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On-Line Technical Training Course

1. Consult the Service Manual for each procedure listed above or visit our Website at www invacare com for more technical information or Contact Invacare Technical Support toll free at 1 800 832 4707 for more information Please have the following information prior to calling e Model and Serial Number e Version of Electronics and Error Codes e tisrecommendegd that you stay with the product while contacting Invacare e Make sure you have already ruled out the batteries before contacting Invacare Power Mobility Guide Rev 2 08 page 2 2 1 Service amp Parts Education REAR BASE ASSEMBLY AND BATTERY CHARGER BOX INSPECTION 1 Remove the seat the battery charger box and rear base assembly Then remove the top covering of battery charger box and the shroud of the rear base assembly to begin the wiring inspection process 2 Inspect battery charger box and rear base assembly for loose or broken connections and corrosion Replace if needed 3 Takeastatic voltage reading from the batteries to verify state of charge This can be performed easily by testing at battery box connection 25 0 VDC or higher for the pair is GOOD fully charged 4 Pluginthe charger to verify that it is in good working condition Static voltage with the charger ON should be above 27 0 VDC 5 Perform a load test on the batteries if unsure of battery condition Field load test or Hand Held load test 6 Check circuit breaker connections l
2. Service amp Parts Education MK6i SPJ JOYSTICK CABLE Joystick cable for the NX level of electronics can be removed tested and replaced if needed Test this cable as you would any other wiring JOYSTICK CABLE PINOUT Positive Communication Buss Communication Buss Negative MK6i BATTERY TO CONTROLLER CABLE The battery to controller cable is connected between the battery connection and the controller Test this cable as you would any other wiring These connnections are marked as Positive and Negative to assist in troubleshooting BATTERY TO CONTROLLER CABLE PINOUT a Eg f Power Mobility Guide Rev 1 09 TER 3 9 Service amp Parts Education MK6i CONTROL MODULES MK6i Control Modules in NX level of electronics holds all programming aspects including any faults and error codes Never open or modify control module There are 3 types of MK6i NX controllers MK660ACC MK6i controller for 2 pole motors with or without powered seating MK690 MK6i controller for 4 pole motors without powered seating MK690ACC MK6i controller for 4 pole motors with powered seating MK6i CONTROL MODULES PINOUT g wm LG enn h amp is I l dil LL LIL a co DEI amp j m Control e ut 3 M Unit aT le s g S e 24 V E 24 V Park Brake EL Park Brake MI TM gn E um Motor Motor Power Mobility Guide 4 3 4 Rev 1 09 TER
3. 4 5 motor if high reading is present 5 5 Ohms Normal Replace gearbox Leave power ON and allow controller to count down and recharge the chair overnight with power ON Engage motors to drive chair Ohm out motors check or replace brushes Swap out motor leads Check for error codes with programmer Inflate tires or replace if worn Use programmer to balance motors 2 4 Pole Only Recalibrate joystick with programmer or replace inductive if necessary Recalibrate motors with programmer Check all connections Ohm out each brake coil 45 80 Ohms Good Swap motor leads to see if code switches sides call Tech Services Replace brake coil Service amp Parts Education MOTOR GEARBOX BRAKES TROUBLESHOOTING GUIDE Possible Cause Corrective Action Gearbox is leaking fluid Excessive clicking coming from motor gearbox Gearbox shaft movement or bent shaft GB motors clicking Brake lever not engaging brake coil Motor stutters Bad seal around drive shaft or loose hardware Bad bearing in motor or gearbox Loose wheel hardware Hough driving Excessive load on chair or damage from rough terrain Loose hub on motor Bent lever or internal damaged Bad micro switch or out of adjustment Poor connection or worn brushes GB motor calibration If seal is bad replace gearbox If loose hardware is found retighten hardware Heplace motor or gearbox Tighten loose hardware
4. EEEUTONEEN oser Connector AS GATEN on chair base MKIV Avoid stalling motors for longer than 15 seconds Stalling the motors for more than 15 seconds may cause hot spots on the commutator plates or cause the chair to go into 100 Current Rollback Cy MK5 Charger Static Battery Connector Voltage Test Point Service amp Parts Education HAND HELD FIELD LOAD TEST PROCEDURE The tester draws current from the battery while measuring its voltage level The voltage level of a good battery will remain relatively steady under load but a defective battery will show a rapid loss in voltage Turn the power switch to the off position Make sure the static battery voltage is above 25 0 VDC Disconnect batteries from equipment Connect negative black clamp to the negative NEG N battery post Connect positive red clamp to positive POS P battery post Rock clamps back and forth to insure a good electrical connection CAUTION do not let the positive and negative to make contact 5 With clamps connected tester s meter will indicate battery s STATE OF CHARGE If state of charge is less then 12 volts the battery should be recharged before load testing If recharging does not bring voltage to 12 4 or higher battery is defective If meter needle is off scale to the left check for loose or reversed clamps otherwise battery is defective 6 Depress load switch for 10 seconds 7 Read meter at the end of 10
