Phoenix Plus Service Manual
Contents
1. PHOENIX PLUS SERVICE GUIDE INTRODUCTION This manual provides basic details to enable the PHOENIX Wheelchair 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 adequately maintained The manual includes detailing assemblies that are maintainable and the relevant procedures The Wheelchair is manufactured by INVACARE Ltd South Road Bridgend Industrial Estate Bridgend Mid Glamorgan CF31 3PY SALES TEL NO 01656 647327 TECHNICAL SERVICE TEL NO 01656 753337 FAX NO 01656 649016 FAX NO 01656 753299 For TECHNICAL ADVICE repairs servicing contact Technical Services For SPARE PARTS orders contact Sales Quote the following details at all times 5 1 Part Number 5 2 Description 5 3 Quantity required 5 4 Serial Number 5 5 Chair Type POLICY INVACARE Ltd repair is as follows Repairs to ANY component other than those detailed in this manual are not covered Repairs to ANY tube 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 In the event of repairing a crash damaged Vehicle we strongly advise you contact INVACARE TECHNICAL SERVICES DEPARTMENT before proceeding with repairs Failure to comply with the above absolves INVACARE Ltd of liability Note Certain components will require removal2. Digital motor control Built in diagnostics with fault display and fault logging Complies with ISO7176 part 14 when correctly installed Load compensation described below SAFETY AND PROTECTION FEATURES The DL has the following safety and protection features Soft top or controlled speed reduction to a stop if a fault is detected or the controller switched off Protected against external faults such as reverse battery connection overloaded motors or park brakes and external short circuits Joystick out of neutral at power up detection with drive inhibit Over voltage shut down Detection of open circuit motors Detection of open or short circuit park brake outputs Battery under voltage protection with battery saver to prevent battery damage through over discharge Thermal overload protection with progressive motor current roll back and automatic recovery Driving inhibit when a battery charger is connected to the built in charger socket THE BATTERY DISCHARGE INDICATOR The three colour Battery Gauge gives an indication of the amount of charge in the batteries The display also provides an on or off status indication for the controller and diagnostic information in the event of a fault Diagnostics are described in section 8 WHAT TO DO IN THE EVENT OF A FAULT SYMPTOM CHECK ACTION ON OFF button pressed to ON Is the main cable loom plug properly inserted lamp does not light up wheelchair into the rear
3. STEP 6 With a voltmeter or a multimeter set to volts range 30v test the charging voltage at the battery supply red blue ve wires The reading should increase to 28 4v during charging NOTE NO DISMANTLING IS NECESSARY FOR CHARGERS INSPECTION OF PLUGS ONLY 12 Phoenix 11 01 MOTOR ASSEMBLY PARTS Electro Magnetic Brake Brush Motor Plug Motor Complete Commutator Motor End Cap Op Sl de eel Tools Required No1 Phillips Screwdriver Flat Headed Screwdriver Soldering Iron Multi Meter 3mm Allen Key INSPECTION STEP 1 Check motor assembly for damage STEP 2 Set multimeter to continuity test STEP 3 Test continuity of motor leads and electro magnetic brake leads motor lead shows in diagram Brake resistance should read 50ohms 80 ohms STEP 4 Check all joints for bad connection cracked or dry solder joints and oxidation STEP 5 Check that all the brushes can move freely in the brush guides with no obstruction this can be easily done by pulling on the free brush feeder wire STEP 6 Check that all the brushes are not chipped cracked or worn STEP 7 Check that the brush spring is positioned to the centre of the brush body to apply even force Also check the brush spring tensions STEP 8 Check the condition of the brush feeder wire and check that the termination screws are secure 13 Phoenix 11 01 MOTOR ASSEMBLY STEP 9 Visually inspect the commutator for carbon deposits
