Service Manual
Contents
1. 3 5 Backrest Assembly her jor T ee 3 9 Armrest and Controller Assemblies 3 11 Rear Wheel and Motor Assemblies 3 13 Brake 5 EE 3 15 Castor Wheel Assemblies 0 000 ccc 3 17 Swinging Detachable Footrest Assembly 3 19 Seat Canvas Assembly 3 21 Batteries Loom 3 23 Kerb Climber Assembly cee deka ier eee eee ia 3 25 Options Accessories and Non Standard Accessories 3 26 E E Ei 02 02 Page 1 3 Apolo LEFT BLANK INTENTIONALLY Page 1 4 02 02 w INTRODUCTION Em Chapter 1 Introduction 02 02 Page 1 5 Figure 1 0 Apollo Indoor Wheelchair General Arrangement 02 02 Page 1 6 w INTRODUCTION En Introduction 1 This manual provides basic details to enable the Apollo range of wheelchairs to be maintained It is not intended to be a comprehensive maintenance guide policy but is intended for use by competent personnel to enable the chair to be adequately maintained 2 The manual is split into the following chapters Chapter 2 Detailing assemblies that are maintainable and the relevant procedures Chapter 3 Detailing parts that are available to enable the maintenance in Chapter 2 to be complied wi2. Apolo LEFT BLANK INTENTIONALLY Page 1 2 02 02 5 mwa Contents Page Chapter1 Introduction IntrodUcliOn NE 1 7 PollGy s O RR 1 9 iT chinical Details 5o spiate en eten 1 9 Chapter 2 Maintenance SCOPE colle RARE ER n ve 2 3 wow wa DE aee 2 3 018 aa EE ERE E 2 5 Removing And Replacing Backrest Canvas and Push Handles 2 7 Removing And Replacing Armrest 2 11 Removing And Replacing Rear Wheel and Motor Assemblies 2 15 Removing And Replacing A Brake Assembly 2 21 Removing And Replacing A Castor Wheel Assembly 2 23 Removing And Replacing An Adjustable Footrest Assembly 2 25 Removing And Replacing Seat Canvas 2 27 Removing And Replacing Kerb Climber 2 29 Removing And Replacing Batteries 2 31 Controller Information Dynamic 2 37 Controller Information Penny and Giles 2 38 Chapter 3 Illustrated Parts List Generali ters e retos a ud dus el lg MR EAR HANE AE TR d 3 3 3 3 General
3. v Current Limit The bulk charging current is electronically limited by the charger to ensure that the output current cannot exceed the recommended battery rating Construction The charger is designed and built to comply with the safety requirements of European stan dard EN60335 part 2 29 02 02 2 35 Apolo WARNINGS A For indoor use only do not expose to rain or spray B Do not smoke or expose naked flames near to the battery Do not obstruct the ventilation slots by for example covering the charger with clothing bedding or placing the charger on deep pile carpets or soft furnishings D Do not poke or drop any objects through the slots in the charger case E The charger must be stood on its rubber feet placed on a flat horizontal surface F No user replaceable components inside Dangerous voltages within DO NOT attempt to open the charger case Return to the manufacture if service required FAULT FINDING SYMPTOM POSSIBLE CAUSE SUGGESTED ACTION MAINS ON indicator will not illuminate when charg er supply switched on BULK CHARGING indica tor will not illuminate 90 CHARGED or CHARGE COMPLETE lights do not illuminate even after prolonged charging i e more than 16 hours Charger inlet fuse failed Supply cord plug failed UK only Charger supply not switched on Mains supply not present Charger fault Battery not connected Battery polarity reversed
4. Battery voltage too low below approx 8V the charger output is inhibited Charger fault Battery capacity too large for charger rating Individual cells in battery may be faulty so that charging current remains high An external load is still connected to the battery Charger fault Replace fuse with identical type Replace fuse with identical type Switch supply on Check supply present at socket with another appliance Return charger for repair Switch off charger and check that output leads are connected to battery or that any fuse in the battery circuit is healthy and that there are no loose connections in the wiring Switch off charger and check the battery clips are connected the right way round Switch off charger and check battery voltage Deeply discharged batteries may require special attention for recov ery Return charger for repair Check battery Ah capacity is within charger rating Batteries should be tested for possible faults Check that any equipment connected to the battery is disconnected or switched off Return charger for repair Page 2 36 02 02 w MAINTENANCE 2 10 CONTROLLER INFORMATION Dynamic Diagnostics Diagnostic information is provided to enable a fault in the system to be identified and localised to a major com ponent e g motor The following system diagnostics are provided Flash code sequence 1 Low battery voltage fault High battery voltage faul
5. Tools 3 Refer to the tool list at the beginning of this Chapter Inspection 4 Check the following 4 1 Castor fork is undamaged 4 2 Tyre is not cracked or excessively worn 4 3 Castor wheel rotates freely when lifted clear of the ground and spun 4 4 The tyre is firmly fitted and concentric within the rim Removing A Castor Wheel Assembly 5 To remove the castor wheel assembly proceed as follows 5 1 Raise and support the front of the chair 5 2 Using a torque wrench unscrew the castor wheel until the castor assembly releases from its location 5 3 Remove the castor wheel assembly 5 4 Check that the castor wheel location is undamaged and clean Replacing A Castor Wheel Assembly CAUTION Apply Loctite 242 to the thread of the castor wheel shaft and ensure that the castor wheel is tightened using the fork nut to torque of 30 Ibf ft 6 Replacing the castor wheel assembly is the reverse of the removal ensure the following 6 1 It is firmly located and secure 6 2 Free to rotate through 360 degrees 6 3 ls undamaged 7 Once correctly fitted remove the support and allow the chair to sit on all four wheels Check that it functions correctly 02 02 Page 2 23 Apolo 1 Latch plate 2 Stem tube 3 Footplate assembly 4 Heel loop assembly Figure 2 6 Swinging detachable Footrest Assembly 2 2 4 Page 2 24 02 02 w MAINTENANCE s 2 6 Removing And Replacing An Adjustable Footrest Assembly G