5. Heavy load on motors Check all fuses on the chair and in the charger Make sure charger is plugged into the outlet Check for AC power with a digital multi meter Check for damage and replace if necessary or send in for repair Charge batteries with known good charger Replace batteries Charge for 8 10 hours minimum Perform load test or check Battery Quality Menu with your programmer Torque setting and Power Level setting may be to high Chairs weight distribution may be offset chair may be front loaded Check or replace Batteries have swelledup Batteries have been batteries overcharged Power Mobility Guide Rev 1 09 TER 4 2 Service amp Parts Education CHARGER TROUBLESHOOTING GUIDE Problem Batteries won t charge No LED s on Charger Charger starts up and shuts off after running for a short period of time red or green lights may be flashing Short charge time Power Mobility Guide Rev 1 09 TER Blown fuse or damaged wiring Charger not plugged into outlet or disconnected from wiring harness on chair No AG power at the outlet Power cord may be damaged Charger LED s may be burnt out Charger may have internal fuse that is blown Powerchairs batteries may be severely discharged voltage too low for charger to start One or both batteries may be bad if batteries charge up to soon Possible Cause Corrective Action Replace fuse and check wiring for damage
6. Immediate access to power to overcome obstacles and rough terrain High Speeds often require Low Torque Values Momentum prevails over obstacles Soft response to driver commands at high speeds feels smooth and controlled to many drivers Power Level as a Performance Adjustment is a true power output Current or Amps setting for the controller Power Level does NOT impact speed on level surfaces On an incline however under a load a chair may lose speed if there is insufficient power to maintain the speed under that load oetting the Power Level to a lower value limits the available Current to the motors If the Power Level is set low the chair will stall when it encounters situations that require more power that the set value A good application like this is for a new driver if they tend to accidentally run into walls or furniture low settings would cause the chair to stall rather than causing further damage The Power Level can be set different on each available drive Therefore you can have one drive with less power to prevent damage to the user or the environment and another drive with more power for different environmental situations outdoor driving ramps and soft terrain NOTE Power Current Voltage or IT I Current and T Time The setting of Power Level affects the current in this setting when played with the value of time Where I equals current and T equals time This formula is squared so with a higher val
7. Make sure the charger is plugged into the outlet and check the wiring on the chair Check for AC power with a digital multi meter Check for damage on the power cord replace if damaged or send in for repair Send charger to Invacare for repair Hemove charger cover and check for fuses Remove each battery and use a 12 volt charger on each battery for 1 hour then put both batteries back into battery box es and restart OEM charger or replace batteries if needed Load test each battery and replace if needed Service amp Parts Education WIRING TROUBLESHOOTING GUIDE Problem No power to chair motors E28 Error code No LED s on Joystick or Tiller Corroded wiring or connections Power Mobility Guide Rev 1 09 TER Possible Cause Bad connection or blown fuse Check Joystick connection Loose battery connections Damaged controller connections Drive lockout condition in high back van seat recliners and any Power Seating System Internal Wiring Harness damage perform a continuity test on each connection Charger still plugged when user tries to drive the chair Tiller harness unplugged joystick connection to controller unplugged or damaged Possible water salt or urine damage Corrective Action Check all connections and housings for damage Replace fuse if blown Check battery cable connections may have vibrated loose when driving on rough terrain Repair connection
8. Service amp Parts Education MK6i PROGRAMMER Select Key Right Arrow Key Down Arrow Key MK6i Programmer allows modification of the performance characteristics gives diagonostic information and permits calibration changes in the control module On NX level of electronics this programmer will operate as a MK5 programmer and can not be utilized in conjunction with a SD Memory Card Up amp Down Arrow Keys scrolls through menu options as well as raise and lower selected values Left amp Right Arrow Keys scrolls along menu line items as well as advance to the next or return to the previous screen of highlighted value Select Key allows selection into highlighted and modified value Other functions when prompted Save Key allows programmed value and drives to be saved into system Must be pressed twice to properly save changes Pwr Info Key Powers programmer On Off To operate turn ON power wheelchair plug MK6i Programmer into joystick charger pro gramming port press power key on programmer and wait for communication If communi cation error is present disconnect programmer verify power is ON and or test joystick charger programmer port for proper voltage 25 0 dcv or higher then retry The first display screen shown after powering on the programmer is the main menu and consists of the following options Perfomance Adjust Programs and Others Power Mobility Guide Rev 1 09 TER 3 5 Service amp Parts E
9. TDXSR 22NF GR24 TDXSpree 22NF 22NF GR24 22NF GR24 Ranger II RWD 2 22NF Ranger Il JR 2 U 1 P7E P9000 XDT 2 U 1 Excel 2 22NF P9000 2 U 1 22NF Power Tiger 2 22NF Pronto M6 2 U 1 Xterra GT CWD 2 22NF Pronto M41 50 2 U 1 Pronto M51 61 2 U 1 Pronto M71 R2 2 U 1 22NF Pronto M91 M94 2 22NF Nutron Series 2 U 1 22 NF ATM Adventure SX 3 2 12 12AH Lynx L 3 2 12 12AH Lynx L 3X 2 12 36AH Lynx L 4 2 12 12AH 220 300 400 2 12 12AH or U1 Lynx SX 3P 2 12 17AH Lynx SX 3 2 12 17AH Lynx LX 3 2 12 31 AH Adventure LX 3 2 12 U 1 Lynx LX 3 Plus 2 12 31AH Panther LX 4 2 12 31AH Panther MX 4 2 12 40AH NOTE TDX chairs equipped with a Vent Tray will require 3 22NF batteries The third battery will supply power to the Ventilator wiring harness shipped with base Power Mobility Guide Rev 1 09 TER 1 1 Service amp Parts Education SEALED LEAD ACID amp GEL CELL DEEP CYCLE BATTERIES Pressu Control Y Valve Forged Terminal Posts and Bushings Brushed Plate Lugs ed Premium Glass me a Mat Separators vy Duty Plates der High Density d Th Deep Cycle Oxide gt B 5 rough XD 4 the Partition Connectors Intercell Gasket Se Polypropylene Case amp Cover Grid Alloy Roimforein p Fiberglass Mat Tight t Pack Construction with Gelled Electrolyte How does maintenence free batteries work A Gel cell is a recombinant battery This means that the oxygen that is normally produced o
