Invacare Comet Service Manual
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Invacare Comet Service Manual

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Invacare® Comet
SERVICE MANUAL
These instructions contain information about:
testing work
repair work
Edition:11.04.08

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Summary of Contents for Invacare Comet

  • Page 1 Invacare® Comet SERVICE MANUAL These instructions contain information about: testing work repair work Edition:11.04.08...
  • Page 2 +34 - (0)972 - 49 32 20 contactsp@invacare.com Poligon Industrial de Celrà WWW: www.invacare.es 17460 Celrà (Girona) ESPAÑA +33 - (0)247 - 62 64 66 Invacare® Poirier SAS Fax : +33 - (0)247 - 42 12 24 Route de St Roch F-37230 Fondettes contactfr@invacare.com WWW: www.invacare.fr...
  • Page 3 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 ITALIA +353 - 18 10 70 84 Invacare Ireland Ltd.
  • 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 Important symbols in this manual SAFETY AND ASSEMBLY INSTRUCTIONS Before any inspection or repair work General safety information and notes on assembly / disassembly TIGHTENING TORQUES SERVICE PLAN (1X ANNUALLY) OPERATIONAL FAULTS Operational faults 5.1.1...
  • Page 6 6.10 Replacing steering linkage/steering rod 6.11 Replacing operating console 6.12 Replacing bend speed reducer 6.13 Replacing the potentiometer 6.14 Replacing front headlight (lamp) 6.15 Replacing the front direction indicators 6.16 Replacing centre brake light 6.17 Replacing rear lights/direction indicators 6.18 Replacing the electronics module 6.19 Updating software...

  • Page 7: 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 8 NOTE: This symbol identifies general information which is intended to simplify working with your product and which refers to special functions. Requirements: • This symbol identifies a list of various tools, components and items which you will need in order to carry out certain work.

  • Page 9: Safety And Assembly Instructions

    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 10 • 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 11: 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 Tightening torque 6 Nm 10 Nm 25 Nm...

  • Page 12: Service Plan (1X Annually)

    Service plan (1x annually) Component Check Remedy Notes • Welded seams, • Tighten screws, Seat: fixings and replace parts if upholstery damaged • Check fixings, • Tighten screws, Frames welded seams and replace parts if (chassis) / battery mounting damaged battery •...
  • Page 13 Component Check Remedy Notes • Check drive • Update software Drive program electronics program version Newer version available? • Check cable and • Adjust or replace Speed connecting plug sensor on relay. reduction in • Check function bends...

  • Page 14: Operational Faults

    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. • Carry out the necessary checks and repairs as recommended in the following table. 5.1.1 Drive fault diagnosis PROBLEM...

  • Page 15: Error Codes And Diagnostic Codes

    PROBLEM OTHER POSSIBLE SOLUTION Documentation SYMPTOMS CAUSE Scooter • Replace None Drive motor See "Replacing the judders in motor(s) defective drive motor" on page 19 drive mode • Replacing the Drive lever See "Replacing the potentiometer potentiometer potentiometer" on page defective Batteries •...
  • Page 16 • 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 17 • 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 18 • The motor or its cabling is defective Check the cabling for open or short- circuited circuitry. Miscellaneous Stops driving • Contact your Invacare® dealer. internal fault Push/freewheel Stops driving • The Scooter has exceeded the mode error permissible maximum speed during pushing or freewheeling.

  • Page 19: Repair Work

    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 20 • From the operating manual: • Unscrew the rear wheel fixing bolts. • Remove rear wheels. • Disconnect plugs (1, 2, 3) from electronic module. • Disconnect brake light plug (4). • Disconnect motor brake plug (5). • Remove the bolt (2) on the wheel cover. •...
  • Page 21 • Remove screws (1) on disengaging lever (2). • Remove disengaging lever (2). • Lifted drive out of its holder and take it out of the frames to the side. • Replace drive unit. • Reassembly of the drive takes place in reverse order •...

  • Page 22: Replacing Wheel Suspension

    Replacing wheel suspension CAUTION! Accident hazard. • 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. Requirements: •...
  • Page 23 • Reassembly takes place in the reverse order. • Apply brake and hold, tighten wheel bolts at same time. • Adjust tracking (see chapter "Replacing steering linkage/steering rod“). • Check function (trial run).

  • Page 24: Replacing Shock Absorber

    Replacing shock absorber CAUTION! If the scooter is supported by the support wheels, it will no longer be braked by the motor brake. The scooter can roll away out of control. • Place the scooter rear frame on a piece of supporting wood once you have removed the wheels.
  • Page 25 • Replacing front shock absorber: • Remove top screw (1) on shock absorber (2). • Remove bottom screw (4) on shock absorber (2). • Replace shock absorber (2). • Reassembly of the shock absorber takes place in reverse order. • Use setting screw (3) to set the spring hardness.

  • Page 26: Replacing Front Axle

    Replacing front axle CAUTION! Accident hazard. • 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. NOTE: The front axle can only be replaced on the 3-wheel version.
  • Page 27 • Reassembly of the axle takes place in reverse order • Operate brake and hold, tighten axle bolts at same time. • Check function (trial run).

