.g., from the battery charger). When 0V is applied to this terminal, driving will be inhibited. Status light is FLASHING. Check Error Codes chart on page 102. Part No 1122167 Zoom 300 and Zoom 400...

  • Page 102: Error Codes

    The scooter has drawn too much current for too time-out. long, possibly because the motor has been over- worked, jammed or stalled. Turn the scooter power off, leave for a few minutes and then turn back on again. Zoom 300 and Zoom 400 Part No 1122167...
  • Page 103 The throttle or its wiring is faulty. Check wiring. error. Motor volts Drive Inhibited The motor or its wiring is faulty. Check wiring. error. Other internal Drive Inhibited Call Invacare Technical Services Department. errors. Part No 1122167 Zoom 300 and Zoom 400...

  • Page 104: Section 14-Transporting

    2. Remove the seat. Refer to Removing/Installing the Seat on page 34. 3. Remove the rear shroud. Refer to Removing/Installing the Rear Shroud on page 44. 4. Remove the batteries. Refer to Removing/Installing the Batteries on Zoom 300 on page 50.

  • Page 105: Disassembling/Assembling The Zoom 400

    Rear Shroud on page 44 Refer to Removing/Installing the Front Basket on page 64 Refer to Removing/Installing the Batteries on Zoom 300 on page 50 Refer to Adjusting the Tiller Angle on page 43 FIGURE 14.1 Disassembling/Assembling the Zoom 300 Disassembling/Assembling the Zoom 400 NOTE: For this procedure, refer to FIGURE 14.2.

  • Page 106: Assembling

    (Detail “B” of FIGURE 14.2). 5. Install the batteries. Refer to Removing/Installing the Batteries on Zoom 400 on page 53. 6. Install the rear shroud. Refer to Removing/Installing the Rear Shroud on page 44. Zoom 300 and Zoom 400 Part No 1122167...
  • Page 107 Lock Frame Mounting Front Frame Mounting Lock Bracket Assembly Bracket Lever DETAIL “C” - REMOVE/ Rear Frame INSTALL FRONT FRAME Assembly FROM REAR FRAME ASSEMBLY FIGURE 14.2 Disassembling/Assembling the Zoom 400 Part No 1122167 Zoom 300 and Zoom 400...

  • Page 108: Section 15-Scooter Accessories

    1. To remove: Lift up on the basket and remove it from the mounting clips. 2. To install: A. Align the slots of the basket with the mounting clips on the tiller. B. Push down on the basket to secure it in place. DETAIL “A” - ZOOM 300 Slots Tiller Front...

  • Page 109: Removing/Installing The Front Basket Mounting Bracket

    Installing 1. Perform one (1) of the following: • On Zoom 300 - Install the front basket mounting bracket to the tiller using the two (2) mounting screws, locknuts and washers. • On Zoom 400 - Install the front basket mounting bracket to the mounting tab in the scooter frame using the two (2) mounting screws, locknuts and washers.

  • Page 110: Installing/Removing The Crutch/Cane Holder

    2. Remove the mounting knob that secures the crutch/cane holder in place. 3. Remove the crutch/cane holder from the accessory tube. Crutch Cane Holder Mounting Knob Seat Accessory Tube Hook Base FIGURE 15.3 Installing/Removing the Crutch/Cane Holder Zoom 300 and Zoom 400 Part No 1122167...

  • Page 111: Installing/Removing The Safety Flag

    2. Remove the mounting knob that secures the bracket in place. 3. Remove the bracket from the accessory tube located on the back of the seat. Mounting Knob Seat Safety Flag Bracket Accessory Tube FIGURE 15.4 Installing/Removing the Safety Flag Part No 1122167 Zoom 300 and Zoom 400...

  • Page 112: Installing/Removing/Using The Walker Holder

    NOTE: Walker MUST be folded before using Hook and walker holder. Loop Strap 2. Hang folded walker on walker holder hooks. 3. Secure walker with hook and loop FIGURE 15.6 Using the Walker Holder straps. Zoom 300 and Zoom 400 Part No 1122167...

  • Page 113: Installing/Removing The Rear Mounted Basket

    3. Remove the basket bracket from the accessory tube. 4. Tighten the mounting knob. Mounting Seat Knob Rear Basket Accessory Tube Slots Mounting Clips Basket Bracket FIGURE 15.7 Installing/Removing the Rear Mounted Basket Part No 1122167 Zoom 300 and Zoom 400...
  • Page 114 SECTION 15—SCOOTER ACCESSORIES NOTES Zoom 300 and Zoom 400 Part No 1122167...

  • Page 115: Limited Warranty

    In the event you do not receive satisfactory warranty service, please write directly to Invacare at the address on the bottom of the back cover. Provide dealer's name address, date of purchase, indicate nature of the defect and, if the product is serialized, indicate the serial number.
  • Page 116 Invacare Corporation Canada Invacare is a registered trademark of One Invacare Way 570 Matheson Blvd E Unit 8 Invacare Corporation. Elyria, Ohio USA Mississauga Ontario Teflon is a registered trademark of E.I. 44036-2125 L4Z 4G4 Canada DuPont Nemours and Company.

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Hmv zoom 400

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