10. ON Polarity of the throttle Pot is reversed Left Hand Drive OFF Normal Polarity of the throttle Pot Right Hand Drive e Press ENTER to confirm the value when finished 2 The second option is ENABLE SLEEP Factory Default ON e The Option Menu settings are either ON or OFF Range ON Sleep Time is enabled OFF Sleep Time is disabled e Press ENTER to confirm the value when finished 3 The third option is SLEEP BEEP Factory Default ON e The Option Menu settings are either ON or OFF Range ON Sleep Beep is enabled OFF Sleep Beep is disabled e Press ENTER to confirm the value when finished 4 The fourth option is SOUND FAULT Factory Default OFF e The Option Menu settings are either ON or OFF Range ON Sound Fault is enabled OFF Sound Fault is disabled e Press ENTER to confirm the value when finished NOTE ENABLING SOUND FAULT HELPS IN DIAGNOSIS OF THE SCOOTER ALLOWING SERIES OF BEEPS TO ASSIST IN TROUBLE SHOOTING Power Mobility Guide Rev 2 08 page 9 5 8 INVACARE SERVECE amp FARTS INVACARE Service amp Parts Education SCOOTER PROGRAMMING INSTRUCTIONS HOW TO MAKE ADJUSTMENTS TO THE SPEED LEVER IN NEUTRAL 1 The SPEED LEVER IN NEUTRAL option is used to calibrate the throttle pot for neutral e This menu allows you to calibrate the throttle pot about neutral so that when the throttle is at rest in neutral the controller sees a voltage that translates to zero speed Th
11. ROADRUNINE IK M O B On Line Technical Training Course Roadrunner Mobility Corporate Office 717 Lingco Drive Suite 211 Richardson TX 75081 1800 467 2668 www roadrunnermobility com Service amp Parts Education TABLE OF CONTENTS Introduction Welcome to ISP Technical Education Go EEST EE E 1 Recommended TR vr 2 SERVICE Manual LIST EE 3 What Consumer Need To Know About Power Mobility Products rrrrrrnnrrrrnnrrrvrnnnnenrnnnrrnnnnnrnrnnnnennnnn 4 Power Wheelchair Troubleshooting Procedure rrnrnnnnnrrnnnrnnnnnnrnnnnnnnnnnnnennnnnnrnnnnsnnnnnnnsnnnnnnsnnnnnnennnnnee 6 Section 1 Battery and Charging Systems Banery oze ONAN aeaa EIE o mM 1 1 Sealed Lead Acid amp Gel Cell Deep Cycle Batteries rrrnrrnrvrrnnnnrvvrrnnnnrvvrnnnnrrvvnnnnnnvennnnnnnvennnnnnnvennnn 1 2 Cycle of Deep Cycle Batteries rrrrrrrnnnrrrrrrnnnrrvrrnnnnrrvnrnnnnrrvnnnnnnnennnnnnnnrnnnnnsnrrnnnnnnnernnnnnsnsennnnnnnnasenn 1 3 Sealed Battery Break in Procedure rrrnnnnrrnnnnnnnrrnnnnnnnrrnrnnnnnrnnnnnnnnrnnrnnnnsrnnnnnnnssnnnnnsnsnnnnnnsnsnnnnnsnnessnn 1 4 Battery State OF Oha GE RETE TER 1 5 Field Load Test Procedure NRI em 1 6 Hand Held Load Test Procedure as eee 1 7 Charging Batteries 6 Rules to Remember ccccccsseeeceeceeeeceeceaeesceeceeeeceeeeeeeeeeesseeaeceessaeaeeeeseaeaes 1 8 On Board Fully Automatic Battery Chargers cccccccccccccceseseeeeceeeeeeeeseeeeeeeeseaeeeceeseeeaeeeesseegeeeessa
12. Rev 1 09 TER 3 1 Service amp Parts Education MK6i SINGLE PURPOSE JOYSTICK SPJ Charger Programmer Port On Off button Speed Control Button Horn Speed Indicator Light Service Indicator Inductive Plug Port MK6i SPJ joystick is Invacare s standard joystick in our NX level of electronics The SPJ has limited programming that is contained in the Control Module On Off Button Used to turn On amp Off the power Horn Emits audible signal when pressed Speed Indicator Lights Indicate maximum speed currently set Speed Control Button Tortoise button is used to decrease the speed in 2096 increments while the Hare button is used to increase the speed in 20 increments To adjust in small increments hold both Tortoise and Hare until horn alarms then press and hold either Tortoise or Hare to decrease or increase the speed setting Inductive or Gimble Is the proportional drive control that allows the driver to control the product Charger Programmer Port Is the location where off board chargers plug in to charge the product This port is also used to program the Control Module Service Indicator This Amber light informs the driver and technician when an error or fault occurs This light flashes a number of times with pause in between indicating the actual problem Plug Port Is the location where the control module connects to joystick via joystick cable Power Mobility Guide Rev 1 09 TER 3 2
13. While special battery load testing equipment is available it is costly and difficult to transport Use a digital multimeter to check battery charge level at the charger connector It is located on the side of the wheelchair frame or at the front of the Joystick or display Field Load Test Procedure 1 2 3 Ensure that power is OFF Make sure battery voltage is above 25 0 VDC Hemove the footrests from the wheelchair and seat yourself into the chair Place yourself and the chair in front of a stationary object door jam or a brick wall Insert your multimeter leads into the charger connector on the wheelchair see Figure 1 Most digital multimeters are not affected by polarity however analog meters meters with swinging needles can be and should be used carefully A good meter reading should be 25 0 VDC or higher Have two 2 individuals one 1 on each arm apply as much downward pressure as possible on the arms of the wheelchair Turn the power ON and push the joystick forward trying to drive the wheelchair through the stationary object This puts a heavy load on the batteries as they try to push through the stationary object Read the meter while the motors are stalling to determine the voltage under a load NOTE If the voltage drops to less than 23 0 volts from a pair of fully charged batteries while under load they should be replaced regardless of the unloaded voltages Power Mobility Guide Rev 1 09 TER 1 6 6
