Invacare® Bora / Spectra XTR SERVICE MANUAL These instructions contain information about: testing work repair work Edition:02.06.
Mobitec Mobilitätshilfen GmbH Herzog Odilostrasse 101 A-5310 Mondsee Austria Invacare® n.v. Autobaan 22 B-8210 Loppem (Brugge) Belgium Mobitec Rehab AG Benkenstraße 260 CH-4108 Witterswil Switzerland Invacare Aquatec Alemannenstraße 10 88316 Isny Deutschland Invacare® A/S Sdr.
Återförsäljare: Invacare® AB Fagerstagatan 9 S-163 91 Spånga Sverige (Kundtjänst): Fax (Kundtjänst): @: @: WWW: Tillverkare: Invacare Deutschland GmbH Kleiststraße 49 D-32457 Porta Westfalica Deutschland MÖLNDAL Fax: @: +46 - (0) 8 761 70 90 +46 - (0) 8 761 81 08 sweden@invacare.com finland@invacare.com www.invacare.se +46 - (0) 31 – 86 36 00 +46 - (0) 31 – 86 36 06 ginvacare@invacare.com LANDSKRONA Fax: @: +46 - (0) 418 – 285 40 +46 - (0) 418 – 180 89 linvacare@invacare.
Contents Chapter 1 Introduction 1.1 1.2 1.3 2 5 6 7 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 7.13 8 14 16 Drive fault diagnosis ...............................................................................................................16 REM24 remote: Error codes and diagnostic codes .............................................................18 VR2 remote: Error codes and diagnostic codes ..................................................................
8.1 8.2 8.3 9 Standard seat ...........................................................................................................................50 Fixed seat .................................................................................................................................52 Flex-II seat ................................................................................................................................52 Replacing the holding strap 9.1 9.2 54 Standard seat & Flex II ...
1 Introduction 1.1 General information • Service and maintenance work must be carried out taking this service manual into account. • It is imperative that you observe safety information. • Information about operation or about general maintenance and care work on the mobility device should be taken from the operating manual. • You can find information about ordering spare parts in the spare parts catalogue. • Only use original Invacare® spare parts.
Requirements: • This symbol identifies a list of various tools, components and items which you will need in order to carry out certain work. Please do not attempt to carry out the work if you do not have the listed tools available.
2 Safety and fitting instructions These safety instructions are intended as prevention of accidents at work and it is imperative that they are observed. 2.1 Before any inspection or repair work • • 2.2 Read and observe this repair manual and the associated operating manual! Observe the minimum requirements for carrying out the work (see chapter entitled " General information”).
3 Tightening torques The tightening torques stated in the following list are based on the thread diameter for the nuts and bolts for which no specific values have been determined.All values assume dry and de-greased threads.
4 Layout of components and componentry 4.1 Overview Underneath the seat: 1) Seat disengager 2) Electronics module The electronics modules used are described in Chapter 4.2.
4.2 Electronics modules A variety of electronics modules can be fitted to the mobility device. Before you connect any mobility device components such as adjusting motors/actuators or motors to the electronics modules, you should first ensure that you know exactly which electronics module has been fitted. Please refer to the following table for an overview.
Electronics module 4.2.1 Designation The actuator module is optional. Lighting PCB The lighting PCB is optional. ACS I 60A electronics module ACS II 70A electronics module Connections 1) Bus cable (to remote or ACT) 2) Bus cable (to remote or ACT) 3) Motor M1 4) Battery 24V 5) Motor M2 4.2.3 Notes ACT actuator module Connections 1) Motor M2 2) Battery 24V 3) Bus cable (to remote or ACT) 4) Bus cable (to remote or ACT) 5) Motor M1 4.2.
4.2.4 Shark electronics module 4.2.4.1 Shark with 4-pole DCI BUS CABLE Connections 1) Joystick box 2) DCI for actuators (4-pole) 3) Right-hand motor M1 4) Battery 24V 5) Left-hand motor M2 4.2.4.2 Shark with DCI 12-pole Connections 1) Cable to remote 2) DCI for actuators/lighting (12-pole) 3) Right-hand motor M1 4) Battery 24V 5) Left-hand motor M2 4.2.5 ACT actuator module A range of adjusting motors, also known as actuators, can be fitted to the mobility device.
