Invacare Tornado Service Manual
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Invacare Tornado Service Manual

Invacare Tornado Service Manual

Wheelchair tornado
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Invacare® Tornado

SERVICE MANUAL

These instructions contain information about:
Troubleshooting
Repair
Edition: 03.2004

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Summary of Contents for Invacare Tornado

  • Page 1: Service Manual

    Invacare® Tornado SERVICE MANUAL These instructions contain information about: Troubleshooting Repair Edition: 03.2004...

  • Page 2: General Information

    • You can find information about ordering spare parts in the spare parts catalogue. • Use only genuine Invacare® spare parts. Using parts from any other source will void the warranty! • We reserve the right to make any alterations on the grounds of technical improvements.
  • Page 3 Tornado Service Manual Invacare® Ltd Invacare Mecc San s.r.l. South Road Via Dei Pini, 62 Bridgend I - 36016 Thiene (VI) Mid Glamorgan - CF31-3PY ITALIA United Kingdom +39 - (0) 445-380059 (Customer Service): +44 - (0) 1656 - 647 327...
  • Page 4 Tornado Service Manual As at: 19.03.2004 Page 3...
  • Page 5 Tornado Service Manual Notes on transport • If the wheelchair has to be shipped back to the manufacturer for major repairs, you should always use the original packaging for transport. • You should also include as accurate a fault description as possible.

  • Page 6: Table Of Contents

    5.1.1 Diagnosing driving faults 5.1.2 Diagnosing problems with electric actuators 5.1.3 REM24 Error Codes and Diagnostic Codes Troubleshooting the Invacare® Tornado with Shark Remote 5.2.1 Diagnosing driving faults 5.2.2 Shark Error Codes and Diagnostic Codes REPAIR WORK Replacing the drive motors...
  • Page 7 Tornado Service Manual 6.10 Replacing the Anti-Dive Spring and/or its plastic guides 6.11 Repairing a flat tyre 6.12 Replacing a drive wheel Page 6 As at:19.03.2004...

  • Page 8: Safety And Assembly Instructions

    Tornado Service Manual Safety and assembly instructions These safety instructions are intended to prevent accidents during 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 9: After Completion Of Work / Before Operating The Wheelchair

    Tornado Service Manual After completion of work / before operating the wheelchair: Caution: • Check all fixings for tight fit. • Check all parts for correct interlocking. • Only operate wheelchair with correct tyre pressure (2.5 bar). • Check electrical components for correct functioning, incorrect polarity of cables can result in damage to the electronics.

  • Page 10: Tool List

    • wheel bearing puller • multimeter with probes and various cable clips • soldering iron 30 W • front wheel hub puller (available from INVACARE Service) • circlip pliers for star lock caps (commercially available, make Tigtemeyer) • pop riveting tool •...

  • Page 11: Tightening Torques And Loctite

    Caution: Tighten the front wheel on the castor fork fingertight and without play! Apply micro- encapsulated adhesive to the thread! INVACARE uses VIBRATITE VC3 for this purpose. Caution: When reassembling the front wheel fork in the head tube, ensure that the fork is free- moving! The union should be tightened fingertight, and should not result in stiff movement of the head tube bearing.

  • Page 12: Layout Of Components And Modules

    Tornado Service Manual Layout of components and modules The following image shows the Tornado 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...
  • Page 13 Tornado Service Manual The following image shows the Tornado from the front right, with the lifter raised Lifter actuator Page 12 As at:19.03.2004...

  • Page 14: Service Plan (1X Annually)

    Tornado Service Manual Service plan (1x annually) Component Check Action Notes • Armrest damage and Tighten screws, replace Armrests and fastening padding if damaged side panels • Side panel damage and Tighten screws, replace fixing side panels if damaged • Cushion...
  • Page 15 Tornado Service Manual Component Check Action Notes • Check batteries for See "Replacing Replace batteries if Batteries batteries" on page damage necessary • Check battery charge See User Manual Charge batteries • Check contacts and See "Replacing Clean contacts and batteries"...