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

    Replacing steering column/fork 3-wheel CAUTION! Accident hazard. • 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. Requirements: •...
  • Page 29 • Replacing steering column: • Remove drive lever screws (3). • Remove drive lever (2). • Unscrew the bolts (1) on the drive console. • Remove drive console. • Remove screws (1) on rear steering column cladding. • Remove steering column cladding. •...
  • Page 30 • Disconnect cable (1, 2) from wiring harness. • Remove screws (3) on front steering column cladding. • Remove the front steering column cladding. • Loosen the brake cable. (see Chapter "Replacing brakes“) • Unscrew screw at clamp (1). • Unscrew fixing bolt for steering column and remove.
  • Page 31 • Dismantle front wheel (see chapter "Replace front axle“). • Pull off clamp (1). • Loosen fork bolt (2). • Loosen knurled screw (3). • Replace fork. • Reassembly takes place in the reverse order. • Operate brake and hold, tighten axle bolts at same time.

  • Page 32: Replacing Brakes

    Replacing brakes CAUTION! Accident hazard. • 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. NOTE: The front axle can only be replaced on the 3-wheel version.
  • Page 33 • 4-wheel version: • Slacken both brake cables. • Disconnect brake cable at affected wheel. • Loosen wheel bolt. • Pull wheel and brake off shaft. • Pull brake out of brake drum. • Replace brake lining or complete brake. •...

  • Page 34: Replacing Brake Cable

    Replacing brake cable CAUTION! Accident hazard. • 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. Requirements: •...

  • Page 35: Replacing Lifter/Lifter Electronics

    Replacing lifter/lifter electronics CAUTION! Accident hazard. • 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. Requirements: •...
  • Page 36 • Replacing fuses in lifter electronics: • Unscrew lifter electronics cover. • Replace fuse (1). • Reassembly takes place in the reverse order. • Check function...

  • Page 37: Replacing Steering Linkage/Steering Rod

    6.10 Replacing steering linkage/steering rod CAUTION! Accident hazard. • 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. Requirements: •...
  • Page 38 • 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). • Replace steering rod. •...

  • Page 39: Replacing Operating Console

    6.11 Replacing operating console CAUTION! Burn and scald hazard if power cable is short-circuited! • Interrupt the power supply by removing the battery plugs before you start work on the electronic system. NOTE: The plugs on the operating console cannot be wrongly connected because all plugs have a different size and only fit in one socket.
  • Page 40 • Reassembly of the operating console takes place in reverse order • Check all functions (trial run).

  • Page 41: Replacing Bend Speed Reducer

    6.12 Replacing bend speed reducer CAUTION! Accident hazard. • 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. Requirements: •...
  • Page 42 • 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 43: Replacing The Potentiometer

    6.13 Replacing the potentiometer CAUTION! Burn and scald hazard if power cable is short-circuited! • Interrupt the power supply by removing the battery plugs before you start work on the electronic system. CAUTION! Risk of accidents! • The new potentiometer must be set to the middle position before inserting. Potentiometers which are not in the middle position can result in dangerous driving situations! Requirements: •...
  • Page 44 • Disconnect potentiometer plug (1) from the operating console. • Remove screws (1) on potentiometer. • Replace potentiometer • Reconnect potentiometer plug (1) with operating console.
  • Page 45 • Setting the potentiometer to the middle position: • Loosen the bolts (1) on the drive lever mounting. • Twist the potentiometer shaft (2) until the same resistance (approx. 5kOhm) is measured between the central connection cable (3) and both outputs (4). •...

  • Page 46: Replacing Front Headlight (Lamp)

    6.14 Replacing front headlight (lamp) NOTE: You can replace the headlight without removing the chassis. If, however, the working space is too small, you can remove the chassis as described in chapter "Replacing steering column/forks". Requirements: • Phillips screwdriver • Remove the seat.
  • Page 47 • 4-wheel version • Remove screws (1) on front headlight under front cladding. • Disconnect direction indicator cable (2) at wiring harness behind steering column cladding. • Remove headlight. • Remove screws (1) on headlight glass. • Remove headlight glass. •...

  • Page 48: Replacing The Front Direction Indicators

    6.15 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 49: Replacing Centre Brake Light

    6.16 Replacing centre brake light CAUTION! Danger of electric shock. • Interrupt the power supply by removing the battery plugs before you start work on electric components. 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 50 • 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. • Check functions (trial run).

  • Page 51: Replacing Rear Lights/Direction Indicators

    6.17 Replacing rear lights/direction indicators CAUTION! Danger of electric shock. • Interrupt the power supply by removing the battery plugs before you start work on electric components. 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 52 • Remove rear light. • Remove screws (1) on rear light glass. • Remove rear light glass (1). • Replace lightbulbs (2). • Reassembly of the rear light/direction indicator takes place in reverse order. • Check function...

  • Page 53: Replacing The Electronics Module

    CAUTION: Any modifications made to the drive program can affect the drive behaviour and tipping stability! • Changes to the drive program may only be carried out by trained Invacare® specialist dealers! • Invacare can only provide a guarantee for safe driving - especially tipping stability - for unmodified standard drive programs.
  • Page 54 • 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: • Unscrew the rear wheel fixing bolts. •...
  • Page 55 • Reassembly of the drive and the electronics module takes place in reverse order. • Load drive program onto electronics module. See electronics software description. • Check all functions (trial run).

  • Page 56: Updating Software

    CAUTION: Any modifications made to the drive program can affect the drive behaviour and tipping stability! • Changes to the drive program may only be carried out by trained Invacare® specialist dealers! • Invacare can only provide a guarantee for safe driving - especially tipping stability - for unmodified standard drive programs.

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