Invacare® G40 with ACS
Contents
1. CAUTION e During loading batteries must not lie on side or stand edgewise Do not load batteries with the unregulated charging unit completely Batteries could be destroyed gt Danger of explosion lt e Assemble batterypole clips and connections e Load battery with INVACARE charging unit over charger socket of remote completely The loa ding process should be led for at least 48 hours Battery charging unit NOTE INVACARE charging unit Also note the loading instructions for batteries EE MAINS ON e in the user manual of charging unit e on front and rear of charging unit CHARGE Check of functions FULLY e Plug in mains plug of charging unit CHARGED Red LED MAINS ON lights up e Divide mains plug from mains e Plug in charging plug at charging socket of remote and then plug in mains plug again Green LED FULLY CHARGED lights up for ca 3 sec then changes to yellow LED CHARGE e Pull out mains plug Pull out charger plug Trouble index for INVACARE charging unit e Red LED MAINS ON Mainsvoltage 230 V fails Check 230 V mains is not lit Charging unit defective Replace charging unit e Yellow LED CHARGE Batteries deep discharged Check battery voltage is not lit Charging unit defective Replace charging unit e Green LED FULLY Excess voltage of batteries Check charging voltage CHARGED is not lit Flash code status display Charging unit2. drive off and on again Time limit exceeded at e Switch the maximum current electronics system servo off and on again Compatibility problems e Check modules module 6 0 Arrangement of assemblies components and features 12 The following illustrations show the arrangement of the main assemblies components and features for right handed people The terms are the same as the component terms in the replacement parts catalog G40 front view 1 Leg rests complete appertaining to seat system 2 Chassiscovering 3 Seat shell appertaining to seat system 4 Seat padding appertaining to seat system 5 Back padding appertaining to seat system 6 Mirror 7 Front lighting system integrated in Seat shell 8 Front wheels powered 9 Back wheel steerable G40 side view 10 Frame with back shell 11 and grip grip 12 13 Sides complete with arm rests N D 14 Side grip 15 Covering 10 16 Remote with speedometer 17 Hand brake complete with brake disc 18 19 Back rest adjusting complete 20 Walking stick holder 21 Walking stick loop 15 16 17 18 19 20 Chassis Tube frame back bottom Seat frame appertaining to seat system Seat shell with indentations for electronic modules Locking mechanism of seat support for service Locking mechanism of seat in closed position Gas spring for back rest adjusting Batteries in battery box Battery box Cable form fo
3. 4 5 6 2 11 5 16 Deutsch AN ACHTUNG Feuergefahr besteht falls die Streifensicherung falsch montiert wird e Montieren Sie die Streifensicherung ausschlie Blich in der Reihenfolge wie im Bild rechts gezeigt e Muttern stets mit 3 3 bis 3 5 Nm anziehen Englisch AN WARNING Danger of fire exists if the fuse is incorrectly assembled e Only ever assemble the fuse in the order shown in the illustration at right e Always tighten nuts to between 3 3 and 3 5 Nm Franzosisch AN ATTENTION risque d incendie si le fusible lames est mal mont e Monter le fusible lames exclusivement dans l ordre indiqu sur l illustration de droite e Toujours serrer les crous avec 3 3 3 5 Nm bis 03 2004 1 Streifensicherung 2 Kabelschuh 3 Unterlegscheibe 4 Mutter M5 Until 03 2004 1 Fuse 2 Fuse compartment 3 Washer 4 Nut M5 jusque 03 2004 1 Fusible lames 2 Cosse de c ble 3 Rondelle 4 Ecrou M5 ab 03 2004 1 Streifensicherung 2 Kabelschuh 3 Mutter DIN 6923 After 03 2004 1 Fuse 2 Fuse compartment 3 Nut DIN 6923 a partir de 03 2004 1 Fusible lames 2 Cosse de c ble 3 Ecrou DIN 6923 1 1 Updating software Invacare is continuously carrying out further development and improvements to drive programs for electric mobility products For this reason you should always check whether the drive program version number is up to date when carrying out any
4. e Put wheel on hub set in countersunk screws 6 and tighten crosswise with 25 Nm AN CAUTION e The countersunk screws 6 must not be greased e During factory assembly the screws are set in with plasbolt They can be assembled disassembled up to 6 times e At the latest screws must be cleaned during 7 assembly and then set in with Loctite e Tighten screws with 25 Nm Ty 2 8 3 Wheel suspension back NOTE Wheel suspension back e Change or repair of steering column 4 must be ef aa i done by INVACARE service MT 1 Shock absorber soft 2 Stub axle uf 4 3 floating socket 4 Steering column in steering column 5 Head screw M12x120 6 NutM12 7 Disc 13 0 8 Wheel hub 9 Socket in hub 10 Ball bearing 6001ZZ 11 NutM 8 in hub 12 Disc 8 4 13 Telescopic spring mount 14 Screw M8x55 15 Head screw M8x35 16 Stopper SL35 17 Securing disc M8 not shown 13 15 and 17 top at steering column Check Action Shock absorber defective gt Replace shock absorber e Screwings loose gt Tighten screws e Wheel does not run easily gt Replace wheel bearing Hub damaged gt Replace hub Stub axle defective gt Replace stub axle Disasssembly shock absorber e Prop up wheel chair so that shock absorber is accessible e Remove screw 15 with disc 17 from telescopic spring mount 13 e Remove screw 14 with nut 11 and disc 12 and take off shock absorber Assembly e Assembly is carried out in reverse order Disasse
5. Connections with cable form 5 Battery pole plate 6 Battery pole clips 7 Cable bridge 8 Gel batteries 12V 60Ah Check Action e Voltage of a battery under 11 5 V gt Load batteries see chapter 10 2 e Voltage falls heavily down under load driving operation handbrake applied Switched on lighting system e Battery contacts corrosioned or damaged e Check all cables and plug connections Battery box or battery box coverdamaged e Double tension belt damaged Grip with carrying strap damaged Load batteries see chapter 10 2 or replace Clean or replace contacts Replace if necessary Replace if necessary Replace double tension belt Replace if necessary VV VV VV Measure voltage e Bring seat system in service position and arrest e Pull double tension belts 3 upwards and remove sidewards from battery box cover 2 e Remove battery box cover 2 upwards out of wheelchair e Check single and total voltage of batteries with a multimeter range 50V 25V DC Disassembly e Release screwings and remove connections 4 battery pole clips 6 cable form 7 and battery pole plate 5 e Pull up grips and remove batteries 8 carefully upwards out of wheelchair e Release cross slotted screws on left and right side at bottom of battery box 1 and take out box e Release screws and nuts M5 and remove double tension belts Assembly e Assembly is carried out in reverse order Ty 48 This
6. The abrasion limit is 11mm Working surface e Check working surface visually The working surface must not show any grooves 26 Setting in of carbon brushes e Setin carbon brushes carefully into the carbon brush mounting of motor NOTE e The carbon bruh must not cant e Press feather of carbon brush with soldering cap carefully down until it sticks in mounting e Screw on closure cap Disassembly of driving unit O CAUTION NOTE e Note the weight of driving unit e The driving unit can only be completely replaced gt Danger uf crushing lt e Repairwork at driving unit must be done by INVACARE Service e Bring seat system in service position and arrest e Remove both motor plugs at main module and also plug connection at voltage supply e Remove cable binder at motor cable if necessary e Prop up wheelchair that it is accessible from below and supply driving unit in addition to that e Disassemble front wheels See chapter 8 2 e Disassemble wheel hubs with brake discs See chapter 8 3 e Release three screws 9 and remove mounting of brake caliper 8 e If necessary remove speedometer sensor carefully e Remove screwing at bottom of shock absorber 7 so far that the shock absorbers are freed from front axle e Remove screwing from thread rod 6 so far that the thread rod is freed from gear e Release screws 11 and nuts and remove rubber support 12 with sockets 13 and discs 14 So that the driving u