4. 3 Check the park brakes Using an ohmmeter disconnect each park brake and measure the resistance at the connector If the resistance is less than 20 ohms the park brake is probably faulty PROBLEM 6 Controller fault 7 Motor stalled or joystick out of neutral time out 8 The battery Gauge is on and control box is heard to click but chair does not move or steering is erratic 9 The wheelchair turns in circle or does not drive straight 10 Batteries not charging Phoenix 11 01 gg CHECK ACTION 1 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 2 Disconnect both motors and park brakes Turn the controller off and on leaving the joystick If the controllers relay clicks twice and a left motor fault is now indicated then the controller is OK If another fault other than the left motor is indicated and the relay does not click then a controller fault is confirmed 1 Check joystick is released and in neutral when controller is switched 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 ref wheeling hubs deflecting the joystick forward and observing the hubs to see if both left and right hubs turn 1 Check both free wheeling hubs are engaged With the controller off push or pull the wheelchai
5. front and rear wheel axle bolts are tight c Ensure that all upholstery screws are present and tight Check surface of screw head for sharp edges Servicing Requirements 4 Batteries a Check batteries for any signs of physical damage b Check terminals for cracks or blackness NOTE SHOULD BATTERIES BE SUSPECT USE BATTERY DISCHARGE TESTER BY ASTRA TECH MODEL DC39 TO TEST CAPACITY AND RUN TIME Battery Charger a Check for physical damage of casing b Check all LED s are operational c For testing the battery charger see page 10 section Batteries and charger Phoenix 11 01
6. of the controller does not move Are the batteries completely flat Have you left the battery charger plugged in ON OFF lamp lights up wheelchair Are one or both motors disengaged does not move or behaves erratically freewheel mode controller is hard to click Are the batteries discharged to the critical level Battery Charge indicator flashing slowly wheelchair moves but with reduced speed and sluggish response Battery Charge indicator flashing quickly Are the batteries discharged below the critical twice per second wheelchair not moving safety level Are the batteries overcharged charger fault 18 Phoenix 11 01 Batteries will not accept charge Possible charger fault Is the charger fuse blown screw cap on the rear of the controller DIAGNOSTICS THE DL 40 CONTROLLER HAS FULL ON BOARD DIAGNOSTICS WHICH WILL IN THE EVENT OF A SYSTEM MALFUNCTION IDENTIFY FAULTS QUICKLY AND EASILY Diagnostic information is provided to enable a fault in the system to be identified and localised to a major component eg motor The following system diagnostics are provided Flash code sequence 1 Low battery voltage fault 2 High battery voltage fault 3 Left motor or connection fault 4 Right motor or connection fault o 5 Left or right park brake or connection fault 6 Controller fault _ 7 Motor stalled or joystick out of neutral time out 000
7. 0000 0000000 In the event of a system fault the diagnostic indicators are displayed by the battery gauge flashing Fault are encoded as one for 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 times give by the fault code The flash sequence one to seven is following by a long of period 2 seconds TROUBLESHOOTING The following is a check list to assist with diagnosing an electrical fault on a wheelchair If after consulting the check list the person persists then an authorised service agent should be contracted PROBLEM CHECK ACTION 0 The On status indicator Battery Gauge 1 Check the battery connector to the does not light when the controller is switched on controller is securely plugged into the connector from the battery 2 Check the batteries themselves are connected correctly ie check the battery terminals 3 Check the batteries are not flat 4 Check the battery supply fuse or circuit breaker 1 Low battery voltage fault 1 Check the battery connector to the controller is securely plugged into the connector from the battery 2 High battery voltage fault 1 Check the battery charger Is it over charging the batteries Is the battery charger the right type 19 Phoenix 11 01 PROBLEM 3 Left Motor or connection fault 4 Right Motor or connection fault 5 Right Motor or connection fault 20 CH