14. due to heavy load for an extended period of time Bad Drive Limit switch or Tilt Limit switch Bad Actuators System tilted beyond drive lock out angle 20 degrees Damaged wiring harness Communication Error SOLUTIONS Return to seat back to upright position Limit switch faulty or out of adjustment Charge batteries and verify load test Replace Joystick or send in for repair Check Powered Seating menu to verify proper programing and Diagnostics menu for version Check all connections and test using new switch Check Diagnostics menu to verify or turn power OFF to allow electronics to cool down 2 minutes or more Check the Powered Seating Menu menu to verify speeds and adjust if necessary Check connections on Drive Limit and Tilt Limit switch or replace Check for 24 VDC when switch is activated with a multimeter at the actuator connector coming out of the power seating control module Use new mode switch on Smart Actuators Switch actuator leads from a functioning actuator to the one that is not working activate switch to verify if the actuator is bad or the power seating control module is bad Return to seat back to upright position Possible bad wiring harness check pins 2 and 3 on charger connector for 5 VDC reference when seat is below 20 degrees and 0 VDC when seat is tilted beyond 20 degrees Replace wiring harness inhibit line or charger plug faulty Check the control module for programmin
15. B 03 Motor Terminal Connected to B 04 Left Motor Voltage Fault 05 Left Motor Bridge Fault 06 Too Many Hardware Current Limit Events 07 Current Offset Out of Range 08 Hardware Current Limit Fault 4 E04 00 Right Motor Fault Right Motor Short Circuit 01 Right Motor Open Circuit 02 Right Motor Connection Fault B 03 Motor Terminal Connected to B 04 Right Motor Voltage Fault 05 Right Motor Bridge Fault 06 Too Many Hardware Current Limit Events 07 Current Offset Out of Range 08 Hardware Current Limit Fault 5 E05 00 Left Park Brake Fault Left Park Brake Drive Time Test Failed 01 Left Park Brake Output Enabled When Chair Idle 02 Left Park Brake Output Did Not Enable When Entering Drive Mode 03 Left Park Brake Fault During Power Up Testing 04 Left Park Brake Feedback Low During Drive Park Brake Short 6 E06 00 Right Park Brake Fault Right Park Brake Drive Time Test Failed 01 Right Park Brake Output Enabled When Chair Idle 02 Right Park Brake Output Did Not Enable When Entering Drive Mode 03 Right Park Brake Fault During Power Up Testing 04 Right Park Brake Feedback Low During Drive Park Brake Short 7 E07 00 Remote Fault Local SR Fault CPU EEPROM ect 01 Joystick Fault at the Remote 02 Speed Pot Fault at the Remote 8 E08 00 Controller Fault 01 RAM Fault 02 ROM Fault 03 CPU Fault 04 EEPROM Fault 05 Watchdog Fault 06 Stack Fault 07 Software Fault 08 Power up Testing Fault 09 Relay Fault or Precharge Fault 10 Bridge Fault or Dis
16. Guide Rev 1 09 TER MK660w ACC 2 pole MWD M61 or M51 M61 EURO M61 European model only MWD M71 2P or SPREE SC M71 RWD 2P MK690 amp MK690w ACC 4 pole TDX 4P RWD 4P CWD M91 SP SI CWD M91 HD MK6i NX PROGRAMS VALUES MK660w ACC MK690 amp MK690 w ACC MWD RWD CWD RWD 100 95 95 90 30 25 20 20 25 30 20 25 25 30 20 20 25 30 25 20 30 35 35 25 50 50 50 50 55 55 55 45 40 40 50 30 40 40 35 40 144 144 36 48 Service amp Parts Education MK6i NX OTHERS MENU The last option in the main menu is Others The Others menu provides calibration changes and the diagnostic menu Motor Balance is a calibration used to correct veer when going straight When performing motor balance you change the value to slower side If major changes to Motor Balance is needed check motors for possible issues To properly adjust the Motor Balance Allow for alot of room Straighten all casters and sit in chair Put thumb and index finger together to make a V Place them against the rear of the inductive Close eyes and push inductive forward and hold for 5 seconds Release the inductive and allow chair to stop Verify ending position relative to starting position Adjust balance to compensate for pull in left or right direction Joystick Throw is a calibration used to calibrate the neutral and the full speed travel of the proportional joystick The control module stores the maximum displace ment of the joystick and later dur
17. a Throttle Assembly and the ocooter will not drive 6 flashes are noticed on the Status Indicator LED 1 Turn key off and disengage the brake lever at the back of the scooter Place an object under the frame to raise the drive wheels off of the ground for testing purposes Locate the 2 phillips head screws underneath the front console and remove them Locate and remove the 2 phillips head screws on the throttle handle the throttle handle base should remain 1 Locate and remove the 2 screws under the console and the 2 screws that secures the throttle lever 2 Using a 2mm hex head tool loosen the 2 set screws slightly do not remove the screws 3 Turn the key to the on position and connect the DS100 programmer With the programmer on go to the SET UP option and verify the Buzzer Vol ume is on 2 or higher Then go to the SPEED 2 Loosen the two 2mm hex LEVER IN NEUTRAL OPTION A neutral reading head screws slightly will cause the neutral alarm to sound until the programmer is taken out of this option but if you are experiencing 6 flashes on the Status Indicator LED the throttle pot needs to be re calibrated 4 Tore calibrate the throttle pot leave your DS100 programmer hooked up and use a small flat common screwdriver to adjust the throttle pot Turn the pot clockwise or counter clockwise until your neutral alarm sounds When you have re calibrated the pot tighten the two set screws Engage the brake lever