5 Maintenance plan (1x annually) Component Check Remedy Armrests • Damage to armrests • Armrest fixings • Damage to side panels • Replace covering if damaged • Tighten screws • Replace side panels if damaged • Side panel fixings • Seat lock defective • Tighten screws • Replace seat lock • Tight seating of SL fuses • Replace SL fuses if necessary • • • • • • • Replace parts if damaged • Tighten screws • Replace cable motor if necessary • Tighten screws • Replace components if necessary Side pane
Component Battery case Remote / electronics module Check Remedy • Check locking system, it must engage completely.
6 Operational faults The various electronics modules can be fitted in connection with differing remotes in the mobility device. Rectification of operational faults is dependent on the electronics module fitted. The electronics modules used are described in Chapter 4.2. NOTE: The tables for rectification of operational faults listed in the following chapters are only an excerpt from the original manufacturer's manuals. You can obtain the original manuals from Invacare®.
PROBLEM Mobility device judders in drive mode Batteries not being charged Mobility device runs too slowly Electrical adjustment motor does not react OTHER SYMPTOMS None POSSIBLE CAUSE Batteries defective (unstable voltage) Drive motor(s) defective SOLUTION Documentation Replace batteries See chapter 7.5. Replace motor(s) See chapter 7.2. Replace carbon brushes See chapter 7.2.4. None Batteries defective Replace batteries See chapter 7.5.
6.2 REM24 remote: Error codes and diagnostic codes The drive electronics can automatically rectify some faults. In this case the status display will stop blinking. Switch the remote on and off again several times. Wait around 5 seconds each time before switching the remote on again. If this does not rectify the fault, determine the cause using the blink codes from the following table. Blink Code 1 x blink POSSIBLE CAUSE Module defective 2 x blink Accessory error (e.g.
• The figure shows which LEDs are located on the remote.
Error code 8 LED Battery display plus 2 LED actuators 6.4 POSSIBLE CAUSE Actuator error; SOLUTION Documentation if more than one actuator is fitted, locate the defective actuator. Check cable to actuator See chapter 7.7. Shark II remote Error codes and diagnostic codes The drive electronics can automatically rectify some faults. In this case the status display will stop blinking. Switch the remote on and off again several times. Wait around 5 seconds each time before switching the remote on again.
7 Repair work 7.1 General warning information about fitting work CAUTION: Danger of damage to vehicle! Collisions can be caused if the adjusting washers are removed during fitting work to the drive wheels! • Adjusting washers are often fitted between the drive shaft and the wheel hub to even out tolerances. If these adjusting washers are removed and not replaced again, collisions can be caused! Always replace the adjusting washers exactly as they were before you started dismantling! 7.
7.2.1 • Remove both battery cases as described in Chapter 7.5.1. • Disconnect the motor plug from the motor to be replaced from the electronics module. • The motor cable is secured inside the frames with cable ties. Remove the cable ties with the oblique pliers. • Place the vehicle upside down so that the wheels are facing upwards. When doing so, get the help of a second person because the vehicle is heavy. • Remove the torx screw (1) with a TX40 spanner. • Remove the screw and hubcap.
7.2.2 7.2.3 Replacing the motor • Loosen the motor screw (1) with the 5 mm Allen key. • Remove the motor from the transmission. • The motor is reassembled in reverse order to disassembly. • The motor must be carefully inserted into the transmission to avoid damage. Observe the position of the groove (1) in the transmission. • The cable must be routed so that it does not rub or get trapped. • Insert the motor plug into the electronics module.
7.2.4 • Remove the clutch (2) from the motor (1) using the screwdriver • Place a new clutch on the motor. Observe the position of the groove (3) on the motor. • The motor is reassembled in reverse order to disassembly. • Insert the motor carefully into the transmission to avoid damage. Observe the position of the groove (1) in the transmission. • The cable must be routed so that it does not rub or get trapped. • Insert the motor plug into the electronics module.
• Remove the plastic cap (1) and the carbon brushes (3). • Insert new carbon brushes (3) through the openings (2) on the motors. In doing so, the spring must face upwards. • Carefully screw in the plastic cap (1) on the motor with the screwdriver.
7.3 Replacing the electronics The various electronics modules can be fitted to the mobility device with a range different remotes . The possible electronics modules are described in Chapter 4.2. Replacement is described below using the Shark electronics module as an example. The course of action is the same for other electronics modules. The only difference is the terminal layout.
• Loosen the screws (1) on both sides of the electronics module with the Phillips screwdriver and remove them. • Remove the electronics module. • Reassembly of the electronics module takes place in reverse order. • Update the drive program if a new software version is available as described in Chapter 7.4. • Adapt the drive program using the programming software if necessary. • To complete, check all vehicle functions.