8. AND FORK DISMANTLING STEP 1 Remove castor socket cap with flat bladed screw driver hold the lower fork stem nut secure with 19mm spanner and remove the upper fork stem nut STEP 2 Gently tap the threaded end to the fork stem with a mallet taking care not to damage the threads Remove the castor fork assemblies STEP 3 Lever out the top fork bearings carefully using the fork stem as a lever Take care not to damage the threads STEP 4 Remove the castor fork bearings using a drift and a mallet tapping gently to avoid damaging the castor socket and bearing STEP 5 To remove the castor wheels undo the axle nut with a 13mm spanner using a second spanner at the other end of the axle to lock against rotation Remove the axle bolt and remove the wheel from the fork STEP 6 Remove the bearings by hand To reassemble reverse step 6 amp 7 but adjust tightness of nut until the wheel runs freely to a gradual halt a If the wheel stops abruptly loosen the castor axle nut b If the wheel wobbles sideplay tighten the castor axle nut enough to allow free spinning without sideplay TO RE ASSEMBLE STEP 1 Insert the fork stem bearings using a mallet and drift across the bearing to prevent damage STEP 2 Start at the bottom and place the threaded end of the fork stem through both bearings and in the castor fork socket Phoenix 11 01 CASTOR WHEEL AND FORK TO RE ASSEMBLE STEP 3 Locate fork stem nut on the threaded end of
9. ECK ACTION 1 Check the left and right motor park brake connectors are securely plugged in 2 Check the contacts in the left and right motor connectors for corrosion or damage 3 Check the left and right motors using a ohmmeter disconnect the motors and measure the motor resistances at the motor resistances at the motor connectors If the resistance is more than 1 Ohm or less than 100mili Ohms the motor is probably faulty If the motor seems OK sometimes and not others when rotated then the motors brushes or commutator are is faulty 4 Check the resistance of the motor to its housing Using an ohmmeter measure the resistances of either motor contact to the motor housing If the resistance is less than 1 MegOhms the motor is probably faulty If the motor seems OK sometimes and not others when rotated then the motors brushes may be touching the housing as the commutator is rotated 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 motor fault As above 1 Check the motor park brake connectors are securely plugged in 2 Check the contacts in the connectors or damage
10. Remove the rear wheel and inspect the key and keyway for wear and correct fitting DISMANTLING STEP 1 Remove the rear wheel from the gearbox see page 6 15 Phoenix 11 01 GEARBOX ASSEMBLY DISMANTLING STEP 2 Unplug the motor from the main control box Loosen and remove the six gearbox lid securing screws The lower half of the gearbox will now detach from the top half whilst still attached to the side frame of the chair STEP 3 To dismantle the declutching lever upper and lower parts remove the allen screw and knock out the fixing pin using a pin hammer and punch separate the two halves STEP 4 To detach the gearbox from the motor degrease the gearbox remove the four fixing screws with an 8mm spanner taking care not to deface or damage any gear teeth Separate the gearbox and motor assembly To reassemble reverse steps 1 to 4 ensuring correct motor to gearbox alignment is achieved Replace both gaskets and re pack the gearbox with Shell Albida Grease approx 200g NOTE TO REFIT THE DECLUTCHING LEVER THE GEARBOX TOP MAY NEED TO BE REMOVED FROM THE CHAIR AND A VICE USED TO CLAMP THE UPPER AND LOWER LEVERS IN PLACE 16 Phoenix 11 01 CONTROLLER WITH INTEGRAL JOYSTICK REMOTE DL 40 Tools PARTS No 1 Philips Screw Driver 1 DL40 Controller 5 Harness No 2 Philips Screw Driver 2 Joystick Knob 6 Support Bracket 3 Speed Control 4 Fixing Screw METHOD OF REMOVAL STEP 1 Disconnect motor and ba