7. at remote gt Chapter 12 2 check voltage at main module Status display at aa a E E Error code 1 12 gt Check error code oe Chapter 5 Microswitch defective Check microswitch nur TUV Version 10 km h REES Si Drive motor runs in a jerky manner Chapter 12 1 St rungen Motor defective gt Replace motor gt Chapter 9 1 heck Manual for pro Incorrect program Check program gramming unit or ming ming PCD software i ae Steering servo motor reacts slowly irregularly Motor defective gt Replace motor Chapter 9 1 Manual for pro Incorrect program Check program gramming unit or ee o MY y PCD software Light servo modu Replace light gt le defective 7 Jservo module onapten tes Status display flashes after 4 sec the driving mode display also flashes J oystick not in Switch remote off neutral position LEE Chapter 12 2 and on when switch on gt Remote defective Replace remote Chapter 12 2 gt Lighting system defective gt Light er Replace light bulb Chapterl 11 1 11 2 en Cable connector Check replace Chapter 11 1 11 2 defective cable connector St rungen Light servo modu Repla
8. defective Replace charging unit 31 11 0 Checks and repair work at lighting system 11 1 Lighting system front 32 Front lighting Front lighting single parts 1 Seatshell 2 2 Plastic rivets 3 2 Cutting screws 4 2 Cutting screws 5 Lampholder front 6 Casing with headlights 7 Indicator compl 8 Bulb E10 12V 2 4W 9 Bulb 12V 10W 10 Cable form with plug 15 11 Screw M6x30 12 Disc 6 4 13 Nut M6 14 Disc 6 4 NOTE Check Action e Before controlling the lighting Front lighting failured system secure that batteries are completely gt Replace light servo loaded module Switch on lights at remote for ie Meee elcome ee Soe e One headlight defective gt Replace bulb Replace indicator lamp Release cutting screws 4 and take off indicator cap Remove indicator bulb out of bayonet socket and replace Replace headlight bulb Bring seat system in service position and arrest Remove plastic rivets 2 with a screwdriver and let lighting system fall down out of seatshell Release cutting screws 3 and take off upper part of casing 6 Take out headlight of bottom part of casing pull out socket and replace bulb Complete disassembly of lighting unit e Take lighting unit out of seatshell and remove lamp See above Release plug 15 from connector row at back of chassis and remove cable binder Remove lighting unit completely out of seatshell Remove screw 11 with nut 13 and discs 12 14 and take off head
9. electronics system off and on again Check the connecting cable and plug to the servo motor Engage motor Switch electronics of and back on again Check connections to the Transaxle Check carbon brushes Engage motor Switch electronics of and back on again Check connections to the Transaxle Check carbon brushes Check connections to the magnetic brake Check magnetic brake Remote status bar Servo light module Fault remedy indicator LED blink LED blink code code or in the magnetic e Check magnetic 7 Battery voltage too low e Charge battery 7 Battery voltage too low e Check battery below 17V connections e Check fuses e Check batteries and replace if necessary Battery voltage too high e Switch on lights to this error can occur use electricity and when the batteries are thus lower battery fully charged and the voltage Pp downhil at i nye Sam sem downhill at high speed charger CANL error e Check BUS cable communication error between the modules An invalid voltage was e Check continuity of detected on the CANL the ACS bus cable line fault on the CANL e Check for short line communication circuits between the via CANL not possible contact pins of the ACS bus A short circuit or an interruption in another ACS module can cause this error CANH error e Check BUS cable communication error between the modules An invalid voltage was e Check continuity o
10. i LEES E Weer E WEE CH ei He Ge 8 an ah fl Ge PY bel A rela e elen o EI K e UR Re Rei n 8 d ay i A mn eit s P H keem 5 e ja e Ge AR E da zg y i T i 4 e De Leit B UL ET FE i i Litir 8 Status display For the simple visual assessing of defects the module is equip ped with a green light diode for status display Check of status display e Take padding out of seatshell so that the status display at light servo module can be seen e Switch on wheelchair at remote e Check light diode see diagram below A BUS plug we mien Check Action e Status display lightens gt Module is in order e Status display off gt Check voltage supply of module Plug to Check programming steeringservo e Status display flashes om when indicator is on gt Back indicator bulb defec tive Replace bulb BUS plug e Statusdisplay flashes gt Replace module Check voltage supply to light servo module e Pull BUS plug out of lightservo module e Measure voltage at marked contacts See diagram The voltage must at least be 19 V min 19 Volt AN CAUTION Do not short circuit contacts Danger of short circuit Trouble index for light servo module No voltage BUS cable defective Check replace BUS cable BUS plug defective gt Check replace BUS cable Main module defective gt Check main module Check voltage supply to main module See chapter 12 1 e Voltage under 19
11. released or completely applied Ry e Assembly is carried out in reverse order Disassembly Brake disc Disassemble front wheel See also chapter 8 2 Remove brake caliper 5 from mounting 12 See above Remove nut 18 and disc and take off wheel hub 19 with brake disc from axle Release four countersunk screws M6 with hexagon and take off brake disc 14 from hub Assembly NOTE Assembly is carried out in reverse order e Do not forget roundmagnet and socket Disassembly brake straps and bowden wire Release wing screw 1 and take off brake lever 2 Remove chassis covering See chapter 8 1 Disassemble brake calipers 5 at both front wheels See above Remove cap 23 and release nut 22 until you can draw the bowden wires 6 out of the holder 4 Remove starlock caps 21 with a screwdriver dislever and take off discs 24 Take off brake straps 3 with sockets 20 from chassis and take apart bowden wires 6 from brake straps If necessary pinch up the caps of bowden wires Disassemble bowden wires 6 with bowden wire sleeves 8 from chassis Assembly Assembly is carried out in reverse order NOTE e During assembly new starlock caps must be used e For assembling of caps see chapter 7 3 assembly of starlock caps at backrest 25 9 0 Checks and repair work at motor gear servo and steering 9 1 Driving motor and gear Driving motor 1 Chassis 2 Driving motor 450W 3 Stopp
12. repairs or regular maintenance If a newer version is available the drive program must be updated The procedure for updating the drive program is described in the wizard software operating manual Note If you have carried out customer specific modifications to the drive program you will have to make these changes again after installing the new drive program CAUTION any changes to the drive program can affect the driving characteristics and the tipping stability of the vehicle e Changes to the drive program may only be carried out by trained Invacare specialist dealers e Invacare can only give a warranty for safe vehicle driving behaviour especially the tipping stability for unaltered standard drive program Requirements e Dynamic Wizard software e Operating manual for Wizard software e Further requirements such as a minimum system configuration for the PC used for programming required programming cables etc can be taken from the Wizard software operating manual
13. 23 8 5 Handbrake Wing screw Mx10 Brake lever Brake straps riveted compl Bowden wire holder Brake caliper Bowden wire Cable clamp screw Bowden wire sleeve Hexagon head screw M6x25 10 Brake shoes 11 Fixing screw 12 Mounting 13 Hexagon head screw M6x35 14 Brake disc Brake disc 15 Roundmagnet 625 6 0 disassembled 16 Cable socket 17 Speedometer sensor 15 16 18 Wheel nut M12x1 5 19 Hub ao 20 Sockets TL a A e e em em em em e es a LO OO zl On Ln SS GO 21 Starlock caps 8 0 14 GA 22 NutM8 w 23 Cap SKS 8 SE 3 24 Disc 8 4 i 25 Brake lever button Check Action e Brake shoes defective gt Replace brake shoes e Brake disc defective gt Replace brake discs e Brake does not apply gt Adjust brake e Brake lever defective gt Replace brake lever Disassembly brake lever e Release wing screw 1 and take of brake lever 2 Disassembly brake caliper e Disassemble front wheel See chapter 8 2 e Remove screws 9 with discs and nut and take off brake caliper 5 e Release cable clamp screw with nut and disc pull out bowden wire 6 and remove brake caliper completely Should the occasion arise you first must pinch off the caps of bowden wire e Release screws 13 with discs and nuts and disassemble the halfs of brake caliper e Release cross Slotted screws and remove brake shoes 10 NOTE Assembly e Adjust brake so that the bowden wire has a play of 15mm Brake completely