7.4 Updating software The drive programs for mobility devices are continually being further developed and improved by Invacare. For this reason, you should always check whether the drive program version number is up-to-date when carrying out any repairs or regular maintenance. If a newer version is available, the drive program should be updated. The procedure for updating the drive program is described in the wizard software operating manual.
7.
• Pull the battery cases out using the side handles. • Pull the front battery case backwards using the belt and pull it out using the handles. 7.5.
• Bend the tabs (1) on the cover lightly to the outside and loosen the battery case covers. • Open the battery case (remove cover). • Pull the battery case socket / plug out of the guide. • The rear battery is only fitted with a battery case socket at the front. • The front battery is fitted with a battery case socket at the front (flange central) and with a battery case plug at the rear (flange flush). • Note the fixing position of the battery and the battery case sockets/plugs.
• Remove the terminal cover from the battery terminals (1). • Loosen the battery terminal clamps (1) with the Phillips screwdriver. • First undo the screw on the negative terminal (black cable) with the Phillips screwdriver. • After this, undo the bolt on the positive terminal (red cable). • Reassembly of the batteries takes place in reverse order • Ensure that the battery cage sockets/plugs have been correctly refitted. A polarity diagram is located in each battery case cover.
• Rear battery • The battery case socket is located at the front (flange central). • Socket side A is on the left in the direction of travel. • Socket side B is on the right in the direction of travel. • The battery needs to be inserted tightly into the battery case. Use the foam sections supplied to ensure this. • To complete, check all vehicle functions. 7.5.
CAUTION: fitting the incorrect strip fuse causes a fire hazard! • Only fix the strip fuses in the sequence shown in the image on the right! • Tighten the nuts with 3.3 to 3.5 Nm! 1. Strip fuse 2. Spade terminal 3. DIN 6923 nut Requirements: • Phillips screwdriver • Strip fuse NOTE: A spare fuse is located behind the Invacare logo on the rear battery. NOTE: If the fuseholder is damaged, you can replace this complete with the battery cables. • Remove both battery cases as described in Chapter 7.5.1.
• Undo the strip fuse nuts (2) with the Phillips screwdriver. • Replace the strip fuse. • Reassembly takes place in the reverse order. • To complete, check all vehicle functions.
7.7 Checking the cable The following images show checking the cable using the Shark controller as an example. The plug positions are different for both the DX2 and VR2 controllers. The procedure for checking is otherwise identical. The position of the plugs is described in Chapter 4.2. • Remove legrests. • Release seat (1) and tilt forwards. • Check all cables for visible damage and crushing. Replace damaged cables. • Pull each plug (1) carefully. The plug should not come out of the socket.
• Reassembly takes place in the reverse order. • To complete, check all vehicle functions.
7.8 Differences when replacing the REM24 remote Requirements: • To adapt the drive program: programming software or hand programming device and REM24 electronics system installation manual, available from Invacare®. NOTE: All REM24 remotes are delivered with a standard drive program. If you have carried out customer-specific modifications to the drive program, you will have to make these changes again after installing the new electronics module.
7.
• Loosen the 19 mm nut (1) with the socket spanner and remove it. Hold the wheel so that it does not rotate when the nut is being removed. • Pull the steering head shaft upwards out of the steering head tube. • Take the washers out of the tube. • Take the ball bearing out of the tube. • The adjacent figure shows an overview of the individual parts.
After assembly, the steering wheels should rotate freely but the bearings should have no play. • First tighten the nuts to 20 Nm +/- 2 Nm. • Then loosen them slightly. • Then retighten to 15 Nm +/- 1.5 Nm.
7.10 Repairing punctures CAUTION: Injury hazard if the vehicle starts moving unintentionally during repair work! • Switch the power supply off (ON/OFF key)! • Engage the drive! • Before raising the vehicle, secure the wheels by blocking them with wedges! 7.10.1 Repairing punctures (wheel size 3.00-8") Requirements: • Torx TX40 spanner • Allen key 5 mm • Repair kit for tyre repair or a new inner tube. • Talcum powder Removing the wheel • Block up the vehicle (place wooden blocks under frame).
• Insert the wheel rim halves from outside into the tyre. • Pump a little air into the inner tube. • Insert the Allen screw once again, and screw the wheel rims together tightly. • Ensure that the tyre outer is seated correctly. • Pump the tyre up to the prescribed pressure. • Check that the tyre is seated correctly once again. • Screw the valve cap back on. • Refit the wheel. 7.10.