18. and adjusts the cut off voltage accordingly These chargers also have 1 or 2 LED s that light up to inform the user that the power is on and the charging condition These LED s also will show faults in the system These chargers are found on the high end consumer power chairs NOTE Lower Amp charger require extended charging time if the batteries are less than 25 Power Mobility Guide Rev 1 09 TER 1 9 Service amp Parts Education OFF BOARD FULLY AUTOMATIC BATTERY CHARGERS 24 Volt 8 Amp Lester Battery Charger Lester Dual Mode Charger has a start up voltage of 18 22 VDG This charger has an on off switch and a mode switch to change the cut off voltage depending on battery type This Lester Charger has 2 led s that light up to inform the user that the power is on and the charging condition These led s also will show faults in the system 24 Volt Battery Charger ON BOARD CHARGERS Advantages 24 Volt 8 Amp CTE Battery Charger CTE Battery Charger has a start up voltage of 8 10 VDG The CTE Battery Charger has no on off switch or fuses also it determines battery type and adjusts the cut off voltage accordingly The CTE Battery Charger is a Smart Charger which means that the charger will begin charging anytime the batteries require a charging and will automatically transition to Sleep Mode when the batteries do not require a charge therefore this charger can be connected to the batteries Indefinitely thoug
19. of maximum forward speed and maximum reverse speed 10 fastest limit of maximum forward speed and maximum reverse speed NOTE For example if REDUCE SPEED is set to 7 FORWARD SPEED to 10 and REVERSE SPEED to 6 maximum forward speed will reduce to 7 but maximum REVERSE SPEED will stay at 6 as it is already lower than REDUCE SPEED e Press ENTER to confirm the value when finished 6 The sixth option is BUZZER VOLUME Factory Default 10 Press the VARY key to change the current rate Range 1 a setting of 1 turns the horn buzzer OFF 10 any other value turns the horn buzzer ON 10 being the highest volume e Press ENTER to confirm the value when finished 7 The seventh option is SLEEP TIME Factory Default 30 minutes Press the VARY key to change the rate Range 5 min fastest sleep time setting for scooter scooter powers down after 5 min of inactivity 60 min slowest sleep time setting for scooter scooter powers down after 60 min of inactivity e Press ENTER to confirm the value when finished 8 The eighth option is PARK BRAKE DELAY Factory Default 10 Press the VARY key to change the current rate Range 1 fastest parking brake time engages after stop 30 slowest parking brake time engages after stop e Press ENTER to confirm the value when finished HOW TO MAKE ADJUSTMENTS IN THE OPTIONS MENU 1 The first option is POT REVERSE Factory Default OFF e The Option Menu settings are either ON or OFF Range
20. or clean contacts Return to upright seat and back angle recalibrate mercury switch or reconnect wiring may have come loose Check POT calibration or mercury switch on chairs equipped with power seating Replace wiring harness Unplug charger to drive chair Plug connections back together and check for damage wiring Replace harness Service amp Parts Education MOTOR GEARBOX BRAKES TROUBLESHOOTING GUIDE Problem Possible Cause Corrective Action Motor makes a clicking noise Bad coupler between motor and Replace coupler if bearings gearbox or bad bearings inside are bad replace motor Grinding noise or motor is locking up Motors stall and starts up again Chair will not drive with power on E09 or E10 Motor chatters or runs erratically or only one motor turns Chair veers to the left or right when driving on level surface E09 E10 error code will not go away Brake dragging causing chair to veer Power Mobility Guide Rev 1 09 TER of motor Raised commutator plate inside Ohm out motor and Replace of motor Bad gearbox Current Rollback Check motor locks Damaged connector or worn brushes Controller malfunction Uneven tire pressure Motors out of balance Joystick needs calibrated GB motor calibration needed Bad motor connection Bad brake Coil Bad brake coil or connection On early 2 Pole motors if the Brake Lever is bent it may be rubbing on the brake pad
21. the version of the controller software HOW TO MAKE ADJUSTMENTS IN THE SETUP MENU From the Setup Menu Display press ENTER to scroll through the options 1 The first option is ACCELERATION Factory Default 3 Press the VARY key to change the current rate Range 1 slowest acceleration to maximum forward speed 10 fastest acceleration to maximum forward speed e Press ENTER to confirm the value when finished 2 The second option is DECELERATION Factory Default 7 Press the VARY key to change the current rate Range 1 slowest deceleration from maximum forward speed 10 fastest deceleration from maximum forward speed e Press ENTER to confirm the value when finished 3 The third option is FORWARD SPEED Factory Default 10 Press the VARY key to change the current rate Range 1 slowest forward speed 10 fastest forward speed e Press ENTER to confirm the value when finished Power Mobility Guide Rev 2 08 page 8 9 INVACARE SERVECE R FARTS Service amp Parts Education SCOOTER PROGRAMMING INSTRUCTIONS HOW TO MAKE ADJUSTMENTS IN THE SETUP MENU continued 4 The forth option is REVERSE SPEED Factory Default 4 Press the VARY key to change the current rate Range 1 slowest reverse speed 10 fastest reverse speed e Press ENTER to confirm the value when finished 5 The fifth option is REDUCE SPEED Factory Default 5 Press the VARY key to change the current rate Range 1 slowest limit
22. to push the chair and the current counter reaches the preset cut off value the chair will shut down completely e f in Current Rollback the joystick battery indicator lights will show the left two bars flashing and the right battery level indicator light will still be on e If in Current Rollback the LCD Display may also record the word HOT or scroll an E176 E179 fault code Check the Fault Log in the Diagnostics Menu for the any two consecutive faults between E176 E179 The best remedy for Current Rollback is to leave the chairs power switch ON without driving the chair for approximately 40 minutes This allows the current counter to reset to zero This is easily achieved by charging the batteries with the chairs power left in the ON position The best way to prevent this problem is to make certain Torque and Power Level are appropriately for the desired drives environments and set the Center of Gravity of the chair appropriately for the user This ensures that one of these things alone is not the causing factor Power Mobility Guide INVACARE Rev 1 09 TER 4 13 SS INVACARE SERVICE amp PARTS Service amp Parts Education UNDERSTANDING TORQUE AND POWER LEVEL Torque is one of the most commonly misunderstood performance adjustments on Invacare power chairs Most people think Torque is the amount of power a chair has not true Torque is how fast the chair has the power available to it or how quickly the chair can ra