14. EI Ei Gi E Invacare G40 with ACS System SERVICE MANUAL The manual contains Information on troubleshooting Information on testing parts Repair instructions Edition 12 2001 General information This service manual contains all information necessary for maintenance and servicing of the G40 wheelchair e Maintenance and servicing work is to be carried out in accordance with this service manual Comply with all safety instructions Information on operation general maintenance and servicing can be found in the operating manual of G40 Refer to the replacement parts catalog for information on ordering replacement parts e Maintenance and repair work on the G40 may onla be performed by qualified personnel Maintenance technicians should at least be trained in a relevant field e g as a two wheeled vehicle or orthopaedics technician or have an equivalent amount of professional experience Personnel should also be familiar with electrical measurement equipment multimeters e Should you encounter difficulties or have any questions please contact INVACARE SERVICE Switchboard Tel 049 0 5731 754 0 Fax 049 0 5731 754 111 Service Tel 049 0 5731 7545 70 80 Fax 049 0 5731 7542 08 16 Adress Invacare Deutschland GmbH Dehmer Str 66 D 32549 Bad Oeynhausen PO Box Invacare Deutschland GmbH Postfach 60 01 06 D 32 527 Bad Oeynhausen e INVACARE can not be held liable for changes to the
15. G40 resulting from maintenance and servicing work Carried out incorrectly or not according to the relevant instructions Information concerning transportation e if the wheelchair has to be sent away to the manufacturer for more serious repairs always use the original packaging for transportation e Please include a detailed account of the fault e We reserve the right to make changes in the interests of technical progress You will notice the following symbols in this repair manual NOTE This symbol indicates general information conceming special features and helpful advice for installation AN ACAUTION Please pay special attention to this symbol It indicates gt Safety instructions lt ae 1 0 2 0 3 0 4 0 4 1 4 2 5 0 5 1 6 0 7 0 7 1 s 7 3 7 4 1 5 8 0 8 1 8 2 8 3 8 4 8 5 9 0 9 1 9 2 Contents Safety and installation instructions 4 Bd r LCE 5 Inspection plan 6 Operation troubles 0 00 vee aes 8 General instructions 8 Troubleshooting 8 Error messages at remote 10 Error codes of remote 10 Arrangement of assembly groups components and operation elements 05 12 Checks and repair work at seatsystem 14 Armrests and sides 0 eee 14 LegrestS 15 Backrest with frame upholstery and hand GUD kad ee oe ends co 16 Backrest adjusting 18 Seatframe seat shell and padding 19 Checks a
16. V Battery deep discharged gt Check battery See chapter 10 1 Disassembly Assembly e Remove padding out of seatshell e Assembly is carried out in reverse order e Remove plug from light servo module Take module out of seatshell NOTE e If necessary release BUS plug from main module e Secure that all plugs are clicked in correctly and replace BUS cable completely Ga 12 4 Speedometer NOTE e The speedometer is maintenance free Only basical checks can be done e The speedometer has an own battery T Locking e The pick up for the speedometer is mounted down at the front wheel next to brake disc A e The connection cable for the pick up is fixed with cable binders atthe BUS cable of remote and at the Mounting motor cable Check Action Cable e Speedometer display off gt Replace battery gt Replace speedometer e Speedometer display can not be adjusted Clamp with screw Push buttons top and gt Replace speedometer i bottom ie e Speedometer is in driving operation without func gt Replace pick up tion gt Replace connection cable Klinkenstecker Check speedometer e Prop up wheelchair in a manner that the right front wheel moves freely e Disengage motor freewheel operation e Tum front wheel manually in driving direction and check speedometer Speed gauge KMH must count upwards from 0 to ca 3 to 4 KMH Release Klinkenstecker dislock soeedometer and take off from contact p
17. age supply to remote BUS Plug e Pull BUS plug out of remote e Measure voltage at marked contacts see diagram The voltage must be at least 19 V AN CAUTION Do not short circuit contacts Danger of short circuit Trouble index for remote No voltage BUS cable defective Check replace BUS cable BUS plug defective Check replace BUS cable Main module defective Check main module Check voltage to main module See chapter 12 1 e Voltage under 19 V Deep discharged battery Check battery See chapter 10 1 Disassembly Assembly e Pull out BUS plug ofremote e Assembly is carried out in reverse order e Draw off soeedometer plug e Release wing screws at inner side of armrest Draw off remote out of mounting NOTE II f Remove morning from armrest e During assembly use new cable binders e Remove cable binder release crosstip screws e Secure that all plugs are clicked in correctly and take off soeedometer with mounting from remote e If necessary remove seat padding bring seat in service position and arrest e Remove all cable binders from BUS cable relea se BUS plug at main module and replace BUS cable completely Ty 8 12 3 Light servo module NOTE e The light servo module is maintenance free Only basical checks can be done e The module is mounted in the seatshell Wl NEE e Before control secure that the batteries are loaded A SR Tees esas I wem Ge Ti a vG EG CN
18. ce light gt le defective servo module Chapter 12 3 gt Charging batteries impossible gt Battery defective gt Replace battery chapter 10 1 Charging unit Replace charging Chapter 10 3 defective unit Signal horn defective gt Replace remote gt Chapter 12 2 gt Speedometer defective gt a gt Chapter 12 4 5 Error Codes and Diagnostic Codes When the electronic system recognises an error this is displayed by combined blink code at the remote and at the servo light module Some errors can be automatically corrected by the electronic system To do this switch the remote off and on again Wait approx 5 seconds each time before switching the remote on again If the error can be corrected the blinking on the status bar indicator stops If the error is not corrected by this process localise the error using the following blink codes You must remove the seat cushion to be able to see the servo light module LED The cushions are held by Velcro strips and can easily be removed upwards Remote status bar Servo light module status bar indicator 2 indicator 1 5 1 G40 error codes and diagnostic codes up to serial number 101176 201727 October 2004 Remote status bar Servo light module Cause Fault remedy indicator LED blink LED blink code code a i i fect replace defective module Connections between e Check the the ACS modules co
19. e housing of the potentiometer hasn t come loose e Check the contact pins of the potentiometer for continuity or short circuit e Check that the declutching mechanism is engaged and does not slip e Check that the steering is not overloaded e Check the connecting cable and plug to the servo motor Lighting system e Check the lighting defective error in SLM system for short or in cabling circuit and continuity e Check light bulbs Steering disengaged e Re engage the steering Switch the electronics system off and on again e Check the connecting cable and plug to the servo motor Remote status bar indicator LED blink Servo light module LED blink code Fault remedy code Interruption or short circuit in motor connection M1 motor or motor cable defective carbon brush defective Interruption or short circuit in motor connection M2 motor or motor cable defective carbon brush defective Drive may be disengaged Interruption or short circuit in the connection to the magnetic brake or in the magnetic brake itself Drive may be disengaged Interruption or short circuit in the connection to the magnetic brake or in the magnetic brake itself Battery voltage too low below 17V this error can occur when the batteries are fully charged and the wheelchair is driven downhill at high speed CANL error communication error between the modules An invalid voltage was d