6. 5 9 6 9 7 Available seat sizes 15 inches by 16 inches 16 inches by 16 inches 17 inches by 17 inches 18 inches by 17 inches Seat to ground height 19 inches Wheel types available 8 inches Indoor 12 1 2 inches Outdoor Micro Cellular Plastic tyres MCP Located to frame Maximum user weight 16 stones 100kgs Outdoor 16 stones 100kgs Indoor Backrest type Folding backrest Chair finish Stove enamel paint in red or black Weight of chair Total 55 99kg 122 7lbs to 57 36kg 126 5lbs dependent on configuration 02 02 Page 1 9 Apolo HZ LEFT BLANK INTENTIONALLY EREESEEFEEEEEEEEEEEE IEE Page 1 10 02 02 w MAINTENANCE I Chapter 2 Maintenance 02 02 2 1 Apollo Battery assembly 6 Backrest canvas 7 Armrest assembly 8 Swinging bracket assembly 9 1 Footplate assembly Castor assembly Seat canvas 0 Controller Rear wheel and motor assembly Brake assembly Figure 2 0 1 General Arrangement Apollo Indoor Wheelchair I MUU 2 2 02 02 w MAINTENANCE I 1 This chapter details the removal and or replacement procedures required for the following assemblies and or items It is not intended to be a strict policy of maintenance but should be used as a guide only 2 The assemblies covered refer to Figs 2 0 1 and 2 0 2 are as follows Section Assembly Page 2 1 Backrest canva
7. A torque wrench of 25 Ibf ft rating is required Inspection 5 Inspect on a weekly basis for the following 5 1 Motor cable insulation in good condition Connector properly inserted in Controller socket 5 2 No visible damage to Motor assembly 1 5 3 Motor assembly 1 fixing bolts are tight and in good condition no corrosion etc Note For any fault conditions or irregularities in Motor operation refer to Diagnostics and Trou bleshooting 5 4 Drive wheel 2 shows no signs of physical damage or distortion and is tightly seated on the drive shaft 5 5 When the drive wheel 2 is allowed to freewheel that no binding grating noise or unconcentric rotation are present 5 6 Tyre not excessively worn and not visibly damaged cracks Amount of wear is approximately the same on both tyres of the wheelchair Tyre is correctly inflated for pneumatic tyres only 5 7 Electromagnetic park brake cuts in properly and prevents the wheels from rotating 5 8 Freewheel function test is satisfactory including drive dog release engagement Removing Main Rear Wheel Outdoor 6 To remove a drive wheel refer to fig 2 3 1 proceed as follows 6 1 Raise and support the chair so that the wheel is free of the ground 6 2 Using a thin blade screwdriver prise the Plastic Cap 8 out of the wheel hub 6 3 Carefully remove the Slotted Screw 7 in the wheel hub and retrieve the components of the drive freewheel assembly washer 6 compression spri
8. Figure 2 2 2 Armrest Assembly with controller E Page 2 12 02 02 w MAINTENANCE Im 10 Removing Armrest Panel 4 10 1 Armrest panel is riveted to the armrest frame Drill out the four Briv rivets using 1 8 drill ensuring not to enlarge the holes Replacing Armrest Components 11 To replace the Armrest assembly or any of the components of the Armrest assembly is the reverse of the removal however ensure the following 11 1 The Armrest Panel is flush fitting to the Frame 11 2 Sealing Plugs are undamaged when replaced ao ss 02 02 2 13 Apolo HZ 1 Motor 9 Bolt 2 Wheel 10 Motor MTG plate 3 11 Connector 4 Drive coupling 12 Thrust washer 5 Spring 13 Mounting tube 6 Steel shim washer 14 Spring button 7 Circlip 15 Anti tipping lever 8 Notused Figure 2 3 Rear Wheel Assembly Apollo Indoor 4 2 14 02 02 w MAINTENANCE 2 3 Removing And Replacing Rear Wheel Assemblies General 1 The Apollo range of wheelchairs can be fitted with the following wheel types 1 1 12 1 2 inch diameter wheel Outdoor 1 2 A 8 inch diameter wheel Indoor 2 Check the wheel assembly for any defects refer to paragraph 5 If any defects are observed then refer to paragraphs 6 to 11 for maintenance details and to Chapter 3 for parts 3 The rear wheel assembly can be renewed as a complete assembly Tools 4 Refer to the tool list at the beginning of this Chapter 4 1
9. NAKED FLAMES NEAR THE BATTERY THE GASES THAT CAN BE GIVEN OFF ARE EXPLOSIVE THE ACID CONTAINED WITHIN GEL BATTERIES IS FIXED WITHIN THE GEL ITSELF IT CAN ONLY ESCAPE IF THE CASING IS DAMAGED IT IS STILL ACID AND WILL BURN AVOID CONTACT WITH THE SKIN AND EYES IF YOU DO GET INTO CONTACT WITH ACID WASH IT OFF WITH PLENTY OF WATER AND CONSULT YOUR DOCTOR IF NECESSARY REPORT THE LEAKAGE TO THE BODY THAT ISSUED THE CHAIR BATTERY MAINTENANCE IT IS IMPORTANT TO REALISE THAT GEL BATTERIES ARE DIFFERENT FROM CONVENTIONAL WET LEAD ACID BATTERIES THERE IS ABSOLUTELY NO REQUIREMENT TO TOP UP THE BATTERY AT ALL DO NOT attempt to remove the valve covers This will void any guarantees given with the battery DO NOT put any metal objects on top of the battery This is dangerous and can damage the battery DO NOT allow the battery to be left in a discharged condition DO KEEP the battery top clean and dry DO KEEP the battery terminals clean and smeared with petroleum jelly Vaseline DO LEAVE the battery in a fully charged state before any long period of non use of the chair during winter months for instance In this condition the batteries need no further attention for up to 9 months when it is then recommended to recharge the batteries 24V GEL TYPE BATTERY CHARGER Operating Instructions PLEASE READ AND RETAIN THESE INSTRUCTIONS BEFORE USING THE BATTERY CHARGER General This battery charger has been carefully designed for use with 24 vol
10. switched on Check that the charger is plugged into a working power source Check the charger operation 2 3 Check the charger is the correct type 4 5 Check the fuse next to the power connector on the charger WARNING Disconnect charger from both the mains socket and battery charger socket before checking the fuse Ipu s 02 02 Page 2 39 Apolo 211 CONTROLLER INFORMATION Penny 4 Giles Diagnostics This section is only applicable if you have a PILOT controller fitted with a TrueCharge display The diagram below shows you how to read the TrueCharge display in the event of a fault If you look at the diagram you will see that 10 different types of fault are defined The number of bars flashing on the TrueCharge display indicates the fault type A brief description for each fault type is also included on the dia gram These fault types and their possible sources are described in more detail on page As an example assume that the wires to the solenoid brake has been disconnected The controller would detect this as a fault so in this instance cause 9 bars to flash on the display corresponding to fault type 9 TrueCharge Display Diagnostics Fault type Description 10 Green High battery voltage 9 Green Solenoid brake fault 8 Green Possible controller fault 7 Yellow Possible joystick fault 6 Yellow Inhibit active 5 Yellow Right motor wiring fault 4 Yellow R