11. and remove with a soft brush NOTE ENSURE ALL THE SEGMENTS OF THE COMMUTATOR ARE NOT BRIDGED WITH CONDUCTIVE MATERIALS I E CARBON OR COPPER DISMANTLING STEP 1 Remove the motor end via the two phillips screws STEP 2 Remove the two three electro magnetic brake fixing screws and remove the brake STEP 3 Remove the brush feeder wire termination screws release the brush springs and remove the brushes To reassemble reverse the steps 1 to 4 taking care not to damage the brushes and ensuring correct alignment of the electro magnetic brake Should there be fitting scoring or wear then replace the Motor Unit NOTE WHEN REFITTING MOTORS PLEASE ENSURE THAT BOTH SUPPLY WIRES ARE FASTENED TO THE CONTROLLER IN SUCH A WAY THAT THE RIGHT HAND MOTOR CANNOT BE ACCIDENTLY CONNECTED TO THE LEFT AND VISA VERSA 14 Phoenix 11 01 GEARBOX ASSEMBLY 4 PARTS Motor Gearbox Clamp Nut Gearbox Gasket Declutching Lever Lower Declutching Lever Upper Gearbox Lid Screw Motor Gearbox Clamp Screw Lid to Gearbox Screw Clamp Key DRITTEN DIE Tools Required 5mm Allen Key Pin Hammer Punch 3mm Allen Key Pliers Vice Spanner 8mm Spanner INSPECTION STEP 1 Check casing for cracks or damage or leakages STEP 2 Check Gearbox for noises gears and bearings STEP 3 Check the declutching lever and mechanism engages and disengages correctly STEP 4 Check that the output shaft of the gearbox is not damaged or bent
12. el Hub locate and tighten Wheel Bolts securely Phoenix 101 T Phoenix 11 01 FOOT REST PARTS Hanger assembly 8 Angle Footrest Assembly Extension assembly 9 Tube Sub Assembly Footplate Screw Extension tube Extension adjustment screw Tube end plug LED TOOLS REQUIRED No1 Philips screwdriver Spanner 13mm 4 Flat bladed screwdriver Mallet INSPECTION So j STEP 1 Check that the Footplate fits securely and operates correctly STEP 2 Check the operation of the Footplate extension clamping and adjustment bolt STEP 3 Check the footrest for damage STEP 4 Check for damage and distortion to the footrest hanger paying particular attention to the securing tabs that clamp the extension welds flanges etc DISMANTLING STEP 1 Operate the quick release mechanism and detach the footrest assembly STEP 2 Remove the extension clamping screw with a 13mm spanner and detach the footrest extension from its hanger STEP 3 Remove the bumper rubber screw and pull out the bumper rubber STEP 4 With a mallet gently tap the footplate of the extension To re assemble reverse steps 1 to 4 Phoenix 11 01 MECHANICAL HAND BRAKE PARTS 1 Brake Assembly Complete 2 Brake Shoe 3 Brake clamp bracket 4 Brake fixing nut 5 Rubber tip 6 Brake lever mechanism Tools Required Spanner 10mm No1 Philips screwdriver INSPECTION STEP 1 Check that the brake mechanism has no excessi
13. l Hub Remove the Wheel STEP 3 Deflate the tyre locate loosen and remove Socket Head Cap Screw securing the two halves of the Wheel Rims together Important note Ensure the tyre is fully deflated before attempting to separate to the two halves of the Wheel Rims STEP 4 Remove the tyre and tube STEP 5 To remove the Wheel Hub from the Axle Shaft locate loosen and remove the Wheel Hub Bolt securing the Wheel Hub to the Axle Shaft STEP 6 Gently tap the wheel centre with a mallet and pull the wheel off the gear box shaft take care not to loose the key located in the gearbox shaft TO RE ASSEMBLE STEP 1 Re fit the Wheel Hub to the gearbox shaft ensuring alignment of the keyway of the wheel centre to the key fitted to gearbox shaft Gently tap the wheel centre with a mallet until the threads can be seen inside the shaft STEP 2 Fit the wheel bolt ensuring that the washer has been fitted to the gearbox shaft Torque rating of rear wheel bolt 35 40Mm STEP 3 Locate tyre and tube to the face of the inside Rim that has the hole for the valve to seat in slightly inflate the tube STEP 4 Locate the other half of the Wheel Rim in position insert Socket Cap Screws in position and pro ceed to tighten the screws Ensure the inner tube is not trapped between the Wheel Rim halves Tighten securely Socket Head Cap Screws STEP 5 Inflate to the correct pressure as indicated on the Tyre Side Wall STEP 6 Position Wheel on Whe