20. e clips Check battery voltage Function servo and light module Damage of lights Function of light bulbs Status display flashes Voltage supply Attachment Cables plug connec tions Function joystick Voltage supply Check function gt Clean contacts replace battery or box gt Tighten replace Charge battery replace Replace cable connector or module Replace lights Replace light bulbs Replace module Replace cable connector or module Tighten replace Replace Replace remote Replace cable connector Or panel Replace batteries cable connector speedometer or sensor 4 0 Operation troubles 4 1 General instructions Do the following if there are any troubles in driving mode at lighting system or power supply e Analyze the in 4 2 described troubleshooting e Check the status display at remote and analyze the error codes like in chapter 5 1 Do the required checks repair work Note the cross references in the appertaining chapters in the manual or in the appertaining documentation 4 2 Troubleshooting Wheelchair doesn t drive Drive motor steering Engage motors servo motor disengaged Chapter 6 0 Status display at WEE eg Battery defective gt Replace battery __ Chapter 10 1 Battery deep BEE gt discharged Pre charge battery gt Chapter 10 2 Power supply check overload ace cone Eg interrupted FS protector i check voltage
21. e manner in which the correct continuity is signalized Signalsound or 0 Ohm depends on the construction of multimeter Process e Adjust the multimeter on continuity check or the smallest resistance measuring range Ohm e Release all plug connections of the checked cable e Connect the positive cable of measuring instrument with a contact of entry plug and the negative cable with the corresponding contact of exit plug NOTE e Entry and exit plug can be fixed freely During measuring they must not be changed e Check the continuity over the contacts from entry and exit plug e Check all contacts and cores of cable in that way for short circuit or cable breaking Trouble index for cable Continuity over several contacts cores Short circuit in cable gt Replace cable Continuity not measu rable Cable breaking gt Replace cable NOTE e In a similar way the bulbs windings of motor or switches can be checked 38 14 0 15 0 Programming of wheelchair For trouble diagnostics of ACS electronic and for adjustment of standard or customerspecific driving profiles the DYNAMIC wizard PCD software version 2 0 should be used P rogramming e C onfiguration Diagnostics The programme makes possible diagnosis and adjustment with the help of a commercially available PC up from modelrow 386 SX with the operating systems DOS up from version 3 1 or Windows 95 Beyond thata PC independent programming in
22. er with carbon brush 4 Disengaging lever 5 Gear compl 6 Thread rod with Square hinge 7 Shock absorber 8 Mounting 9 Hexagon head screw M5x20 10 Gear rocker arm 11 Hexagon head screw XX 10 11 12 M8x35 12 Rubber support 13 Socket 12x1 8 8x18 13 14 15 14 Disc 8 4 15 NutM8 16 Brake caliper NOTE a 1 gt e Motor and gear are maintenance free Only basical Check circuit of motor checks can be done e The driving unit can only be replaced completely Kei Check Action e Motor vibrates has operation sounds gt Check or replace motor Motor does not start gt Check or replace motor e Elektric brake does not apply gt Check or replace brake e Gear has operation sounds or blocks gt Replace driving unit Check circuit of motor e Bring seat system in service position and arrest Take off both motor plugs from main module e Engage motor driving mode Check with multimeter measuring range Ohm as shown in diagram It must show circuit e Disengage motor freewheel operation and repeat measurement The measured value should ascend to infinite when driving operation is changed into freewheel operation Check electric brake e Check with multimeter measuring range Ohm as shown in diagram The measured value should lie between 20 and 200 Ohm Check carbon brush e Remove the four closure caps 3 and take out carbon brushes e Measure length of brushes The original length lies at 13mm
23. etected on the CANL line fault on the CANL line communication via CANL not possible CANH error communication error between the modules Battery voltage too high e Switch on lights to Check connections to the Transaxle Check carbon brushes Check connections to the Transaxle Check carbon brushes Engage motor Switch electronics of and back on again Check connections to the magnetic brake Check magnetic brake Engage motor Switch electronics of and back on again Check connections to the magnetic brake Check magnetic brake e Check battery connections e Check fuses e Check batteries and replace if necessary use electricity and thus lower battery voltage e Check battery charger e Check BUS cable e Check continuity of the ACS bus cable e Check for short circuits between the contact pins of the ACS bus A short circuit or an interruption in another ACS module can cause this error e Check BUS cable Remote status bar Servo light module Fault remedy indicator LED blink LED blink code code An invalid voltage was e Check continuity of detected on the CANH the ACS bus cable line fault on the CANH e Check for short line communication circuits between the via CANH not possible contact pins of the ACS bus A short circuit or an interruption in another ACS module can cause this error Time limit exceeded at e Switch the maximum current electronics system
24. f detected on the CANH the ACS bus cable line fault on the CANH e Check for short line communication circuits between the via CANH not possible contact pins of the ACS bus A short circuit or an interruption in another ACS module can cause this error e Check connections to the magnetic brake Interruption or short circuit in the connection to the magnetic brake Time limit exceeded at e Switch the maximum current electronics system drive off and on again Time limit exceeded at e Switch the maximum current electronics system servo off and on again Compatibility problems e Check modules between ACS modules replace incompatible module 5 2 G40 error codes and diagnostic codes from serial number 101176 201728 November 2004 Remote status bar Servo light module Fault remedy indicator LED blink LED blink code code 1 ACS module defective e Check modules replace defective module Connections between e Check the the ACS modules connections between defective or SLM the modules and defective replace if necessary e Replace SLM Error in the servo motor e Check connection to servo motor e Check servo motor for short circuit or interruption ACS accessory parts e Check connections defective to accessories e Check accessories Potentiometer on servo e Check that the motor steering rotating pin in the defective potentiometer is not slipping and that th
25. frame ching mechanism loose gt Tighten screws e Latching mechanism warped or defective gt Straighten or replace NOTE e Take care during disassembly assembly that the cable forms to the front lighting to light servomodule and to remote run freely and aren t damaged e Before disassembly of seatframe and seat shell you first have to remove backframe and backshell After that secure seatframe with fitting sockets at chassis Complete disassembly e Remove backframe and backshell See chapter 7 3 e Secure frame 1 with sockets and remove padding 3 from seat shell 2 velcro fasteners e Release plug from light servomodule and take module out of seat shell 2 e Bring seat in service position and fix it Take off gas spring from seat frame and release bowden wire from gas spring e Remove plastic rivets with a screw driver and take off the front lighting carefully out of seat shell down wards e Draw off plug from connector row 6 remove cable connector disengage lighting cable carefully and remove lamps completely e Release screws from seat support and remove both parts of support from seatframe 1 e Remove securing socket again and take off frame 1 with seat shell 2 from chassis e Press seat shell 2 at front and sides carefully outwards and take off from frame 1 Assembly e Assembly is carried out in reverse order Ty 8 8 0 Checks and repair work at chassis 8 1 20 Chassisco