11. washer 10 Pozidriv screw 11 Seat canvas Figure 2 7 Seat Canvas and Frame Assembly Page 2 26 02 02 w MAINTENANCE I 2 7 Removing And Replacing Seat Canvas General 1 Check the seat canvas 11 for any defects refer to paragraph 3 If any defects are observed then refer to paragraphs 5 to 6 for maintenance details and to Chapter 3 for parts information Tools 2 Refer to the tool list at the beginning of this Chapter Inspection 3 Check for the following 3 1 Damage to seat canvas 11 3 2 Sagging 3 3 Reinforcing bar 2 missing and or damaged 4 Generally replace and or tighten any screws 10 or cup washers 9 and canvas pegs 8 that are missing damaged Removing The Seat Canvas 5 To remove the seat canvas 11 proceed as follows 5 1 Unscrew and remove the countersunk head screws 10 and cup washers 9 on the left side only 5 2 Lift the seat canvas clear of the chair frame Replacing The Seat Canvas Note Check the order for the correct seat canvas size 6 Replacing the seat canvas is the reverse of the removal refer to Chapter 3 for parts information Ensure that all damaged screws 10 washers 9 and seat canvas pegs 8 are replaced 02 02 2 27 Apollo 1 Bolt 5 Location pin 2 Mounting bracket 6 Kerb climber assembly 3 Nuts 7 Screw 4 Spacers Figure 2 8 Kerb Climber Assembly Page 2 28 02 02 w MAINTENANCE I 2 8 Kerb Climber Assembly General
12. 1 Check the condition of the kerb climber for any defects refer to paragraph 3 If any defects are observed then refer to paragraphs 4 to 5 for maintenance details and to Chapter 3 for parts information Tools 2 Refer to the tool list at the beginning of this Chapter Inspection 3 Check for the following on daily basis 3 1 Kerb climber 6 show no sign of physical damage 3 2 Kerb climber operates correctly 3 3 Location pin 5 bolts nuts and spacers are not damaged or missing Removing and Replacing Kerb Climber Assembly 4 To remove the kerb climber proceed as follows 4 1 Remove location pin 5 and lower right hand side of kerb climber assembly 6 from mounting bracket 20 then slide out from left hand mounting bracket 4 2 Remove screw 7 bolts 1 nuts 3 and spacers 4 the remove mounting brackets from side frames 5 Replacing the kerb climber is the reverse of removal 02 02 Page 2 29 Apollo So Clamp strip 7 8 9 Control box 1 Battery box carrier frame Battery strap 10 Boxes with circuit breakers Boxes with circuit breakers Wiring loom Gel battery 2 3 4 5 Boxes without circuit breakers Handwheel 6 Figure 2 9 Batteries 02 02 Page 2 30 w MAINTENANCE 2 9 Batteries 1 Check the condition of the batteries and the associated wiring for any defects refer to paragraph 3 If any defects are observed then
13. 2 7 Apollo 1 Backrest canvas 6 Plunger knob 2 Plug 7 Pozidriv head screw 3 Push handle assembly 8 washer 4 head pivot bolt 9 Handwheel 5 Plunger 10 Pram handle Figure 2 1 1 Folding Backrest Assembly Apollo Indoor Outdoor Page 2 8 02 02 MAINTENANCE I Replacing the backrest canvas and or push handles 9 replace the backrest canvas refer to Fig 2 1 1 is the reverse of the removal however ensure the following 9 1 New Nyloc nuts are fitted 9 2 The securing points are undamaged 9 3 New washers are fitted as required 9 4 That the backrest canvas is stretched evenly and is taut 9 5 The locking mechanism operates correctly Action should be smooth and positive 02 02 Page 2 9 Apolo gt KIT 1 Sealing plug 4 Armrest panel 2 Armrest pad Armrest frame 3 Pozidriv head screw Figure 2 2 1 Armrest Assembly Apollo Indoor Outdoor EZ EF ffHGiERBPl Y ii Page 2 10 02 02 w MAINTENANCE I 2 2 Removing And Replacing Armrest Assembly General Note The armrest assembly comprises the following The armrest pad 2 panel 4 and frame 5 1 Check the armrest pad 2 and frame 5 for any defects refer to paragraph 4 If any defects are observed then refer to paragraphs 5 to 7 for maintenance details and to Chapter 3 for parts information 2 The armrest can be renewed as either 2 1 A complete assembly 2 2 Armpad ki
14. ake 10 battery fault This occurs when the controller detects that the battery voltage has risen above 35V Check the batteries and the connections to them 02 02 Page 2 41
15. aohms the motor is probably faulty N B Due to limitations of the diagnostics a fault in one motor may be indicated as a fault in the other motor 5 Disconnect both motors and park brakes Turn the controller off and on leaving the joystick in neutral If a motor fault is still indicated then the fault is actually with the controller N B Due to limitations of the diagnostics a fault in the controller output electronics may be indicated as a motor fault 4 Right motor or connection As above fault Page 2 38 02 02 MAINTENANCE I Troubleshooting Guide continued PROBLEM CHECK ACTION 5 Left or right park brake or 1 Check the motor solenoid brake connectors are securely plugged in connection fault 2 Check the contacts in the connectors for corrosion or damage 3 Check the park brakes If the resistance is less than 20 ohms or more than 100 ohms the solenoid brake is probably faulty 6 Controller fault Disconnect both motors and park brakes Turn the controller off and on leaving the joystick in neutral If a controller fault is still indicated then the controller fault is confirmed Disconnect both motors and solenoid brakes Turn the controller off and on leaving the joystick in neutral then deflect the joystick If the controller s relay clicks twice and a left motor fault is now indicated then the controller is OK If another fault other than left motor is indi cated and the relay does not clic
16. damage or oxidation 12 3 All Nyloc nuts should be replaced after removal Tools 13 The following list details the basic tools required to carry out the maintenance given in the following sub chapters 13 1 Pliers 13 2 Socket set Metric and Imperial 13 3 Spanners Metric and Imperial 13 4 Pozidriv screwdriver 13 5 Slotted screwdriver 13 6 Adjustable spanner 13 7 Torque wrench 20 to 40 Ibf ft rating 13 8 Set of Allen keys Metric and Imperial 13 9 Protected jaw grips 13 10 Nylon mallet 13 11 Pop rivet gun 13 12 Nut insert application tool 13 13 Rule 13 14 Circlip pliers Note The above list is not exhaustive 02 02 2 5 Apollo 1 Backrest canvas 6 Plunger knob 2 Plug 7 Pozidriv head screw 3 Push handle assembly 8 Cup washer 4 Hex head pivot bolt 9 Handwheel 5 Plunger 10 handle Figure 2 1 1 Folding Backrest Assembly Apollo Indoor Outdoor Page 2 6 02 02 w MAINTENANCE Im 2 1 Removing And Replacing Backrest Canvas And Or Push Handles and Pram Handle if Fitted General 1 Check the backrest canvas refer to Fig 2 1 1 and push handles for any defects refer to paragraphs 4 and 5 If any defects are observed then refer to paragraphs 6 to 7 for maintenance details and to Chapter 3 for parts information 2 Ensure that the push handle locks securely into place and that the locking mechanism functions correctly Tools 3 Refer to the too