  • Page 16: Troubleshooting The Tornado

    Tornado Service Manual Troubleshooting the Tornado Troubleshooting the Tornado with ACS If a problem occurs with the wheelchair, then please proceed as follows: • Identify the possible cause of the fault by using the troubleshooting tables below. • Check the Status Display on the remote. Identify the error code if it is flashing.
  • Page 17 Tornado Service Manual PROBLEM OTHER POSSIBLE SOLUTION REFERENCE SYMPTOMS CAUSE • Replace Status display Speed See "Adjusting and on remote reduction replacing the speed cable or flashes 2x, switch on the reduction switch" on switch drive mode lifter may be...

  • Page 18: Diagnosing Problems With Electric Actuators

    Tornado Service Manual 5.1.2 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 • Replace the Electric Remote CLAM is See "Replacing...

  • Page 19: Rem24 Error Codes And Diagnostic Codes

    Tornado Service Manual 5.1.3 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.
  • Page 20 Tornado Service Manual Flash code: Meaning: Solution: Notes • Completely discharge See User Manual 7 x flashes Pre-charge battery battery • 8 x flashes Battery voltage too high See User Manual Switch lights on to of battery charger lower battery voltage •...

  • Page 21: Troubleshooting The Invacare® Tornado With Shark Remote

    Tornado Service Manual Troubleshooting the Invacare® Tornado with Shark Remote If a problem occurs with the wheelchair, then please proceed as follows: • Identify the possible cause of the fault by using the troubleshooting tables below. • Check the Status Display on the remote. Identify the error code if it is flashing.
  • Page 22 Tornado Service Manual PROBLEM OTHER POSSIBLE SOLUTION REFERENCE SYMPTOMS CAUSE Wheelchai None • Replace the Batteries may See "Replacing r does not be defective batteries" on page 29 batteries drive (voltage not smoothly stable) • Replace the Drive motor(s) See "Replacing the may be drive motors"...

  • Page 23: Shark Error Codes And Diagnostic Codes

    Tornado Service Manual 5.2.2 Shark 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.
  • Page 24 Tornado Service Manual FLASH Meaning Solution Notes CODE • Error in Shark See "Checking the Check all cables and connecting plugs power module cables" on page in the Shark system. • Replace power module See "Replacing components of the ACS or Shark electronics"...

  • Page 25: Repair Work

    Repair Work Replacing the drive motors Find out here how to replace the Tornado drive motors. 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 26 Tornado Service Manual • Loosen the turn-lock fasteners (1) and remove the inner side panelling. • Remove the securing ring (1) and release the uncoupling rod assembly from the drive unit. • Open the electronic panelling, pushing the rear side panelling away slightly using a large, flat screwdriver.
  • Page 27 Tornado Service Manual • Secure the drive unit against falling out by placing a wooden block or styrofoam block underneath. • Insert the hexagon socket (5mm) through the bore and unscrew the rear bolts (1) on the drive suspension. •...

  • Page 28: Replacing Components Of The Acs Or Shark Electronics

    Tornado Service Manual Replacing components of the ACS or Shark electronics This chapter will explain how to replace the components of either the ACS or the Shark electronic systems on the Tornado. Requirements: • Large flat-bladed screwdriver • Phillips screwdriver •...
  • Page 29 Tornado Service Manual If replacing the Power Module (ACS or Shark): • Remove the hexagonal socket head screws (1) on both sides of Power Module. • Pull the Module up and out. If replacing the CLAM / Lighting Module : •...