26. ide frame so that you can insert backmount socket 3 with discs e Putin the starlock caps into the pliers as you can See below e Position pliers with caps 4 on both sides on the backmount socket and tighten e Tighten pliers with a ring spanner until the caps are completely pressed on Release starlock pliers and take off e Complete assembly of backrest Starlock pliers with caps Insertion of caps 17 7 4 18 Backrestadjusting A kA Go eau CO JO Un P DIE Gas spring and bow den wire compl Gas spring 14 Fork M10x1 Trip lever for gas spring Adjustment screw Clamping screw Bowden wire Bowden wire sleeve Backframe Clutch Wing screw M6x10 Hexagon head screw qe 10 M10x35 a 2 discs 10 5 Une o Nut M10 a WEN a Adjusting lever for backrest RW Cap for bowden wire 11 t2 13 wg Check Action Check gas spring and bowden wire gt Readjust bowden wire e Bowden wire defective gt Replace bowden wire e Bowden wire sleeve defective gt Replace bowden wire sleeve e Gas spring defective gt Replace gas spring Trip lever does not move easily or is defective gt Make moving or replace trip lever e Fork defective gt Replace fork e Hanger assembly of gas spring does not move gt Make moving hanger assembly or replace easily screwing e Clutch defective gt Replace clutch e Adjusting defective gt Replace adjusting lever Complete disassembly e Release wing scre
27. l NOTE assembled e Back and front wheels are all fixed with four countersunk screws on the wheel hubs e Construction of rims is equal e Because of that the disassembly is identical 1 Front wheel compl 7 Back wheel compl 2 Rim part 1 with 3 part2 8 Rim part 1 with 9 part 2 4 Tyre casing with tube 5 10 Tyre casing with tube 11 6 Countersunk screw with 12 Had cap screw with hexa hexagon socket Check Action Back wheel Tyre looses air gt Repair or replace tube disassemble ggi gt Check casing on foreign substance e Tyre casing damaged gt Replace tyre casing e Screws loose gt Tighten screws e Rims damaged gt Replace rims Complete disassembly e Release countersunk screws 6 crosswise e Prop up wheel chair so that the wheel is free e Screw out countersunk screws 6 completely and take off wheel 1or7 e Let out air release head screw 12 crosswise and remove e Disassemble rim partl part 2 e Remove tube out of tyre casing e Repair or renew tube size 3 00 10 front 3 00 8 back Assembly e Fill in little air until tube is round e Put tube in tyre casing and put in both rim halfs from outside into casing N CAUTION e The recesses ofrim halfs must surround the valve The tube must not be squeezed between the nm halfs e Putin head screw 12 drive in crosswise and tighten with torque wrench 25 to 30 Nm e Pump up tyre to a pressure of 2 5 bar and screw on valvecap
28. late e Vheck continuity of the cable between Klinkenstecker and contact plate with a multimeter Ohmmeter Check connection cable e Screw off Klinkenbuchse that contacts are accessible e Remove front wheel that pick up is accessible e Remove Schrupfschlauch at bottom of pick up from connection cable that soldering places are accessible e Check continuity of cable between Klinkenbuchse and pick up with a multimeter Ohmmeter Disassembly e Disbolt speedometer and take off from contact plate e Release cross Slotted screwsat back of speedometer take off covering and replace batteries 2x 1 5V type SR44 e Release screw with clamp and cable binder from remote e Draw off rubber ring and take off contact plate with cable and Klinkensteckerfrom mounting e Release two cross slotted screws and remove mounting from remote e Remove cable binder remove Schrupfschlauch solder off cable from pick up and remove cable e Geber abschrauben und entfernen Assembly NOTE e Assembly is carried out in reverse order e Renew Schrupfschlauch and cable binder 37 13 0 Continuity check of cables Measuring construction Measuring example Continuity check at BUS cable Entry plug Exit plug ef Z d n NOTE e Information on handling of multimeter can be taken out of appertaining user manual All cables can be examined on defects like e g cable breaking with a continuity check The check is done with a multimeter Th
29. light casing 6 from lampholder 5 Open indicator remove lamp and mirror solder off cable and screw off indicator casing from lampholder 5 Assembly NOTE e Note connecting order Assembly is carried out in reverse order ae Lighting system back Back lighting Back lighting single parts 1 Backlightholder 2 Backlight compl 3 Indicator bulb 12V 21W 4 Backlight bulb 12V 5W 5 Holding square for plug 6 Cable form with plug 7 NOTE 8 Countersunk screw M5x20 9 Fillister head screw M4x15 Before controlling the lighting Geh secure that batteries are Check Action e Back lighting failured gt Replace light servo e For control switch on lights at completely module remote e One indicator defective gt Replace bulb e One backlight defective gt Replace bulb Replace indicator bulb e Insert a flat screwdriver into recess at side of light see arrows push away clicking lever softly from light and draw off simultaneously backlight cap backwards e Repeat operation on the other side and take off backlight cap e Remove indicator bulb out of bayonet socket and replace Replace backlight e Remove backlight as described above e Remove backlight bulb out of bayonet socket and replace Complete disassembly of backlight e Remove backlight cap like above e Remove lamps like above NOTE Flachsteckh l e Note connecting order e Remove two screws 9 and take off backlight 2 f
30. mbly of stub axle and wheel hub e Disassemble back wheel See chapter 8 2 e Disassemble shock absorber See above e Remove nuts 6 and discs 7 from floating socket 3 e Screw out screw 5 out of stub axle 2 and remove with disc 7 from steering column e Take off stub axle 2 with wheel hub 8 from steering column 4 e Remove stopper 16 from wheel hub 8 e Remove nut 6 with disc 7 draw off screw 5 with disc 7 out of wheel hub 8 and take wheel hub from Stub axle 2 e Remove ball bearing 10 with a special tool out of hub 8 and remove socket 9 Assembly e Assembly is carried out in reverse order NOTE Before set in ball bearing 10 you must set in the socket 9 Do not cant bearing during pressing in Do not forget floating socket 3 during assembly of stub axle Do not forget discs and stick on in right order Hold up nuts 6 during assembly 22 8 4 Wheel suspension front NOTE Wheel suspension front e Change or repair of front axle 5 gear rocker arm 2 and all components appertaining to gear must be done by INVACARE service 1 Shock absorber hard 2 Gear rocker arm 3 Wheel hub 4 Brake disc 160x2 5 Front axle compl 6 Bowden wire compl 7 Brake caliper compl 8 Cable socket 9 Roundmagnet 625 6 0 10 Mounting for sensor for speedometer sensor with soeedom sensor 11 Head screw M6x12 12 Head screw M8x35 13 Nut M8 14 Disc 8 4 15 Wheel nut M12x1 5 16 Disc 13 0 17 Moun
31. nd repair work at chassis 20 Chassis covering grips and cover coating20 Wheels and tyres 21 Back wheel Suspension 22 Front wheel suspension 23 Handbrake cee es 24 Checks and repair work at motor gears servo and steering 26 Driving motor and gears Power assisted steering unit 10 0 10 1 10 2 10 3 11 0 11 1 11 2 12 0 121 12 2 12 3 12 4 13 0 14 0 15 0 Checks and repair work at power supply Batteries battery box and check of battery voltage nnna naana anaa 29 Battery charging 000 ae 30 Battery chargerunit 0005 31 Checks and repair work at lighting System saaana 32 Front lighting system 32 Back lighting system 33 Checks and repair work at electronics EEN 34 Main module eee ees 34 EE gegen Geass niai oti eae aes 35 Light servo module anaana 36 Speedometer 37 Continuity check of cables 38 Programming of wheelchair 39 Storing of wheelchair n oaaaaaa aaaea 39 1 0 Safety and installation instructions The safety instructions are provided in the interests of working safety and must under all circumstances be complied with Prior to all inspection and repair work e Read this service manual and the appertaining user manual e Ensure that minimum qualifications for performing relevant work are fulfilled see chapter entitled General information AN Caution e Note that
