Service manual

Contents
Chapter Page
1 Introduction 6
1.1 General information ..................................................................................................................6
1.2 Notes on transport ....................................................................................................................6
1.3 Important symbols in this manual ...........................................................................................6
2 Safety and fitting instructions 8
2.1 Before any inspection or repair work......................................................................................8
2.2 General safety information and information about fitting / removal....................................8
3 Tightening torques 9
4 Layout of components and componentry 10
4.1 Overview...................................................................................................................................10
4.2 Electronics modules ...............................................................................................................11
4.2.1 ACS I 60A electronics module......................................................................................12
4.2.2 ACS II 70A electronics module.....................................................................................12
4.2.3 VR2 electronics module................................................................................................12
4.2.4 Shark electronics module .............................................................................................13
4.2.4.1 Shark with 4-pole DCI..............................................................................................13
4.2.4.2 Shark with DCI 12-pole............................................................................................13
4.2.5 ACT actuator module....................................................................................................13
4.2.5.1 ACT 2 actuator module............................................................................................13
4.2.5.2 ACT 4 actuator module............................................................................................13
4.2.6 Lighting PCB.................................................................................................................13
5 Maintenance plan (1x annually) 14
6 Operational faults 16
6.1 Drive fault diagnosis ...............................................................................................................16
6.2 REM24 remote: Error codes and diagnostic codes .............................................................18
6.3 VR2 remote: Error codes and diagnostic codes ..................................................................18
6.4 Shark II remote Error codes and diagnostic codes .............................................................20
7 Repair work 21
7.1 General warning information about fitting work ..................................................................21
7.2 Replacing drive components .................................................................................................21
7.2.1 Replacing the complete drive unit ................................................................................22
7.2.2 Replacing the motor......................................................................................................23
7.2.3 Replacing the jaw clutch...............................................................................................23
7.2.4 Replace carbon brushes...............................................................................................24
7.3 Replacing the electronics.......................................................................................................26
7.4 Updating software ...................................................................................................................28
7.5 Replacing batteries .................................................................................................................29
7.5.1 Removing the battery cases .........................................................................................29
7.5.2 Removing the batteries.................................................................................................30
7.5.3 Correct handling of damaged batteries ........................................................................33
7.6 Checking and replacing the main fuse..................................................................................33
7.7 Checking the cable..................................................................................................................36
7.8 Differences when replacing the REM24 remote ...................................................................38
7.9 Replacing the steering head bearings on the steering wheels ..........................................39
7.10 Repairing punctures................................................................................................................42
7.10.1 Repairing punctures (wheel size 3.00-8").....................................................................42
7.10.2 Repairing punctures (wheel size 280/250-4)................................................................43
7.11 Replacing a drive wheel..........................................................................................................45
7.12 Checking an adjusting motor.................................................................................................47
7.13 Replacing the seat tilting........................................................................................................47
8 Adjusting the seat depth to the user's seating position 50