17. eck the battery connector to the controller is securely plugged into tery Gauge does not light the connector from the battery when the controller is Check the batteries themselves are connected correctly i e check switched on the battery terminals Check the batteries are not measuring less than 15V using a volt meter Check the battery supply fuse or circuit breaker If the fuse has blown check for wiring faults 1 Low battery voltage fault Check the battery connector to the controller is securely plugged into the connector from the battery and is in a good condition free from corrosion 2 Check that the battery terminals are tight and in good condition 3 Check the batteries are not at the end of their life Check the batteries are not measuring less than 15V using a volt meter 2 High battery voltage fault Check the battery charger Is it overcharging the batteries Is the charger the correct type Battery voltage should not be greater than 32V with battery removed from charger 3 Left motor or connection Check the left and right motor solenoid brake connectors are fault securely plugged in Check the contacts in the left and right motor connectors for corro sion or damage Check the left and right motors If the resistance is more than 1 Ohm or less than 100 milliohms the motor is probably faulty Check the resistance of the motor to its housing If the resistance is less than 1 Meg
18. eneral 1 Check the adjustable footrest assembly for any defects refer to paragraph 3 If any defects are observed then refer to paragraphs 5 to 9 for maintenance details and to Chapter 3 for parts information Tools 2 Refer to the tool list at the beginning of this Chapter Inspection 3 Check the following 3 1 Footplate Fig 2 6 3 is undamaged fitted securely to the stem tube 2 assembly swivels up and down smoothly and is effectively supported in horizontal 3 2 Heel loop assembly 4 is undamaged and securely fastened to the footplate 3 3 3 Latching mechanism 1 functions correctly and the footrest assembly locks securely in place 3 4 Stem tube assembly is undamaged 3 5 Locating holes and Lugs are free from damage 4 Any defects to the above will require the assembly to be repaired Removing A Swing Detachable Footrest Assembly 5 To remove the swing detachable footrest assembly proceed as follows 5 1 Operate the latching mechanism and allow the footrest assembly to rotate away from the frame 5 2 Lift the swing detachable footrest assembly free of the locating lugs Replacing A Swing Detachable Footrest Assembly 6 Replacing any component previously mentioned is the reverse of the removal 02 02 Page 2 25 Apolo 1 Side 2 Reinforcing strip 3 Armrest locking plunger 4 Armrest locking spring 5 Plastic cap 6 cam assembly 7 Starlock washer 8 Seat canvas peg 9 Cup
19. f removal refer to Chapter 3 for parts information rel 02 02 Page 2 31 Apolo HII 6 Twenty things that can affect the life and running time of your DRYFIT battery when used with small electric vehicles 6 1 Low pneumatic tyre pressures 6 2 Heavy loads 6 3 Hills 6 4 Muddy ground 6 5 Very cold weather 6 6 Very warm weather 6 7 Insufficient recharge time 6 8 Use of a wrong charger 6 9 Battery age 6 10 Loose connections 6 11 Failure to recharge immediately after use 6 12 Exhausted cycle life of the battery 6 13 Running until the battery is totally flat 6 14 Leaving it connected to the charger when the charger is switched off 6 15 Worn or obstructed wheel bearings 6 16 Tampering with the battery 6 17 Faulty charger 6 18 Faulty vehicle controls 6 19 Damaged connecting cables 6 20 Faulty battery fortunately a very rare occurrence with dryfit gel lead acid batteries GUIDELINES FOR USING DRYFIT GEL LEAD ACID BATTERIES Never do the following Never use your battery unless it is fully recharged Never connect the battery the wrong way round The battery terminals are clearly marked with the positive and negative signs Do not allow loose connections to the battery Do not use a non approved charger Do not leave your battery in a flat discharged state Do not leave the battery connected to the charger unless the charger is switched on Do not attempt to top up the batter
20. ight motor disconnected 3 Red li Left motor wiring fault 2 Red L Left motor disconnected 1 Red wr Low battery voltage Fault Types and their Possible Causes 1 Low battery fault This occurs when the controller detects that the battery voltage has fallen below 13 5V Check the condition of the battery 2 Left motor disconnected This occurs when the controller detects that the left motor has become disconnected Check the left motor motor connectors and wiring 3 Left motor wiring fault This occurs when the controller detects a fault in the wiring to the left motor in particular a motor connection has short circuited to a battery connection Check the left motor connectors and wiring 4 Right motor disconnected This occurs when the controller detects that the right motor has become disconnected Check the right motor motor connectors and wiring 5 Right motor wiring fault This occurs when the controller detects a fault in the wiring to the right motor in particular a motor connection has short circuited to a battery connection Check the right motor connectors and wiring 6 Inhibit active This occurs when the controller detects that the inhibit input is connected The most common use for the inhibit input is for disabling the drive when the charger is connected Check that the battery charger is disconnected from the wheelchair Please note this fault occurs if you connect a programmer to a working controller when it is tur