32. nit is freed from gear rocker arms 10 e Remove driving unit downwards out of wheelchair Assembly e Assembly is carried out in reverse order 21 9 2 28 Power assisted steering unit View from below 1 2 Servo motor 3 Steering bracket 4 nuts and split pins 5 Steering rod 6 Disengaging lever NOTE Check e The powerassisted steerin unit is maintenance free e Steeering servo e Only basical checks can be done does not react e The unit can only be completely replaced Repairwork at power assisted steering unit must be e Steering bracket or done by INVACARE Service gear rocker arms damaged Disassembly of power assisted steering unit compl Remove seat padding so that light servo module is accessible Release connector to power assisted steering unit Prop up wheelchair so far that the powerassisted steering unit is accessible NOTE e Before disassembling mark note the adjustment of square hin ges on the thread rods Release screwings and free up thread rods 4 from steering rod 5 Power assisted steering unit Power asswisted steering unit compl Thread rods M8x188 RL with square hinges 7 Hexagon head screws M5x15 Action gt Replace power assisted steering unit gt Replace defec tive parts Release four hexagon head screws 7 and remove power assisted steering servo 1 with connector cable downwards out of wheelchair Release screwings and take off thread
33. nnections between defective or SLM the modules and defective replace if necessary e Replace SLM Error in the servo motor e Check connection to servo motor e Check servo motor for short circuit or interruption ACS accessory parts e Check connections defective to accessories e Check accessories Remote status bar indicator LED blink Servo light module LED blink code Fault remedy code Potentiometer on servo motor steering defective Lighting system defective error in SLM or in cabling Steering disengaged Drive may be disengaged Interruption or short circuit in motor connection M1 motor or motor cable defective carbon brush defective Drive may be disengaged Interruption or short circuit in motor connection M2 motor or motor cable defective carbon brush defective Interruption or short circuit in the connection to the magnetic brake or in the magnetic brake itself Check that the rotating pin in the potentiometer is not slipping and that the housing of the potentiometer hasn t come loose Check the contact pins of the potentiometer for continuity or short circuit Check that the declutching mechanism is engaged and does not slip Check that the steering is not overloaded Check the connecting cable and plug to the servo motor Check the lighting system for short circuit and continuity Check light bulbs Re engage the steering Switch the
34. page was inserted here to provide an important warning WARNING Danger of fire exists if the fuse is incorrectly assembled Only ever assemble the fuse in the order shown in the illustration at right Always tighten nuts to between 3 3 and 3 5 Nm Until 03 2004 After 03 2004 1 Fuse 1 Fuse 2 Fuse compartment 2 Fuse compartment 3 Washer 3 Nut DIN 6923 4 Nut M5 10 2 Load batteries NOTE INVACARE Charging unit Also note the loading instructions for batteries e in the user manual of G40 e in the user manual of charging unit e on front and rear of charging unit For care and maintenance of mechanical compo nents of batteries see chapter 10 1 AN CAUTION e Exercise care when checking loading Avoid Short circuit at battery poles gt Danger of short circuit lt Check Action Remote e Status display at remote flashes 7 e Status display at remote flashes 8 Charging plug times excess voltage gt Charging unit defective q YE i e Measure voltage of batteries See chapter 10 3 k E e Voltage under 11 5V gt Load with original charging Charging socket Voltage under 8V a Battery deep discharged gt Pre load with unregulated charging unit up to 9V Different voltage Description see below Tolerance 0 2 V at both batte nee gt Replace batteries Loading process A CAUTION e During loading batteries must not lie on side or stand edgewise The batterypoles m
35. r drive motor G40 back view Disengaging lever for servo motor Gear box with front axle Drive motor flange mounted to gear box Main module of drive electronics Servo steering with motor Wheel suspension back G40 service view Disengaging lever for drive motor Cable form for servo light module Lighting system back integrated in chassis Shock absorbers back Steering rod appertaining to power assisted steering G40 bottom view 7 0 Checks and repair work at seat system 7 1 Arm rests and sides Right side complete Left side complete 1 Arm rest tube frame Arm rest 3 Side covering Bag not illustrated 5 Side mount Clip lever M8x60 7 Mirror Wing screw M6x10 9 Hexagon head screw M6x16 Nut M8 self locking with cap 11 Hexagon head screw M5x35 Disc 5 4 13 Nut M8 Check Action e Arm rest damaged gt Replace arm rest e Screws of arm rest loose gt Tighten screws e Bag damaged gt Replace bag e Side covering damaged e Arm rest tube frame damaged Side mount damaged e Clip lever damaged e Mirror damaged Replace side covering Replace arm rest tube frame Replace side mount Replace clip lever Replace mirror VM MN VV NOTE If bere e an arm rest with integrated remote Switch off wheelchair take plug out of remote release remote and take it out of arm rest Complete disassembly e Bring seat system in service position and arrest e Release wing screw 8 and dra
36. rods 4 from steering bracket 3 Release nuts and screw off square hinges from thread rods Remove hexagon head screw M5x20 with disc and take off steering bracket 3 from powerassisted steering unit Assembly Assembly is carried out in reverse order NOTE e During assembly take care that the thread rods with square hinges are adjusted in right length e Before assembly the balls and ball pans of square hinges must be cleaned and greased again The square hinges must show upwards during assembly The correct position of securing pins must be checked The square hinges must be countered with the appertaining nuts 10 0 Checks and repair work at voltage supply 10 1 Check of batteries battery box and batteryvoltage NOTE e Secure that both batteries are loaded If total voltage lies under 24 V load batteries completely see chapter 10 2 e Sinks batteryvoltage during operation under 24 V the voltage supply to the motor Is interrup ted and remote display flashes e The voltage of each battery should not sink under 11 5 V e A fall of voltage can be checked in driving mode with switched on lighting system and applied hand brake N CAUTION Batteries complete e Be careful with tools e Do not bridge battery poles gt Danger of short circuit lt ii d e Note the high weight of batteries gt Danger of crushing lt 1 Battery box 2 Battery box cover not shown 3 Double tension belt 4
37. rom backlightholder Disassemble cable form e Remove backlight like above e Prop up wheelchair that it is accessible from below e Draw off plug 7 pull cable form carefully out of holder 1 and remove Assembly e Assembly is carried out in reverse order 8 12 0 checks and repair work at electronics 12 1 Main module 34 e The main module is maintenance free Only basical checks Main module serviceview can be done e The module is mounted at back of chassis in front of the backwheels e Before control you must secure that the batteries are loaded Status display a For a simple visual assessing of defects the module is equipped with a green light diode for status display Check of status display Main module Batteries e Swith on wheelchair at remote Main module e Check light diode see index below Remotecable par bl atterycable Check Action Light servo e Status display lightens gt Module is in order WEE Motorcable e Status display off gt Check voltage supply of module Check programming e Status display flashes gt Replace module ene Check voltage supply to main module e Bring seat system in service position and arrest cS e Draw off plug of batterycable out of main module e Measure voltage at contacts of batteryplug Both left contact pins are connected with the positive pole both right contact pins are connected with the negative pole of battery The voltage mus