Repairing the flat tyre • Unscrew valve cap. • Depressurise tyre by pressing in the pin in the valve . • Unscrew the 5 Allen screws (back of the wheel, 2). • Remove the rim halves from the tyre. • Remove the inner tube from the tyre. • Repair inner tube and replace, or insert new. NOTE: If the old inner tube is to be repaired and re-used, and has become wet during repair, you can make replacement easier by sprinkling the inner tube with a little talcum powder. • Put the tyre back on the rim.
7.11 Replacing a drive wheel CAUTION! Danger of mobility device tipping or rolling away! • Prevent the mobility device tipping by propping it up on a wooden block which is long and wide enough under the battery case! If the wooden block is too short or too high, the mobility device can still tip! • Switch the mobility device off at the remote! Tools/parts required: • Torx TX40 spanner • wooden block (approx.
• Under the 4 bolts which secure the wheel (1) using the Torx TX40 spanner. • Remove the wheel from the hub. • Reassembly takes place in the reverse order.
7.12 Checking an adjusting motor Tools/parts required: • Multimeter 7.13 • Remove legrests. • Release seat (1) and tilt forwards. • Remove the adjusting motor plug from the electronics module or ACT (see Chapter 4.2. • Check the electrical resistance at the adjusting motor plug (1). The plug may have a different shape to that shown in the picture. • If the resistance is close to infinity, the motor is probably burnt out. • If the resistance is below 1 Ω, the motor has a short-circuit.
• Remove legrests. • Release seat (1) and tilt forwards. • Disconnect the remote bus cable from the electronics module or ACT. • Lift the seat out of the front anchorage and remove it. When doing so, get the help of a second person because the seat is heavy. • Remove both battery cases as described in Chapter 7.5.1. • Pull the adjusting motor plug out of the electronics module. • The adjusting motor cable is secured inside the frames with cable ties.
• Pull the adjustment spindle with adjusting motor out. • Insert a new adjustment spindle with adjusting motor. • Reinsert the fixing bolts and SL fuses. Fix the SL fuses securely to the fixing bolt with the hammer. • Reinsert the adjusting motor plug into the electronics module. • Secure the adjusting motor cable to the frame with cable ties. The cable must be routed so that it does not rub or get trapped. • To complete, check all seat tilting functions.
8 Adjusting the seat depth to the user's seating position In order to adapt the mobility device optimally to the requirements of the user, we recommend that you ask your authorised Invacare® the dealer toadjust the seat depth individually. Adapting the seat to the user's seating position depends on which seat has been fitted, and should be carried out in the following sequence. 1. 2. 3. 4. Adjust the seat depth to the seat frame. Adjust the seat area.
• Rear bolts (1) • Front bolts (2) • Seat plate (3) • Seat frame (4) The seat plate can be fixed in three different positions on the seat frame. • Front fixing (V) • Centre fixing (M) • Rear fixing (H) The picture shows where the drillholes for fixing the seat frame (3) are located on the base frame. • Rear drillholes (1) • Front bolts (2) The seat frame can only be fixed in one position on the base frame. The picture shows the seat frame with the drillholes for the standard seat.
8.2 Fixed seat The picture shows the fixed seat from below. The fixed seat is fixed directly to the base frame. • Rear drillholes (1) • Front drillholes (2) 8.3 Flex-II seat The pictures show the standard seat from above without seat support.
The Flex-II seat is fixed directly to the base frame.
9 Replacing the holding strap 9.1 Standard seat & Flex II Requirements: • open-ended spanner, 13 mm • 5 mm Allen key Note A nut is fixed between the two washers (2) and (4) as a spacer so that the belt mounting can rotate freely. • Remove the plastic cap (5). • Loosen the bolt (3) and the associated nut (in the figure this is covered by the plastic cap) with a 5 mm Allen key and a 13 mm socket spanner. • Remove the nut. • Remove the bolt including safety belt and flat washers (2) and (4).
9.2 Fixed seat unit Requirements: • open-ended spanner, 13 mm • 13 mm jaw spanner • Loosen the bolt (1) with a 13 mm socket spanner. Hold the nut using a 13 mm jaw spanner to prevent rotation (not visible in figure). • Remove the bolt together with the flat washer (3), the safety belt (4) and the spacer (2). • Replace the safety belt (1). • Refit the parts in the reverse order.