14. lock Nut Washer Nyloc Nut Nyloc Nut Washer Skt Cap Screw Nut Nyloc Nut Nyloc Nut Spring 22 Phoenix 11 01 Tools Required No1 Phillips Screwdriver Flat Bladed Screwdriver 8mm Spanner 13mm Spanner 4mm Allen Key INSPECTION STEP 1 Check all tubing for misalignment damage or bending of the frame or crossbar assembly STEP 2 Check that no misalignment is present at the castor mount area castor fork and socket STEP 3 Check all brazed welded joints for fractures or damage STEP 4 Check the crossbar assembly is not damaged pivot bolt should not be over tightened STEP 5 Check the paint or chrome finish for damage or peeling STEP 6 Check that the chair folds easily and that the crossbar pivots and folding mechanisms oper ate correctly FRAMES AND CHASSIS DISMANTLING STEP 1 Remove the arm rest assemblies and footrest STEP 2 Unplug and remove the battery boxes joystick assembly and control box see pages 10 19 STEP 3 Remove the back assembly complete by removing the two hand knobs and pulling the push handles upwards STEP 4 Remove the seat upholstery see page 2 23 Phoenix 11 01 STEP 5 Loosen and detach the top crossbar link assembly using 11mm spanner and 4mm allen key see diagram on page 24 STEP 6 Remove the bottom rail screws and nuts with a Philips No1 screwdriver and an 11mm spanner STEP 7 Remove the side frame from the crossbar assembly see
15. mpad Fixing Screws 1 Armrest Pad IS ee OP a a ee NT Tools Required No1 Phillips Screwdriver Flat Headed Screwdriver 6mm Allen Key INTRODUCTION STEP 1 Check that the skirtguard is fixed and not physically damaged If the panel is loose re tighten the fixing screw install a new panel if necessary STEP 2 Check for armpad wear or damage Replace if necessary STEP 3 Check for corrosion or paint damage to the bracketry and replace affected parts where necessary DISMANTLING STEP 1 Remove the handknob by rotating it anti clockwise Pull out the arm assembly STEP 2 Remove the two armpad fixing screws under the armpad and remove the armpad STEP 3 Remove the allen screw and pull out the armpad bracket STEP 4 Carefully remove the 2 caps with a flat headed screwdriver remove the 2 phillips screws and remove the skirtguard Take care not to loosen the washers To re assemble reverse step 4 to 1 taking care not to over tighten the fixing screws as this could cause burrs and split the plastic washer Phoenix 11 01 Too 1 UPHOLSTERY AND BACK SEAT CLOTH PARTS One Piece Backrest Complete One Piece Backpost Taptite Screw Upholstery Washer Seat Upholstery 40cm High Back Upholstery OO DT Tools Required No1 Phillips Screwdriver INTRODUCTION STEP 1 Check that the upholstery does not sag and is not unevenly stretched torn or excessively worn paying attenti
16. on to the adjustment features within the tension adjustable back upholstery STEP 2 Check that all stitches are in good condition STEP 3 Check that all screws and washers are tight and free of sharp edges and burrs DISMANTLING STEP 1 Remove all fixing screws and detach upholstery from tubework To re assemble reverse above procedure ensuring that the fixing holes in the upholstery and tubes are properly aligned NOTE TAKE CARE NOT TO OVER TIGHTEN SCREWS AS THIS MIGHT CAUSE BURRS Phoenix 11 01 Too 2 Phoenix 11 01 CASTOR WHEEL AND FORK PARTS Castor fork Washer Nyloc Nut Axle Bolt Nyloc Nut Pneumatic Castor Bearing Tyre Inner Tube 10 Hub Centre 11 Castor Wheel 12 Fork Stem 13 Bearings Se Oh o Tools Required 19mm Socket Spanner x 2 Flat Bladed Screwdriver Mallet Pressure Gauge 10 8 Tyre Levers Pump Drift INTRODUCTION STEP 1 Check castor wheels are not buckled or physically damaged Replace if required STEP2 Check that the wheel bearings run freely without excessive play STEP 3 Check that the castor wheel and fork nuts are tight STEP4 Check that the castor forks are bent or damaged STEP 5 Check the crown castor fork bearings for wear and correct adjustment STEP 6 Check tyres for wear and correct inflation Both wheels should show the same degree of wear see side of tyre pressure rating For tyre fitment see rear tyre section Phoenix 11 01 CASTOR WHEEL
17. page 24 STEP 8 Remove the crossbar bolt with a 13mm spanner using a second spanner on the nut to hold against rotation Take care not to loose the washer see page 24 STEP 9 Remove all rubber and plastic end stops with a flat bladed screwdriver To reassemble reverse steps 1 to 9 remembering to lubricate the inner bottom rail with a light grease prior to fitment servicing Requirements We recommend that routine servicing be carried out at six monthly intervals The routine ser vice consists of the following 1 Motors a Inspect plugs for physical damage b Inspect insulation for cracks and splits c Check and clean brake Resistance Appx 50 80 Ohms d Inspect and clean brushes and commutator e Check action to clutch mechanism f Check and inspect gear box for excess wave noise replace grease recommended grease Shell Albida R2 Q1100Z 2 Controller and Joystick Assy a Check for physical damage to outer casings b Inspect joystick shroud and gaiter for cracks and splits c Check all switch operations and Led s 24 d Check joystick lead and plug ends for signs of cracks wear or physical damage e Check status LED on side of controller is on Stable f Check diagnostics To assure no faults present on systems Check On Off lamp status if flashing refer to diagnostics supplement on page 23 24 3 Chassis a Inspect all fixtures and fittings for tightness and integrity b Check