38. some components are heavy You should take this into account above all when removing the batteries e The power supply for the wheelchair must be switched off before any conductive parts are removed Remove the batteries e When performing tests on conductive parts ensure that the contacts are not short circuited gt Danger of fire and injury from bums lt e Only use tools which are in perfect working order and are not damaged During work and assembly e Mark the current settings of the wheelchair seat armrests back etc and the combination of cable connec tions before carrying out disassembly work This will make assembly an easier task afterwards o ACHTUNG e Support the raised wheelchair with suitable supports before you begin assembly Use the bottom tube frames of the chassis Also see the illustration G40 bottom view chapter 6 0 e You should under no circumstances use normal nuts instead of self locking nuts e Always use correctly sized washers or separators Note All plug connectors are fitted with mechanical clamps which prevent slipping when the wheelchair is in operation e These clamps must be pressed in to release the connectors e When carrying out assembly work ensure that the clamps are fitted properly e For checks and repair works you can fold up the seat system and arrest This position is called service position Prior to Initial use after repair work O Caution e Check firm mo
39. strument can be used The article number of software or the programming instrument can be found in chapter 2 0 list of tools Storing of wheelchair If it is necessary to store the wheelchair for a longer period you should do following actions e Check tyre pressure and fill up to rated pressure if necessary See chapter 8 2 e Load batteries for 48 hours with INVACARE charging unit See chapter 10 2 e Remove pole clips of batteries See chapter 10 1 e Store batteries in a cool place if necessary disassemble and store separately See chapter 10 1 During renewed putting it into operation check tyre pressure and battery voltage and fill in load if necessary 39 Warnings on modifying the programming of the wheelchair WARNING Every alteration to the drive programme can influence vehicle handling and the tipping stability of the wheelchair e Alterations to the drive programme must only be carried out by authorised Invacare dealers e 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 Torques Please note the following torques for all adjustment and maintenance work during which it is necessary to loosen and re tighten screws or nuts Thread diameter Fastening torque Nm Fastening torque mkp 0 35 0 80 0 60 0 80 1 4 1 9 6 3
40. t Replace footplate mount gt Replace insertion tube gt Replace top of legrest gt Make pivot moving or replace gt Replace slide e Bring seat system in service position and arrest e Release clamping lever 10 and draw off legrest from chassis e Release hexagon head screw und draw off top of legrest from insertion tube e Release fillister head screwand draw off calfsupport e Release countersunk screws 13 and nuts 14 and remove calf pad mount 7 e Remove nut 17 and disc 18 and remove calfsupport holder 5 from pivot 8 e Remove clamping sleeve 23 and remove calfsupport pivot 8 from clip part 7 e Remove tin screws 19 and draw off footplate 4 from footplate mount e Remove screw 15 with hatnut 20 and discs 9 and draw off footplate mount from insertion tube e Release slide 21 22 from footplate mount top of legrest with a screwdriver Assembly e Assembly is carried out in reverse order NOTE e The screw 15 with nut 16 serves for adjusting of footplate e Don t tighten the screw 15 with hatnut 20 and nut 17 too strong erh 15 12 16 Backrest with frame padding and grip Backrest front view without padding Backrest back view 15 Back shel Backframe 2 Backmount socket 4 Starlock caps 16 0 Disc 17 0 6 Backpadding not shown Clutch part for gas spring 8 Wing screw M6x10 Safety belt not shown 10 Mounting plate for safety belt Hexagon head scre
41. t be at least 19 V Trouble index for main module e Voltage under 19 V Batteries deep dis gt Pre charge battery charged See chapter 10 2 gt Replace battery e No voltage Cable defective gt Replace cable Disassembly Assembly e Bring seat system in service position and arrest e Assembly is carried out in reverse order e Mark plugs and draw off from main module e Release both cross slotted screws of module Screws are accessible from rear of wheelchair bot BEE tom e Secure that all plugs are clicked in correctly e Remove module e If necessary release the voltage supply cable from batteries remove batteries See chapter 10 1 Release cable socket at battery box and replace cable completely ae 12 2 Remote NOTE e Before control of remote check the charging state of batte ries e Then check status display on errorcodes Standardremote Kontrolle Ma nahme e Status display flashes gt Check error codes See chapter 5 1 BUS plug defective gt Replace BUS cable e BUS cable damaged Replace BUS cable e Movement of drive lever Impaired damaged e Remote mounting armrest gt Replace remote gt Renew wing screws replace damaged mounting e Display or keyboard faulty e Voltage supply to remote gt Replace remote faulty l gt Check Measurement see below Battery voltage BUS plug BUS cable main module Speedometerplug BUS plug Check volt
42. tenings stitching ce parts 75 Backrest with safety belt Latching mechanism of seat in service position Chassis with frame side grips and cover ing Wheel suspension and wheels Hand brake Drive and steering asssembly Legrests e Adjustment function e Damage and screw fastenings stitching e Belt and belt buckle e Damage and secure lat ching into place e Screw attachments wel ded joints damages e Function and damage of shock absorbers e Wheel suspension e Wheel bearing e Tyre equipment e Function e Loose bowden wires slee ves damaged e Wear damage of brake discs and brake calipers e Check function in driving and freewheel operation e Check toggle link e Welded joint lock screw attachment e Footboard gt Adjust or replacebow den wire gas spring 7 3 gt Tighten screws Repla ce parts gt Replace gt Make moving gt Tighten screws 1 5 ei Replace parts gt Replace 8 2 gt Replace bis gt Adjust replace Se gt Fiton new ones gt Adjust replace gt Tighten adjust 85 replace gt Replace Se el ei gt Tighten replace gt Adjust replace gt Tighten replace gt Tighten replace ae Batteries Light servo module and lighting system Drive electronic and main module Drive electronic Remote Speedometer e Damage of battery and box corrosion on contacts Check of contacts and pol
43. ting of brake caliper 18 Stopper SL35 not shown Check Action e Shock absorber defective gt Replace shock absorbers e Screwings loose gt Tighten screws e Hub damaged gt Replace hub Disassembly shock absorbers Disassemble front wheel See chapter 8 2 Bring seat system in service position and arrest Remove screw 12 with disc 14 and nut 13 at bottom and remove mounting 10 with sensor Remove screw 12 with disc 14 and nut 13 at top of chassis and take off shock absorbers Assembly Assembly is carried out in reverse order Disassembly wheel hub NOTE e Disassemble front wheel See chapter 8 2 e Muttern und Scheiben zu Schrauben 11 nicht ver Release two screws 11 and remove brake caliper 7 lieren Die M uttern sind im Bremssattel eingelassen from mounting 17 e Palsfeder f r Radnabe in Vorderachse eingelas Release stopper 18 sen nicht verlieren Remove wheel nut 15 and disc 16 and take off wheel hub 3 and brake disc 4 with a removing tool Release four countersunk screws M6 with hexagon and take off brake disc 4 from hub 3 Assembly Assembly is carried out in reverse order CAUTION e The front axle must not be greased erh e Dirt or rust is to be removed Use rust remover or fine emery paper NOTE e Puton hub during assembly in such way that the feather glides into the free space of hub without canting e For tightening the nut 15 engage motor