21. k then a controller fault is confirmed 3 Check the motors per problem 3 or 4 N B Due to limitations of the diagnostics a fault in a motor while driving may be indicated as a fault in the controller Motor stalled or joystick out Check joystick is released and in neutral when controller is switched of neutral time out on 2 Check wheelchair is able to move and is not blocked by an obstacle 3 Check motors and gearboxes are OK by releasing the free wheeling hubs deflecting the joystick forward and observing the hubs to see if both left and right hubs turn The Battery Gauge is on and 1 Check both free wheeling hubs are engaged With the controller off control box is heard to click push or pull the wheelchair to ensure both left and right wheels do not but chair does not move or free wheel steering is erratic The wheelchair turns in circle 1 Check motors and gearboxes are OK by releasing the free wheeling or does not drive straight hubs deflecting the joystick forward and observing the hubs to see if both left and right hubs turn Check both free wheeling hubs engaged With the controller off push or pull the wheelchair to ensure both left and right wheels do not free wheel Check if one park brake is dragging Does one or both park brakes get hot after driving The park brake should be able to be touched without any discomfort 10 Batterries not charging 1 Check the battery charger is plugged in and
22. l list at the beginning of this Chapter Inspection 4 Inspect on a weekly basis for the following 4 1 No signs of sagging stretching or excessive wear in the canvas 1 4 2 No evidence of fraying especially around the fastener points 4 3 Pozidriv head screws not missing 4 4 Cup washers not missing 5 Inspect the locking mechanism for the following 5 1 Release levers are not deformed or damaged 5 2 Locks safely when the push handle is in the upright position 5 3 Not excessively stiff to operate action should be smooth and positive Removal of the pram handle 6 To remove the pram handle refer to Fig 2 1 1 and proceed as follows 6 1 Unscrew handwheels 9 from push handle assembly 3 6 2 Pull the pram handle 10 upwards and out of the push handle tubes 3 Replacing the pram handle 7 Replacing the pram handle is the reverse of removal However ensure handwheels 9 are correctly located in push handles Removal of the backrest canvas and or push handles 8 To remove or replace the backrest canvas refer to Fig 2 1 1 1 proceed as follows 8 1 Unscrew and remove the four pozidriv head countersunk screws 7 and cup washers 8 8 2 Unscrew and remove the two Hex head pivot bolts 4 Nyloc nuts and washers 8 3 Hold the push handle 3 and slide the lower half of the backrest canvas 1 off 8 4 Hold the canvas and slide the push handle down and off the canvas e s 02 02 Page
23. lever is the reverse of the removal However ensure spring button 14 locates correctly in the mounting tube hole 13 02 02 Page 2 17 Apollo Motor Assembly General Description 1 The Fracmo motor has been specially designed for powered wheelchairs to give high performance extended battery life and high efficiency 2 The unit is supplied with a electromagnetic brake which can be supplied wound either for 12 or 24 volts depending on the system requirements 3 The carbon brushes have been selected to give extended life low noise and are easy to replace if required 4 The geared unit consists of a hardened worm cut on the armature shaft and a bronze worm wheel fitted to hardened pinion gear which then drives a hardened output gear fitted to the shaft 5 The motor uses high powered magnets and the armature is balanced to reduce any vibrations 6 The motors can be supplied with suppression to make EMC compliance easier 7 The unit has been designed to give a maximum noise level off load of 60 62 when measured at 12 or 30cms from all surfaces Specifications Apollo Indoor Weight of unit Geared Motor 4kg Part No 451 25 025 G30 35A B Drawing No 45225 025 Motor type Permanent magnet Frame size M45225 Motor voltage 24 volts Bearings Single row ball bearings Holding brake torque 1 5Nm Holding brake voltage 12V Watts output 70W Watts input 116W Motor rpm 4000 Full load curre
24. mounting bolts 9 and nyloc nuts 8 4 Fully unscrew and remove the two upper mounting bolts and nyloc nuts 8 5 Support motor assembly 1 and remove the lower 9 mounting bolt and nyloc nut Replacing Drive Wheel and Motor Assemblies 9 Replacing the drive wheel 2 and motor 1 assemblies is the reverse of the removal Caution If mounting bolts and nuts show any sign of wear thread or corrosion replace A them The Nyloc nuts must be renewed on every occasion the wheel is removed Wheel nuts bolted down to a torque of 35 40Nm Slotted Screws 7 and the Compression Spring 5 should be renewed if signs of sluggishness or distortion are visible It is also important to check cleanliness and condition of the drive shaft in particular its thread Note No attempt should be made to dismantle the motor 1 unit for repair or servicing in the field In the event of damage or faults the unit should be returned to the factory Replacing Main Wheel Assembly CAUTION OUTDOOR ONLY Apply Loctite 242 to the thread of the motor shaft and ensure A that the locknut is tightened to a torque of 25 Ibf ft 10 Replacing the main wheel assemblies is the reverse of the removal Removing Anti Tipping Lever Mk4 if fitted and Mk2 11 To remove anti tipping lever proceed as follows 11 1 Depress the spring button 14 and withdraw anti tipping lever 15 from mounting tube 13 Replacing Anti Tipping Lever 12 Replacing the anti tipping
25. nd the wheels are not damaged 02 02 Page 2 3 Apolo MMMM tay p Battery assembly Backrest canvas Armrest assembly Rear wheel and motor assembly Brake assembly Footplate assembly Castor assembly Swinging bracket assembly Seat canvas 0 Controller 1 Kerb climber GQ N O ON Figure 2 0 2 General Arrangement Apollo Outdoor Wheelchair Page 2 4 02 02 w MAINTENANCE 9 7 If stabilisers fitted they firmly locked place 9 8 Electrics 9 8 1 Controller has visible physical damage 9 8 2 Batteries show no sign of damage 9 8 3 Interconnecting and main cable looms are in good condition i e insulation 9 8 4 Plug and socket connections are tight and connectors are free of damage 9 8 5 Retaining straps are secure and tight 9 8 6 Battery carrier is properly seated on the chassis tubes 9 8 7 Charger No physical damage to the charger case 9 8 8 No physical damage to the motor gearbox 10 Check the finish of the chair for any damage Note Some finishes are unique to the chair Check with INVACARE Ltd for details 11 Check that all bungs and handgrips are fitted and undamaged 12 Before reassembly of any components the following examination should be carried out 12 1 All brazed joints should be examined and any damaged component should be replaced 12 2 All plated parts should be checked to ensure that surfaces are free from wear