  • Page 30: Replacing Batteries

    Tornado Service Manual Replacing batteries Find out here how to replace the Tornado 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 31 Tornado Service Manual • Move the lifter to the uppermost position. • Raise the lifter just a little more so that the retaining mechanism (1) locks into place. • Check whether the retaining mechanism (1) is fully locked into place.
  • Page 32 Tornado Service Manual CAUTION! Electronics can be damaged! • Disconnect all electronic components from the batteries before commencing work on the batteries. A short-circuit during the following work could otherwise damage the electronics. • Disconnect all plugs from the electronic components.
  • Page 33 Tornado Service Manual • Installation is carried out in the reverse order. Please note The battery inserters can be inserted between the battery and the carrying belt. They are thus easier to install. Please note The battery poles on the rear battery must point backward and those on the front battery to the front.
  • Page 34 Tornado Service Manual • 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.

  • Page 35: Replacing The Main Fuse

    Needless to say, using such a device against Invacare’s strong recommendation not to (in the User Manual) will void the warranty. CAUTION! Danger of fire! •...
  • Page 36 Tornado Service Manual • Reassemble all parts, such as the rear cover, in reverse order. • Test all wheelchair functions to make sure everything is working properly. As at: 19.03.2004 Page 35...

  • Page 37: Checking The Cables

    Service Manual Checking the cables Find out here how you can check the plug connections on the Tornado electronics. CAUTION! Cables can pull off! • Remove the electronic panelling carefully on vehicles with a lighting system so that the cables are not pulled off the light circuit board.
  • Page 38 Tornado Service Manual • Check all vehicle functions. As at: 19.03.2004 Page 37...

  • Page 39: Replacing The Remote

    Tornado Service Manual Replacing the remote Pre-requisites: • Crosstip screwdriver • Wizard software or hand programming device Please note All remotes are supplied with a standard drive programme. This does not enable lighting and regulating motors to function. If you do not wish to re-adjust all parameters, preferably save the current drive programme before replacing the remote.

  • Page 40: Testing An Actuator Motor

    Tornado Service Manual 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 41: Adjusting And Replacing The Speed Reduction Switch

    Tornado Service Manual 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 42: Replacing The Steering Head Bearings On The Front Or Rear Castor Wheels

    Tornado Service Manual 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...
  • Page 43 Tornado Service Manual • Prop the wheelchair up on the side that you want to change the bearings on by placing an object underneath the drive wheel. • Loosen and remove the 19 mm nut using the socket wrench. Hold the wheel so it does not rotate while removing the nut.

  • Page 44: Rear Castor Wheels

    Tornado Service Manual 6.9.2 Rear Castor Wheels • Use the flat-bladed screwdriver to carefully pry the rear plastic cover off, as shown in the picture. • Prop up the wheelchair by lifting it up on the side that you want to work on and then placing the wooden block underneath the battery box on that side.
  • Page 45 Tornado Service Manual The steering wheels should swivel freely after assembly, but there should be no play in the bearings. • First tighten the nut to 20 Nm +/- 2 Nm. • Loosen the nut a little. • Retighten to 15 Nm +/- 1.5 Nm Page 44 As at:19.03.2004...
  • Page 46 Tornado Service Manual 6.10 Replacing the Anti-Dive Spring and/or its plastic guides 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 47 Tornado Service Manual • Release the forward plastic clip (1) that holds the inner shroud. • Remove the inner shroud. • Use the 6 mm Allen key and the 13 mm open-ended wrench to remove the lower bolt (1) that attaches the Walking Beam and the steering head tube of the front castor wheel.
  • Page 48 Tornado Service Manual • Reassembly is done in reverse order. As at: 19.03.2004 Page 47...

  • Page 49: Repairing A Flat Tyre

    Tornado Service Manual 6.11 Repairing a flat tyre 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 50 Tornado Service Manual • Unscrew valve cap. • Depressurise tyre by pressing in the pin in the valve . • Remove the 5 cylinder head screws (back of the wheel, 2. • Remove the rim halves from the tyre. •...
  • Page 51 Tornado Service Manual 6.12 Replacing a drive wheel 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! •...

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