18. r to ensure both left and right wheel do not free wheel 1 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 2 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 3 Check if one park brake is dragging Does one or both park braked get hot after driving The park brake should be able to be touched without any discomfort 1 Check the battery charger is plugged switched on 2 Check the charger is the correct type 3 Check the charger operation 4 Check the fuse next to the power connector on the charger Warning Disconnect charger from both the mains socket before checking the fuse Phoenix 11 01 FRAMES AND CHASSIS PARTS 1 Sideframe Assembly RH 2 Sideframe Assembly LH 3 4 Crossbrace Assembly 5 Anti Tipping Lever 6 Inner Bottom Rail 7 Footrest Release Lever RH Footrest Release Lever LH 8 Footrest Hinge Pin Upper 9 Footrest Hinge Pin Lower 10 Pin Footrest Release 11 Handknob 12 Tee Bar 13 Bolt 14 Crossbar Link Arm 15 Crossbar Link Bracket 16 Seat Clamp Screw 17 Seat Guide 15 34 lt F Nyloc Nut Castor Socket Cap Handknob Armrest Bracket Screw Crossbar Washer Crossbar Nut Crossbar Bolt Tube End Plug Screw Domed Ny
19. ries STEP 3 For the battery charger operate the battery voltage must be shown above 8v each If not the batteries must be removed and charged with an unregulated charger until the voltage reaches 9v Re connect the batteries and charge through a complete charge cycle this may or may not recover the batteries if not replace the batteries STEP 4 On completion of charge the battery voltage must read 14 20v at 20 C or combined 28 4v 11 Phoenix 11 01 BATTERIES AND CHARGER DISMANTLING BATTERIES STEP 1 Unplug the battery lead disconnect the battery box from the connecting plug lift off the battery cradle and remove the battery cradle from the mounting bars STEP 2 Remove the battery boxes battery box from cradle STEP 3 Unclip the battery box lids with a 10mm spanner undo the battery terminals and remove the batteries from the cases To re assemble reverse steps 1 to 3 and charge the battery fully INSPECTION CHARGER STEP 1 Check the charger case for physical damage STEP 2 Check the input and output leads and plugs for damage cuts and wear STEP 3 Check that the charging charge complete and power on lamps are operating correctly STEP 4 With an ammeter or a multimeter set to amp range 10A test the charging current NOTE AMMETERS MUST BE CONNECTED IN SERIES WITH THE BATTERY CIRCUIT STEP5 The current reading should read approximately 7amp at charge start and 0 2 amp at complete charge
20. the stem and tighten with a 19mm spanner just enough to allow the fork to swivel freely STEP 4 To check for correct tightness preform the following test a Tip chair backwards and rest the push handles on the floor remove the battery boxes first b Raise castor wheel towards ceiling then gently push downward to either side The wheel and fork should freely rotate down and hang straight towards the floor after a pendulum type swing NOTE IF THE WHEEL STOPS ANGLED TO ONE SIDE LOOSEN THE FORK STEM NUT SLIGHTLY IF THE WHEEL CONTINUES TO SWING TO BOTH SIDES LIKE A PENDULUM TIGHTEN THE FORK STEM NUT SLIGHTLY CHECK BEARINGS FOR EXCESSIVE PLAY BY GENTLY ROCKING THE FORK ASSEMBLY Phoenix 11 01 REAR WHEEL AND TYRES PARTS 1 Tyre 2 Inner Tube 3 Outer Rim Inner Rim 4 Socket Head Cap Screw 5 Washer 6 Wheel Bolts 7 Wheel Hub 8 Key Tools Required Allen Key 6mm Spanner 13mm Mallet Tyre Levers Pressure Gauge Pump Vice Talcum Powder Valve Remover Flat Bladed Screwdriver DISMANTLING ALLOY TYPE WHEELS INSPECTION STEP 1 Check wheel is not buckled or physically damaged Replace if required STEP2 Check tyres for wear and correct inflation both wheels should allow the same degree of wear see side of tyre for pressure rating DISMANTLING STEP 1 Jack up one of the gearboxes to lift one wheel off the floor STEP 2 Remove the 5 M8 Wheel Bolts securing the Wheel to the Whee