23. too high Inhibited 4 Current Limit Drive time out Inhibited Power Mobility Guide Rev 2 08 page 11 5 10 Notes Battery charge is running low Recharge the batteries as soon as possible Battery charge is empty Recharge the batteries If the Scooter is left off for a few minutes battery charge may recover sufficiently to allow driving for a short period of time Battery charge is too high Scooter will charge batteries when travelling down slopes or decelerating Excessive charging in this manner may cause this fault Turn the scooter power off and then back on again The scooter has drawn too much current for too long possibly because the motor has been overworked jammed or stalled Turn the scooter power off leave for afew minutes and then turn back on again The controller has detected a shorted motor Check the wiring harness for shorts and check the motor Service amp Parts Education SCOOTER ERROR CODES continued The scooter tillers are equipped with a status indicator LED that will flash diagnostic code information The status indicator LED will flash in burst separated by a pause to provide diagnostic information See page 5 3 for tiller faceplate status indicator light location Number Impact on of Flashes Scooter Brake Fault Drive Check that the park brake release Inhibited lever is in the engaged position The park brake coil or wiring is faulty Check the park brake and wiring f
24. type batteries are for starting purposes only and are not intended for power mobility products Deep Cycle batteries are FAA and DOT approved and are the safest for transport both private and public Deep Cycle batteries are Maintenance Free batteries NEVER open or modify Deep Cycle batteries DO NOT have a memory NEVER allow Deep cycle batteries to completely discharge The depth of discharge does effect the life of Deep Cycles batteries the greater the discharge the sooner they will need replaced g Systems Use only manufacturers charger on all models and no more than 8 amps MAX Charge Deep Cycle batteries frequently to maintain a high level of charge Charge mobilty products with the power ON to reduce current rollback All Deep Cycle batteries have a Break In Period of 20 days Charge power mobility products everyday for the first 20 days reguardless of use Charging of power mobility products may take 8 hours under normal use and up to 16 hours with severely discharged products NEVER top off power mobility products with short charges once recharging begins it must be allowed to finish This could take 10 hours NEVER leave charger connected for times exceeding 36 hours NEVER charge power mobility products with both an ON BOARD amp OFF BOARD chargers at same time DO NOT use an extension cord to charge power mobility products DO NOT charge power mobility products outside Chargers may get warm if excessive hea
25. wheelchairs utilize a battery box harness and a charger harness that have the remote possibility to short and cause a fire While the likelihood of this occurring remains remote all potential for fire must be eliminated If you have a consumer who has purchased a power wheelchair during these time periods please contact Invacare for details on how to get the new components installed Power Mobility Guide Rev 1 09 TER 1 12 INVACARE SERVICE amp PARTS INVACARE SERVICE amp PARTS Power Drive Systems Visit the Technical Zone at www invacare com or Call us Toll FREE at 1 800 832 4707 Service amp Parts Education M1 AND M2 MOTOR ERROR CODES E09 AND E10 IMPORTANT RWD chairs will display Error Codes and represent them in the following manner RWD M1 z RIGHT SIDE MOTOR BRAKE ERROR RWD M2 LEFT SIDE MOTOR BRAKE ERROR CWD chairs will display Error Codes and represent them in the following manner CWD M1 z LEFT SIDE MOTOR BRAKE ERROR CWD M2 RIGHT SIDE MOTOR BRAKE ERROR Troubleshooting Tips e Before unplugging the motor lead to test for resistance note the orientation of each lead plugging into the motor slots on the controller e Mark leads if necessary going into the controller M1 and M2 e Ohm each connector one at a time to ensure that they don t get mixed up when plugging them back into the controller LJ cw RWD Storm Series Power Mobility Guide Rev 1 09 TER 2 1 Servi
26. Replace gearbox Replace motor Bad internal bearings replace motor Tighten loose hardware Replace brake coil Repair micro switch readjust switch or replace brake coil or complete motor Check motor connector and brushes replace if necessary Hecalibrate motors Power Mobility Guide Rev 1 09 TER 4 6 Service amp Parts Education MOTOR GEARBOX BRAKES TROUBLESHOOTING GUIDE Motor fails to start after initial installation Motor is running then fails to restart when stopped Motor runs but loses power Scooter or Chair loses all power while driving Power Mobility Guide Rev 1 09 TER Motor is miswired Battery voltage is too low Switch motor leads Heavy load on the motors and chair is in the Current Rollback mode Circuit breaker may have tripped Blown fuse in Wiring Harness OHM out motor to check for possible internal damaged Worn out brushes may be possible Controller power stage board or relays may be damaged Controller senses heavy load and has entered the Current Rollback mode Soft Stop is engaged If key power is turned OFF while driving the chair artificially holds power for 1 5 seconds slowly decelerating until to a Stop 4 7 Corrective Action Verify wiring to motor from controller Check batteries and re charge if necessary Replace motor or controller Leave power ON and allow controller to count down and recharge the chair overnight wi