26. ned on This fault is not actually a fault but incorrect use of the programmer To program you must connect the programmer before the controller is turned on Page 2 40 02 02 w MAINTENANCE 7 Possible joystick fault This occurs when the controller detects a fault in the joystick or the connections to it The course of action will differ depending on whether you have an integral joystick in main box or remote separate joystick module system Integral the fault is in the joystick or connections to it As the joystick is within the main box then the controller must be assumed defective and repaired by an authorised person Remote the fault is in the joystick or connections to it The fault could be in the joystick module or the cable to it which is attached to the controller If you have a spare working joystick module connect it and see if it cures the problem if it does the original joystick module must be assumed defective and repaired by an authorised person If the fault is still present with the spare joystick module then the controller must be assumed defective and repaired by an authorised person 8 Possible controller fault This occurs when the controller detects a fault in itself The controller must assumed defective and repaired by an authorised person 9 Solenoid brake fault This occurs when the controller detects a fault in the solenoid brake or connections to it Check these connections and the solenoid br
27. ng 5 and drive dog 4 6 4 Using a socket wrench unscrew the wheel nut 3 and pull the drive wheel 2 from the drive shaft If necessary tap the wheel centre gently with a mallet to loosen it 5 i 02 02 Page 2 15 Apollo 1 Motor 9 Bolt 2 Drive wheel 10 Motor bracket 3 Nut 11 Connector 4 Drive coupling 12 Motor shaft spacer 5 Compresion spring 13 Mounting tube 6 Washer 14 Spring button 7 Slotted set screw 15 Anti tipping lever 8 Plastic hub cap Figure 2 3 1 Rear Wheel Assembly Apollo Outdoor E 2 2 16 02 02 w MAINTENANCE Removing Rear Wheel Indoor 7 To remove a drive wheel refer to Fig 2 3 proceed as follows 7 1 Raise and support the chair so that the wheel is free of the ground 7 2 Using circlip pliers carefully remove circlip 7 Be carefull not to lose washer 6 and spring 5 Remove washer 6 spring 5 and drive coupling 4 from the wheel assembly 7 3 Using the circlip pliers remove the larger circlip 3 and pull the drive wheel 2 from the shaft If necessary tap the wheel centre gently with a mallet to loosen it Removing Motor Assembly 8 To remove the motor assembly 1 refer to Fig 2 3 1 proceed as follows 8 1 Carry out the procedure detailed in paragraphs 6 1 to 6 4 8 2 Disconnect the motor cable connector 11 from the wiring loom 8 3 Using open ended spanners of the correct size slacken all three motor
28. nt 4 85 amperes Gearbox Type RAWS 30 Ratio 35 1 Output rpm 115 Output torque 2 7Nm Page 2 18 02 02 Specifications Apollo Outdoor Weight of unit Geared Motor Part No Drawing No Motor type Frame size Motor voltage Bearings Holding brake torque Holding brake voltage Watts output Watts input Motor rpm Full load current Gearbox Type Ratio Output rpm Output torque Maintenance and Servicing 8 9 10 11 12 13 Check for loose damaged or corroded connectors and terminals 4 5kg 452 75 096 G30 30C D 45275 096 Permanent magnet M45275 24 volts Single row ball bearings 1 5Nm 12V 160W 273W 3500 11 4 amperes RAWS 30 30 1 115 11Nm Check motor leads for damage and replace as necessary Check gearbox mounting bolts for tightness Check for grease leaks around any seals or output shaft Check for damaged commutator Check free movement of brushes MAINTENANCE 02 02 Page 2 19 Apollo 1 Indoor brake 2 Outdoor brake Figure 2 4 Brake Assemblies ee Page 2 20 02 02 w MAINTENANCE 2 4 Removing Replacing Brake Assembly General Note The brake assembly is handed ensure that if both assemblies are removed that the correct assembly is fitted to the correct side 1 Check the brake assembly for any defects refer to paragraph 4 If any defects are observed then refer to paragraphs 5 to 6 fo
29. r maintenance details and to Chapter 3 for parts information 2 It is not intended that any other part is maintainable Tools 3 Refer to the tool list at the beginning of this Chapter Inspection 4 Check the following daily 4 1 Brake assembly fully locks and the chair is unable to move 4 2 Brake action is positive and is not stiff Removing Brake assembly T Note For ease of maintenance the brake assembly can be removed as a complete assembly b Note the position of the brake assembly b The following procedure applies to any brake assembly 5 To remove the brake assembly proceed as follows 5 1 Ensure that brake assembly is in the unlocked position 5 2 Unscrew the two retaining bolts fastening the brake assembly to the frame and the motor bracket 5 3 Remove the brake assembly refer to fig 2 4 1 from its location Replacing Brake Assembly 6 To replace a brake assembly is the reverse of the removal E ii ff if F fP FFffe amp I pz SK i 02 02 Page 2 21 Apolo Figure 2 5 Castor Wheel Assembly er 2 22 02 02 _ F MAINTENANCE 2 5 Removing And Replacing A Castor Wheel Assembly General 1 Check the castor wheel assembly for any defects refer to paragraph 4 If any defects are observed then refer to paragraphs 5 to 8 for maintenance details and to Chapter 3 for parts information 2 It is not intended that any other part is maintainable
30. refer to paragraphs 4 to 5 for maintenance details and to Chapter 3 for parts information The information provided in paragraph 6 onwards is for guidance only Tools 2 Refer to the tool list at the beginning of this Chapter Inspection 3 Check for the following on daily basis 3 1 Batteries 4 show no sign of physical damage 3 2 Interconnecting cable and wiring loom 3 are in good condition Socket connections are tight and connectors are undamaged 3 3 Retaining battery straps are secure and tight 3 4 The battery carrier 8 is properly seated on the wheelchair chassis Removal of Batteries 4 To Remove the batteries proceed as follows 4 1 Lift the right hand canvas from the seat 4 2 Unfasten the battery retaining straps and disconnect the interconnecting cable 3 4 3 Disconnect the wiring loom if fitted from the connectors on the battery boxes 5 4 4 Ensure that the battery boxes are free from any obstructions and carefully lift out the battery boxes from the carrier assembly 8 4 5 Remove the Battery Covers 2 Removal of Battery Box Carrier Frame 5 To remove battery box carrier proceed as follows 5 1 Unscrew the four handwheels 6 on each side 5 2 Remove clamp strap 7 from each side 5 3 Lift battery box carrier 8 from frame Replacing the Battery Box Carrier Frame 6 Replacing the battery box carrier is the reverse of removal Replacement of Batteries 7 Replacing the batteries is the reverse o