21. to carry out maintenance With the exception of fasteners those components should be refitted CONTENTS Page Armrests 1 Upholstery and Back Seat Cloth 2 Castor Wheel amp Fork 3 Rear Wheel amp Tyres 6 Footrest 8 Mechanical Brake 9 Batteries amp Charger 10 Motor Assembly 13 Gearbox Assembly 15 Controller with Integral Joystick Remote DL 40 17 What to do in the event of a fault 18 Troubleshooting 19 Diagnostics 19 Frame amp Chassis 22 TOOLS REQUIRED THE FOLLOWING LIST DETAILS THE BASIC TOOLS REQUIRED TO CARRY OUT THE MAINTENANCE GIVEN IN THE FOLLOWING CHAPTERS 2 Open End Spanner 13mm 1 Open End Spanner 11mm 2 Open End Spanner 10mm 1 Open End Spanner 8mm 1 4 BSW Open End Spanner Combination Spanner 19mm Socket Wrench Shallow 19mm Phillips Screwdriver No 1 Flat Bladed Screwdriver No 1 Nylon Mallet 4 4 4 4 4 4 1 Torque Wrench 1 Allen Key 6mm 1 Allen Key 6mm 1 Allen Key 8mm 1 Allen Key 4mm 1 Knife 1 Pressure Gauge 2 Tyre Levers 1 Pump 1 Drift 1 Vice 1 Talcum Powder 1 Valve Remover 1 Multi Meter 1 Soldering Iron 1 Pin Hammer 1 Punch 1 Pair Pliers 1 Battery Discharge Tester 1 HHP Programmer NOTE THE ABOVE LIST IS NOT EXHAUSTIVE ARM REST PARTS Armrest Pad Bracket Hand Knob Armrest Bracket Arm Upright Assembly 3 Washer Cap Screw Skirt Guard Screw Allen 0 Ar
22. ttery feed wires Unfasten cable ties from chassis STEP2 Undo controller mounting bracket fixing Unplug motor connectors Controller will then be free from the chair INSPECTION STEP 1 Check for any physical damage to the outer casing 1 STEP 2 Inspect the rubber gaiter around the joystick knob for any cracks splits or perishing This would enable water or moisture to access the unit This would cause serious damage to the controller STEP 3 Check speed control knob is secure and its action is free and easy in rotation To adjust the needle pointer remove the end cap with a knife by sliding it down between the small gap at the knob Using a No1 Philips Screw Driver loosen off the fixing screw The knob can then be removed Turn the potentiometer shaft fully clockwise re fit the knob onto the potentiometer shaft and position the needle pointer on the cap to apx 11 o clock and tighten up firmly NOTE CHECK THAT MAX SPEED IS 11 O CLOCK MIN SPEED IS 2 00 O CLOCK TO REASSEMBLE REVERSE STEPS 1 TO 3 READ THE FOLLOWING CAREFULLY THIS INFORMATION IS DESIGNED TO HELP US UNDERSTAND HOW THE CONTROL SYSTEM FUNCTIONS GENERAL FEATURES The DP PWC has the following general features Radio frequency interference compatible to 20 Volts metre Ergonomic on off switch Audible on off switch feedback and low battery charge warning True state of charge battery gauge with three colour display 17 Phoenix 11 01
23. ve looseness is not worn or damaged STEP 2 Check that the brake shoe is positioned correctly to provide maximum surface area contact on the tyre tread and gives the positive brake hold apx 10 11 gap between tyre and brake shoe DISMANTLING STEP 1 Loosen and remove the brake fixing bolt with an 10mm spanner STEP 2 Remove the brake from the sideframe slide off the rubber tip STEP 3 Use a 10mm spanner to dismantle lever mechanism if necessary STEP 4 Use No1 Philips screw driver to remove brake block fixing screw To re assemble reverse steps 1 to 4 BATTERIES AND CHARGER PARTS Rear Battery Box Battery not shown Front Battery Battery not shown Battery Cradle Power Lead not shown Battery Box Lid Front Moulding Battery Box Lid Rear Moulding Connector Plug Plug Cover 40 Amp Circuit Breaker 10 40 Ah Sonnenschien Battery Not shown 11 Power Socket not shown 12 Power Lead Plug not shown 13 Battery Terminal Cover RH Not Shown 14 Battery Terminal Cover LH Not Shown 15 Battery Chargers EN OP Ob ee Tools Required Pliers Flat Bladed Screwdriver 10mm Spanner No 1 Phillips Screwdriver Multi Meter Astratech Battery Discharger INSPECTION BATTERIES STEP 1 Check that the battery box case leads sockets and batteries are not damaged Phoenix 11 01 gg Phoenix 11 01 STEP 2 Measure the battery voltages the values must be the same 0 2v If not replace the batte
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