27. TER ig INVACARE SERVECE R FARTS Service amp Parts Education POWER WHEELCHAIR TROUBLESHOOTING PROCEDURE 1 Check the static battery voltage with a digital multimeter otatic DC Volts at Charger Connector 2 lest battery charger to ensure that it is functioning properly DC Voltage at Batteries with Charger ON 3 Check all fuses and connections for damage e Battery Box Fuses OK Bad e Wiring Harness Fuses OK Bad e Motor Connections OK Bad e Joystick Connections OK Bad e Control Module Connections OK Bad Power Seating Connections OK Bad 4 Test both motor and brake components with a digital multimeter Test Motor Connection 5 5 Ohms Good higher Ohm reading indicate internal problems RWD CWD RT M1 ohms LT M2 ohms LT M1 ohms RTM2 ohms M1 Motor Brushes OK Bad M2 Motor Brushes OK Bad Test Brake Coil make sure the lever is engaged 40 80 Ohm Ranges Good O L indicates an internal problem M1 Motor Ohms M2 Motor Ohms M1 Micro Switch OK Bad M2 Micro Switch OK Bad 5 Check the Others Menu for any error codes with a remote programmer First 3 Error Codes Power Mobility Guide m Rev 1 09 TER 6 INVACARE SERVICE amp PARTS Battery and Charging Systems Visit the Technical Zone at www invacare com or Call us Toll FREE at 1 800 832 4707 Service amp Parts Education BATTERY SIZES CHART Battery Type TDX3 22NF GR24 TDX4 22NF GR24 TDX5 22NF GR24 TDXSP 22NF TDXSC U 1 TDXSI 22NF
28. Tremors Higher value delays response from joystick commands Lower value increases respones from joystick commands Torque Sets how quickly the chair has the power available to it Simular to acceleration torque ramps up to the full power level allowed by the controller Used to climb over obsticals or ramps In MK6i adjust torque in 4 ohms increments only High torque value could cause the chair to overheat Low torque could cause the chair to stall at obsticals Power Mobility Guide Rev 1 09 TER 3 6 Service amp Parts Education MK6i NX PROGRAMS MENU The second option in the main menu is Programs or Standard Programs The Programs menu is used as a reference point for initial set up of a power wheelchair for final settings or whenever major changes have been made in the Performance Adjust and a starting point has to be reestablished This setting also sets the motor configuration on the NX level of electronics Always set this initially before changing any perfomance changes Once any Performance Adjustment has been made in MK6i the Programs values must be reset manually To set the Programs you will set the motor configuration type of chair and motor type pole Controller Type Motor configuration Forward Speed Turning Speed Acceleration Fwd Acceleration Rev Turn Acceleration Turn Deceleration Braking Forward Braking Reverse Reverse Speed Tremor Dampening Torque ohms Power Mobility
29. a ET E E A E E 3 5 MK6i NX Performance Adjust Menu s icoodau ena sci ront E pax eh ian etat ano bark pae rndamen oec rt deek erba cen dix etat initia 3 6 MOR FOTS Om 3 7 MON ee EE 3 8 MK6i NX Error Codes Description Lausanne ibstqnc St dael enden buit oesbuups laesi mt uS Cu DEnP Un uiri bau Ses adi E 3 9 Power Mobility Guide Ere Rev 1 09 TER INVACARE INVACARE SERVECE R FARTS Service amp Parts Education TABLE OF CONTENTS Section 4 MK6i Troubleshooting and Diagnostics MK6i Troubleshooting and Diagnostics i c riter ara en soto euet tameu e Fanta in aha cues senec ntn nne o due 4 1 Battery Troubleshooting Guide EE 4 2 Charger Troubleshooting GUI muntau at une ni datas lanea niad aada Ke aasid dae ieca lusu duis dba nd cde 4 3 Wiring Iroubleshooting era 4 4 Motor Gearbox Brakes Troubleshooting Guide cccccecccceccsseeeeeceeeeeeeeceeeeseeeseeeeceeseeeeeeeessseeeeeseas 4 5 MK6i Formula TRE amp OG Troubleshooting Guide soc ccee csicdconsanweitionsnrcccccesancenccadnctandeoendemolindnedeccesstactens 4 8 MK6i PTO PIUS amp Super Low Troubleshooting Guide os sscssnssccvernacnt aterm rnnt dre eua cr ERE er docs nie 4 9 MEN ENN 4 10 MOEN 4 12 ME TA SN 4 13 MIKS gt GB ESS KE EE Pu NE Tr tuse dU UR iS 4 15 MK6i EX Error Code NNN m 4 16 Understanding Current RO IDACK nete torna taie o peti pec hi cade cehinetenctusdeeedtectavadornseesesSecieueds 4 20 Understanding Torque amp Power EeVel u s ueecciitusici ethos tent to suu r
30. aaes 1 9 Off Board Fully Automatic Battery Chargers v u asset sie rte vrbe oi EDU beet aie Risus acer E Ree ote gEs 1 10 Battery Charger Troubleshooting Tips lessen enne nnne 1 11 VIN AAS TE Ma RE mmm 1 12 Section 2 Power Drive Systems M1 and M2 Error Codes and Motor Troubleshooting cccccseeccceeceeeeeeeeseeeeeeeseeeeseeeseaeeseessseeeeeeeas 2 1 bea erede ein ETT R 2 2 Permanent Magnet DC Motors How does it work cccceceeeceeseeeeeeseeeeeeeeeseeeseaeeeseaeeesseneeeeaaeeeeens 2 3 DC Motor Component Identification amber anda iR btoracniDudu ans Duo ratu Rn usu imta 2 4 Gearbox and O76 Ule EE E T ODE NE 2 5 BG orci une s 2 6 2 Pole Motor Brush Removal and HeplacelrTielil succcuipavuucesekeiitnerens cxi kx en pica C Eua Pau ets name nd tee ip en 2 7 2 Pole Schmitt and 4 Pole Motor Brush Removal Replacement esee 2 8 Electromechanical Parking Brake Testing savne naermere 2 9 2 Pole Motor Brake Replacement EEE gurssanboontanavtadianntesunieshasoniaanamiepenacete 2 10 4 Pole Motor Brake FN Eee de 2 11 GB MIDO EEE A E 2 14 GB Motor Calibration Procedure Lurer eee 2 15 Section 3 MK6i Consumer NX Electronics MO Gornsumer NX BEG ONS Lanserer utut RUE Lees aem aieeaa kanani 3 1 MK6i Single Purpose Joystick SPJ vase eee 3 2 MK6i SPJ Joystick Cable amp Controller Cable esses nnne 3 3 MKG CONYO WO CUES NG 3 4 Mises Mmdfero AIO arer