44. unting of all fastening screws e Check that all parts are properly locked in place e Check regulation tyre pressure 2 5 bar before starting the machine e Always perform a test drive after repair work 2 0 List of tools A standard toolkit comprising the following minimum inventory is required Combination ring and open end spanner SW 6 7 8 10 11 12 13 17 19 Allan key 2 5 mm 3mm 4mm 5mm 6 mm 8mm 10mm Torque wrench commercially available Socket spanner set Screwdrivers for slotted screws various Crosstip screwdriver No 1 No 2 Side cutting pliers Flat pliers Round pliers Cable lug pliers Wooden or plastic hammer Tyre repair set commercially available Air pressure gauge Valve extraction tools Special tool for removing wheel bearing Multimeter with test points and various cable clips Bridging cable Soldering iron 30W Assembly pliers for Starlock caps commercially available Removing tools for font wheel hub available by INVACARE Service You will require the following for setting at the ACS control Programming unit Item no Software package incl interface cable and dongle Item no 3 0 Inspecton plan Armrests and sides e Damage to and attachment of armrests e Damage to and attach ment of side panels e Mirrors gt Tighten screws Repla ce overlay gt Tighten screws Repla 1 1 ce sides gt Replace Seat e Damage and screw gt Tighten screws Repla fas
45. ust show upwards e At G40 with ACS use only gelbatteries loading power maximal 7 A Wetbatteries loading power max 10 A overload cables e Batteries and charging unit must be set out ambient temperature because the loading is also controlled with temperature sensors Elongated cables and different locations of charging unit and batteries cause faulty loading NOTE e Processing during loading of batteries with INVACARE charging unit Also see user manual of G40 e Pay attention to connecting order of INVACARE charging unit First connect charging plug then mains plug e Deep discharged batteries can not be loaded with INVACARE charging unit e If batteries are not loaded completely they must be replaced e During full loading the display full loading on charging unit must light When a charging voltage of 28 V is reached also the LED s at remote flash The voltage of a single battery shall amount during full loading and in room temperature ca 20 22 C 14 0 2 V T B Loading of deep discharged batteries When measuring a battery voltage of under 8 V the battery is deep descharged For loading deep discharged batteries do the following e Remove batterypole clips and connections to wheelchair See chapter 10 1 e Pre charge each battery and measure charging voltage e Pre charge battery with an unregulated charging unit up to 9 V After that interrupt charging process with unregulated charging unit
46. vering grips and cover coating Chassiscovering Side grip a AN Side grip 3 Cover coating Chassiscovering 2 Rosettes 5 Stick holder 6 Plastic rivet Brake lever 8 Wing screw M6x10 9 Cap SKS 8 Hexagon head screw 11 Securing disc Schnorr M8 Check Action e Cover coating loose or damaged gt Stick or replace coating e Side grip or rosette damaged gt Replace side grip or rosette e Chassiscovering damaged gt Replace chassiscovering e Stick holder damaged gt Replace stick holder Disassembly side grip e Bring seat system in service position and arrest e Remove caps 9 remove hexagon head screws 10 with discs 11 and take off grip 2 with rosettes 4 Assembly e Assembly is carried out in reverse order disassembly chassiscovering NOTE Before thedisassembly of chassiscovering you first must disassemble the seat system completely See chapter 7 1 to 7 5 e Remove hexagon head screws with nuts and take off stick holder 5 e Release wing screw 8 and take off brake lever 7 e Remove side grips 2 with rosettes 4 e Remove the eight plastic rivets 6 two at sides two at front two at back For doing that you first must draw off the pins in covering with pliers out of the rivets Then remove the rivets from outside with a screwdriver e Take off chassiscovering from chassis upwards Assembly e Assembly is carried out in reverse order 8 2 Wheels and tyres Front whee
47. w 10 and draw off clutch 9 from backframe 8 e Bring seat system in service position and arrest e Release hexagon head screw with nut and discs and take off fork 2 from seat frame e Turn gas spring 1 out of fork 2 e Release screw 11 with nut 13 and discs 12 and take off clutch 9 from gas spring 1 e Release clamping screws 5 and nuts and screw out adjusting screws 4 e Pinch off caps 15 from bowden wire 6 and take off bowden wire sleeve 7 e Release screw and nut and take off trip lever 3 from fork 2 Assembly e Assembly is carried out in reverse order NOTE e Mark or note the position of adjusting screws beforedisassembly e Screw in gas spring at assembly until stop into fork e After drawing in a new bowden wire caps must be squeezed on e The adjusting lever is stored in seat frame and arrested with a starlock cap For disassembly you first have to remove the seat shell See chapter 7 5 ae 7 5 Seatframe seat shell and padding Seatframe Seat shell Light servo module em vm mm NEE SE A E E 2 1 Seatframe 2 Seat shell 3 Padding not shown 4 Latching mechanism 5 Front lighting equipment compl 6 Connector row for lighting system Check Action e Padding damaged gt Replace padding e Seat shell damaged gt Replace seat shell Seatframe warped or gt Straighten frame welded joints defective e Screwed connections of lat gt Replace
48. w M6x20 12 Disc 6 4 Threaded bolt M6x6 14 Walking stick loop Grip 16 Chassis Check Action e Backpadding damaged gt Replace backpadding e Screws at backframe loose gt Tighten screws Backshell damaged gt Replace back shell e Backframe damaged welded joints defective gt Replace backframe e Grip damaged gt Replace grip e Walking stick loop damaged gt Replace walking stick holder e Safety belt damaged gt Replace safety belt e Backframe does not go easily gt Make moving or replace backmount socket Complete disassembly e Draw off backpadding from seat shell velcro fasteners e Release crosstip screw and remove walking stick loop 14 e Release threaded bolts 13 and pull out grip 15 e Release wing screw 8 and pull out clutch part from backframe 2 downwards e Release hexagon head screws 11 with discs 12 and remove safety belt 9 with mounting plate 10 e Pull out backshell 1 from backframe 2 downwards e Note position of discs 5 e Release starlock caps 4 with a flat screwdriver and remove backmount socket 3 with discs 5 e Remove backframe 2 from chassis ae Assembly e Assembly is carried out in reverse order NOTE e Use new Starlock caps 4 for assembly e During assembly of backframe 2 take care that the discs 5 are pushed into the backmount socket in right order For assembly of backframe at chassis do the following e Positon chassis back and s
49. w off sides with arm rest sideways away from chassis e Release clip lever and draw off side mount downwards e Release bag 4 from side covering 3 velcro fastener e Release screws 11 with discs 12 at side covering and draw off arm rest 2 e Release plastic rivets at bottom of side covering with a screw driver and draw off side covering 3 from arm rest tube frame e Remove cap release nut 10 and draw off mirror 7 out of arm rest tube frame 1 Assembly e The assembly is carried out in reverse order 14 7 2 Legrests 1 Legrest top 2 4 Footplate 5 7 Calf pad mount 8 10 Clamping lever M6x10 11 13 Countersunk screw M5x25 14 16 Nut M6 17 19 Fillister head self tapping screw 20 22 Slide F30x15 23 Check e Screws loose e Calfsupport damaged e Footplate damaged e Footplate mount damaged e Welded joints or insertion tube defective e Welded joints or top legrest defective e Calfsupport pivot goes heavily defective e Slides missing or damaged Complete disassembly Legrests compl Insertion tube Legrest Parts Footplate mount Calfsupport holder Calfsupport Calfsupport pivot 2 Plastic discs 17x6 5 Hexagon head screw M6x10 12 Fillister head screw M6x16 Nut M5 self locking 15 Screw Mox45 Nut M8 18 Disc 8 4 Hat nut M6 21 Slide SL 18 Clamping sleeve 5x20 Not shown belongs to 7 and 8 Action gt Tighten screws gt Replace calfsupport gt Replace footplate g
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