31. rrent to the battery during the initial bulk charge phase the output current being limited electronically to the rating of the charger This constant current stage is main tained until the battery voltage reaches the maximum permitted value for a gel type battery The charger will then accurately maintain this voltage for a fixed period until the battery is fully charged which is indicated by the Charge Complete indicator Page 2 34 02 02 w MAINTENANCE I Indicators Four coloured lights on the front panel provide charging status indication as shown below COLOUR STATE OF CHARGE Yellow Mains On Green Bulk Charging Yellow 90 Charged Red Charge Complete OPERATING INSTRUCTIONS 1 Connect the charger output lead to the battery If the output lead is fitted with a plug this is simply plugged into the matching socket on the battery installation 2 Connect the battery charger to the mains supply and switch on The MAINS ON and BULK CHARGING indicators will illuminate 3 When the battery is 90 recharged the 90 CHARGED indicator will illuminate Occasionally the battery can be used now but a full recharge must be given us soon as possible 4 The battery is fully charged when the CHARGE COMPLETE light illuminates The battery may be left on charge at this point to maintain the battery in a fully charged condition 5 Switch off the mains supply before removing the charger plug G The battery charger includes a timer to control
32. s assemblies 2 7 2 2 Armrest assemblies 2 11 2 3 Rear wheels and motor assemblies 2 15 2 4 Brake assemblies 2 21 2 5 Castor assemblies 2 23 2 6 Swing Detachable footrest assemblies 2 25 2 7 Seat canvas and frame assemblies 2 27 2 8 Kerb climber 2 29 2 9 Batteries 2 31 2 10 Controller 2 37 3 For the tools required refer to the list of tools detailed in paragraph 13 Any special tooling and or torque requirements will be referred to within the relevant text 4 General engineering practices and safe working practices must be adhered to at all times 5 For further information on the assemblies contained within this chapter contact Customer Services INVACARE Ltd refer to address in chapter 1 quoting the following details 5 1 Part Number 5 2 Description 5 3 Quantity required 6 For certain orders the following should also be quoted 6 1 Serial or batch number 6 2 End user 7 For any ordering or spares procurement contact INVACARE Ltd refer to address in Chapter 1 quoting the details in paragraphs 5 and 6 Inspection 8 In general a weekly visual check will meet all the inspection requirements 9 Ensure that the following are checked 9 1 Fabric is undamaged and has no signs of sagging 9 2 The footrest is correctly fitted 9 3 Both armrests securely fitted place 9 4 Brake mechanism operates freely and when locked the chair does not move 9 5 Footplates are undamaged and are correctly fitted 9 6 Tyres are in good order a
33. t KIT 2 3 Armrest panel Tools 3 Refer to the tool list at the beginning of this Chapter Inspection 4 Inspect on a weekly basis for the following 4 1 Frame 5 panel 4 and finish are undamaged 4 2 Armrest pad 2 is undamaged and securely fastened in place Repairing An Armrest Assembly Note For ease of maintenance the armrest assembly can be replaced as a complete assembly 5 To remove individual components of the armrest assembly proceed as follows 6 To remove the controller from the armrest refer to fig 2 2 2 proceed as follows 6 1 On the controller side disconnect the control cable Beau connector 2 from the wiring loom 6 2 Remove the two M5 slotted set screws 4 that retain the controller 1 to the armrest assembly Caution In the event of any damage or malfunctioning of the Controller it must be A returned via Technical services DO NOT attempt to open the Controller or carry out any repair on it 8 To remove the Armrest assembly proceed refer to fig 2 2 1 as follows 8 1 Release the armrest plunger lock in the side frame front tube and pull the armrest assembly out of the chassis 9 Removing the armrest pad refer to fig 2 2 1 2 9 1 Unscrew and remove the two pozidriv screws 3 9 2 Remove the armrest pad from the frame 5 D 02 02 Page 2 11 Apollo 1 Controller Dynamic 2 Beau connector 3 Controller Penny amp Giles 4 Slottedset screw
34. t ee ee ee Left motor or connection fault Left or right electromagnetic brake or connection faul eeeee 2 3 4 Right motor or connection faul eeee eeee 5 6 Controller fault eeeeee 7 Motor stalled or joystick out of neutral time out _ eeeeeee where is a flash and _ is a pause In the event of a system fault the diagnostic indications are displayed by the battery gauge flashing Faults are encoded as one for a low battery voltage fault to seven for a motor stalled or joystick out of neutral time out fault and displayed by flashing all LED s the number of items given by the fault code The flash sequence one to seven is followed by a long off period 2 seconds All faults latch disabling the controller and require the controller to be turned off then on again even if the source of the fault is removed Troubleshooting Guide The following is a check list to assist with diagnosing an electrical fault on a wheelchair If after consulting the check list the problem persists then an authorised service agent should be contacted mn 02 02 Page 2 37 Apolo Troubleshooting Guide The following is a check list to assist with diagnosing an electrical fault on a wheelchair If after consulting the check list the problem persists then an authorised service agent should be contacted PROBLEM CHECK ACTION 0 The On status indicator Bat Ch
