Invacare Tornado Service Manual
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Invacare Tornado Service Manual

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Invacare® Tornado
SERVICE MANUAL
This manual contains information on:
Troubleshooting
Maintenance
Repair
Version: 20.07.06

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Summary of Contents for Invacare Tornado

  • Page 1 Invacare® Tornado SERVICE MANUAL This manual contains information on: Troubleshooting Maintenance Repair Version: 20.07.06...
  • Page 2 +41 - (0)61 - 48 77 08 1 Benkenstraße 260 office@mobitec-rehab.ch CH-4108 Witterswil Switzerland switzerland@invacare.com WWW: www.mobitec-rehab.ch Invacare® Deutschland GmbH (Technische Hotline): 0180 - 5 26 22 64 Kleiststraße 49 Fax (Technische Hotline): 0180 - 5 26 22 75 info@invacare.de 32457 Porta Westfalica WWW: www.invacare.de...
  • 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 (Kundeservice): +47 - (0)22 57 95 10 Invacare® AS...

  • 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) OPERATIONAL FAULTS Troubleshooting the Tornado with ACS 6.1.1 Diagnosing driving faults 6.1.2 Diagnosing problems with electric actuators 6.1.3...
  • Page 5 Replacing the remote Testing an actuator motor Adjusting and replacing the speed reduction switch 7.10 Replacing the steering head bearings on the front or rear castor wheels 7.10.1 Front Castor Wheels 7.10.2 Rear Castor Wheels 7.11 Replacing the Anti-Dive Spring and/or its plastic guides 7.12 Repairing a flat tyre 7.13...

  • Page 6: Introduction

    • Alterations to the wheelchair, 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 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 8: 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 9 • Alterations to the drive programme may only be carried out by trained Invacare®-dealers! • Invacare® supplies all wheelchairs from the factory with a standard drive programme. Invacare® can only assume a warranty for the safe vehicle handling of the wheelchair – in particular tipping stability - for this standard drive programme!

  • Page 10: 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 11: Layout Of Components And Modules

    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 CLAM (Combined Light...
  • Page 12 The following image shows the Tornado from the front right, with the lifter raised Lifter actuator...

  • Page 13: 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 14 Component Check Action Notes ⇒ Replace batteries if • See "Replacing Check batteries for Batteries batteries" on page damage necessary ⇒ Charge batteries See User Manual • Check battery charge ⇒ Clean contacts and See "Replacing • Check contacts and batteries"...

  • Page 15: Operational Faults

    Operational Faults 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 16 PROBLEM OTHER POSSIBLE SOLUTION REFERENCE SYMPTOMS CAUSE Remote may • See "Replacing the Exchang be defective remote" on page 39 e the remote on the wheelcha ir for a different one to eliminate possibilit y that the remote may be cause.
  • Page 17 PROBLEM OTHER POSSIBLE SOLUTION REFERENCE SYMPTOMS CAUSE Wheelchai None Batteries may • See "Replacing Replace r does not be defective batteries" on page 30 drive (voltage not batteries smoothly stable) Drive motor(s) See "Replacing the drive • Replace may be motors"...

  • Page 18: 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 components of the ACS or...

  • Page 19: 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 20 Flash code: Meaning: Solution: Notes 7 x flashes Completely discharge See User Manual • Pre-charge battery battery 8 x flashes Battery voltage too high • See User Manual Switch lights of battery charger on to lower battery voltage • Check battery charger 9 or 10 x flashes Faulty data transmission...

  • Page 21: Operational Faults On A Wheelchair Fitted With Shark Electronics

    Operational faults on a wheelchair fitted with Shark electronics Please proceed as follows in the event of operational faults: • First of all analyse the possible cause of the disorder on the basis of the following tables. • Check the status display on the remote. Analyse the flashing error code. •...
  • Page 22 PROBLEM • SOLUTION OTHER POSSIBLE DOCUMENTATION SYMPTOMS CAUSE Wheelchair None • Replace the batteries Batteries may be See "Replacing jerky in faulty (instable batteries" on page drive voltage) operation • Replace motor(s) Actuation Siehe "Replacing motor(s) may be the drive motors" faulty on page 25 Batteries...

  • Page 23: Shark Error Codes And Diagnostic Codes

    6.2.2 Shark error codes and diagnostic codes The actuation electronics can automatically remedy certain disorders. In this case the status display will stop flashing. Please switch the remote on and off several times. Please wait about 5 seconds every time before switching the remote on again. If the error is not remedied by this, please diagnose the cause on the basis on the following flashing codes.
  • Page 24 FLASHING Meaning Solution FLASHING CODE CODE Fault on Shark • See "Checking the Check all cables and connectors on main module cables" on page the Shark system. • Replace the main module. See "Replacing components of the ACS or Shark electronics"...

  • Page 25: Repair Work

    Please install all shim rings in exactly the same positions they were in before dismantling. 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 • Loosen the screws (1) using a 6mm hexagon socket and remove the outer side panelling. • 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.
  • Page 27 • Pull the motor plug (1) for the right-hand or left-hand drive out of the electronics. • • 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

    Replacing components of the ACS or Shark electronics Requirements: • Large flat-bladed screwdriver • Phillips screwdriver • Hexagonal socket head key 4 mm • Use the flat-bladed screwdriver to carefully pry the plastic cover off, as shown in the picture. The picture at right shows the positions of the CLAM and the Power Module of the ACS System.
  • Page 29 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 : • Detach the CLAM from it’s holder by simply pulling it upwards.

  • Page 30: Replacing Batteries

    Replacing 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. • If acid should come into contact with the skin, rinse immediately using plenty of freshwater. •...
  • Page 31 • Move the lifter to the uppermost position. • Raise the lifter further by pulling the piston rod of the actuator towards the front (to unfasten the piston rod head from its socket) and simultaneously pulling the seat upwards, so that the retaining mechanism (1) locks into place.
  • Page 32 • Open the electronic panelling. In doing so, push the rear side panelling away slightly using a large, flat screwdriver. 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. •...
  • Page 33 • Pull the battieres out to the front using the carrying belt. 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 34 • Move the regulating motor to the uppermost position and ensure that it slides into the upper guiding device (1). • Raise the lifter slightly and unlock the retaining mechanism (1). The entire lifter load is now on the regulating motor again. •...

  • 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 • Open the lid of the fuse compartment (1). • If the main fuse is burnt out, then first determine what caused this. Only when the problem has been fixed may the fuse be replaced. • Check the battery cables (2) in their entirety for damage.

  • Page 37: Checking The Cables

    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. The connectors do not have to be removed.
  • Page 38 • Check all vehicle functions.

  • Page 39: Replacing The Remote

    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

    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

    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

    7.10 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 43 • 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: 7.10.2 Rear Castor Wheels

    7.10.2 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 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 46: Replacing The Anti-Dive Spring And/Or Its Plastic Guides

    7.11 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 • 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 • Reassembly is done in reverse order.

  • Page 49: Repairing A Flat Tyre

    7.12 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 • 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), using the Allen key. •...

  • Page 51: Replacing A Drive Wheel

    7.13 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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