35. t GEL type sealed lead acid bat teries only Do not attempt to charge any other type or rechargeable battery or batteries which are non recharge able Important ensure safe and efficient charging the battery charger must be used with the correct size of bat tery Refer to the table below CHARGER RATING RECOMMENDED BATTERY SIZE Amps hours 5 20 40 7 25 50 If advice charging batteries outside this range is required please contact technical department Mains Input The charger is designed to operate from the 230V 50 Hz AC supply which is standard across EU countries The supply is connected to the charger by an IEC inlet and a detachable supply cord The inlet is fit ted with a fuse located a sliding drawer and is accessible when the supply cord is disconnected If this fuse fails it must be replaced with an identical type as detailed below Fuse size 20 x 5mm Rating 5A antisurge T high rupture capacity 1500A 250V ac For supply cords fitted with a UK style plug the plug fuse is also rated at 5A Persistent supply use failure may indicate a faulty charger The charger should then be returned to the supplier for examination The charger is of double insulat ed class 2 construction and does not require a connection to the supply earth mains on off switch is available as an optional extra Output The charger supplies a constant charging cu
36. th 3 The Apollo range of wheelchair is manufactured by INVACARE Ltd South Road Bridgend Industrial Estate Bridgend Mid Glamorgan CF31 3PY 4 For Customer Service enquires repairs servicing and spares contact INVACARE Ltd at the address below and quote all the details as indicated in paragraphs 6 and 7 5 INVACARE Ltd South Road Bridgend Industrial Estate Bridgend Mid Glamorgan CF31 3PY Tel No 01656 647327 Fax No 01656 649016 6 Quote the following details at all times 6 1 Part Number 6 2 Description 6 3 Quantity required 7 For certain orders the following should also be quoted 7 1 Serial or batch number 7 2 End user 02 02 Page 1 7 Apolo Figure 1 1 Apollo Outdoor Wheelchair General Arrangement XXX S Page 1 8 02 02 w INTRODUCTION En Policy 8 INVACARE Ltd repair policy is as follows Repairs to ANY component other than those detailed in Chapter 2 are not covered Repairs to ANY metal work is not generally permitted without express permission of INVACARE Ltd ALL fasteners i e bolts Nyloc nuts and any fastener showing damage MUST be renewed Failure to comply with the above absolves INVACARE Ltd of liability Note Certain components will require removal to carry out maintenance With the exception of fas teners these components should be refitted Technical Details 9 The following data applies to the Apollo range of wheelchairs 9 1 9 2 9 3 9 4 9
37. the final stage of the charge cycle Please note that the minimum period from start of charge until the CHARGE COMPLETE light illuminates will be approximately 5 to 8 hours even for batteries which are only partially discharged 7 In automotive or marine applications there is a potential fire or explosion hazard arising from close proximity to petroleum products such as fuel and bottled gas When connecting the charger to the battery first connect the appropriate output conductor to the unearthed battery terminal then connect the other output conductor to the chassis away from the battery and fuel line To stop charging disconnect charger supply chassis conductor and battery conductor in this order Protection The following protective features are included in this charger 1 Reverse Battery Protection protects against incorrect battery connection ii Slow Start A short delay is incorporated to ensure that the charger output does not switch on until the battery connections have been made correctly iii Thermal Protection non resetting thermal fuse is built into the transformer to switch off the mains supply to the transformer in the event of severe overheating This could occur if for example the ventilation slots are obstructed or the charger is located where the surrounding temperature exceeds 30 C iv Low Battery Inhibit The charger will not operate if connected to a deeply discharged battery standing at less than 8V
38. use of an unsuitable charger may seriously reduce the service lifetime of your battery and will invalidate possible warranty claims assurance should be sought from any potential charger supplier that the requirements are met for the specific battery type and size Allow sufficient time to completely recharge your battery between periods of use The normal recharge time for a completely discharged battery will be about 14 hours Partly discharged batteries will obviously recharge faster If you do not use your battery for long periods of time we recommend a periodic recharge approximately every nine months Always recharge your battery as quickly as possible after use and in any case not longer than 14 days afterwards Always ensure your battery is fully recharged before long periods of non use Store out of use batteries in a cool dry location If your battery is installed in a box or compartment always ensure that the container has plenty of ventilation holes in the lid and sides Keep your battery clean with a dry brush Dispose of used batteries through your local council disposal yard They have special areas for used batteries EE 02 02 Page 2 33 Apolo HII HOW TO LOOK AFTER YOUR GEL BATTERY AND CHARGER Read these instructions very carefully before carrying out any battery maintenance or charging They have been produced to help you get the best performance from your equipment WARNING NEVER SMOKE OR USE
39. y They never need it Never attempt to remove the valve covers at the top of the battery These batteries are totally maintenance free 2 32 02 02 w MAINTENANCE Do not allow tools metal objects to short out the battery terminals Never allow naked flames or matches to be used in the vicinity of any battery Do not use different size or different type batteries together with the same equipment Never attempt to lift batteries by their terminals or connectors Do not drop or crush Do not dispose of used batteries with normal waste Always dispose via your local council disposal yard GUIDELINES FOR USING DRYFIT GEL LEAD ACID BATTERIES Always do the following Give the battery a full recharge before using it for the first time It may need this after being in storage for some time at your suppliers premises Ensure that the cables from your equipment are connected to the battery the right way round The battery terminals are clearly marked with and signs Ensure these connections are correctly tightened Loose connections can lead to reduced battery life or in extreme circumstances could overheat and cause fires Connect the positive connection first and the negative last When disconnecting take off the negative first Only use a charger which meets the requirement specification for dryfit batteries These requirements may be obtained by reference to the battery brochure The
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