31. able All Fault 11 Electronics Fault Thermistor 12 Calibration Setting Fault 9 E09 00 Communication Fault Remote Connection Lost 01 Low Communication Mode 10 E10 00 General Fault General Fault 11 E11 00 Incorrect Remote Incompatible Remote Power Mobility Guide Rev 1 09 TER 3 9 INVACARE SERVICE amp PARTS INVACARE SERVICE amp PARTS MK6i Troubleshooting amp Diagnostics Visit the Technical Zone at www invacare com or Call us Toll FREE at 1 800 832 4707 Service amp Parts Education MK6i TROUBLESHOOTING amp DIAGNOSTICS This section contains troubleshooting for both NX and EX levels of electronics Each section of this book goes over troubleshooting of the 5 main components of Invacare s power wheelchair This section primarily contains the Error Code Listing Power Mobility Guide Rev 1 09 TER 4 1 Service amp Parts Education BATTERY TROUBLESHOOTING GUIDE Possible Cause Corrective Action Batteries won t charge Batteries have short driving range during a single charge or battery gauge falls off faster than normal Blown fuse in wiring harness or charger Charger not plugged into outlet No AC power at the outlet Charger power cord may be damaged or the connector may be damaged Charger may have internal damage Battery voltage too low for charger to start charging cycle Consumer not charging batteries long enough Batteries may be weak Check programming settings
32. aft S Release the brake lever to realign the brake coil pad if necessary Reattach the brake coil to the motor housing using the fasteners you removed in step 2 8 Reapply the protective covering or use new material to protect the wiring from being damaged Then slide the Anderson housing on before reassembling the individual Anderson connectors to the contacts The two brake coil wires go together side by side and the red and black motor connectors go beneath the brake coil connectors View the opposite motor connector in case you have forgotten 9 Before reattaching the motor to the power chair temporarily hook it up the controller Test your repair for the brake coil by raising the drive wheels off of the ground Verify again that the drive wheels are off of the ground and power up the chair with both motors engaged If the joystick is equipped with a speed potentiometer turn it down to the slow setting Raise both of the drive Give the joystick a forward and reverse wheels off of the ground command to verify the motor and brake pes Cue pen Horn of both caters before operation if an error code exist E09 or testing motor and brake E10 call Technical Services assembly Power Mobility Guide Rev 1 09 TER 2 13 Service amp Parts Education GB MOTORS Gearless Brushless DC Motor A DISCOVERY FROM THE PAST THAT WILL CHANGE THE FUTURE It was once one of those moments of discovery that is easily taken for
33. and turn the key off then back on Look at the Status Indicator LED you should notice a solid green LED if you do you should be able to drive the scooter Test drive the scooter while the wheels are still raised 3 amp 4 Using the DS100 programmer to calibrate the throttle potentiometer Power Mobility Guide 5 6 Rev 2 08 page 7 Service amp Parts Education SCOOTER PROGRAMMING INSTRUCTIONS 1 Turn OFF the scooter 2 Remove the seat the foot board mat and the controller cover pan WARNING The scooter cannot be driven while the programmer is plugged into the controller Before making any connections to the controller either elevate the drive wheels or secure the scooter 3 Turn the scooter ON 4 Locate the programmer socket 5 Remove the protective plug and plug in your scooter Programmer 6 Press the MENU key to scroll through all of the menus available see chart below Main Menu Options 1 Setup Menu Allows the scooter to be customized for the user s driving preferences or environment Adjustable feature include Acceleration Deceleration e Forward Speed e Reverse Speed e Reduce Speed e Buzzer Volume e Sleep Time e Park Brake Delay 2 Options Menu Allows you to change two factory preset values Pot Reverse e Enable Sleep e Sleep Beep e Sound Fault 3 Speed Lever in Neutral Menu Allows you to calibrate the throttle about neutral 4 Controller Version Menu Provides you with
34. ce amp Parts Education DC MOTOR IDENTIFICATION Invacare has two types of motors pole motors and GB motors A Pole motor is a motor with brushes that make connection between the communtator and the motor connection Pole motors are further defined by the number of motor brushes 2 Pole motors have either 2 internal or external motor brushes 4 Pole motors all have 4 external brushes and have a removable gearbox while coming geared standard or for heavy duty applications GB motors have NO brushes or gears and is considered an electromagnetic motor 2 POLE DC MOTORS 4 POLE DC MOTORS Schmitt motor with 2 external High speed or H D motors brushes m with 4 external brushes GB MOTORS Older 2 pole motor with 2 internal brushes M41 motor with 2 internal GB motor with NO brushes brushes or gearbox TECH TIP Knowing the difference in the motor types and how the chair was set up originally will help in replacing the motor with the correct one and choosing the correct programming profile Power Mobility Guide Rev 1 09 TER 2 2 Service amp Parts Education PERMANENT MAGNET DC MOTORS DC Motor Operation Electrical current supplied by the power wheelchair batteries passes through the motor brushes to the windings and energizes the coil and laminations thus it becomes an electrical magnet One end magnetizes as the north pole and the opposite as the south pole The north pole windings are positioned next to the motor casin
35. ches its cutoff voltage point Once the cutoff voltage is noticed by the charger the charger will automatically stop charging the batteries Fully Automatic Chargers also have a start up voltage reference point The term Start up Voltage means that once the battery charger is plugged in and turned ON it must notice a minimum voltage in order to stay on and recharge the batteries 24 Volt 2 Amp Battery Charger on board 2 amp On board battery chargers have a start up voltage of 20 22 VDC These chargers have no on off switch or fuses also it determines battery type and adjusts the cut off voltage accord E ingly These chargers also have 1 LED that light up to inform the user that the power is on and the charging condition These chargers are normally found on scooters 24 Volt 3 Amp Battery Charger on board 3 amp On board battery chargers have a start up voltage of 18 22 VDC These chargers have no on off switch or fuses also it determines battery type and adjusts the cut off voltage accordingly These chargers also have 2 LED s that light up to inform the user that the power is on and the charging condition These LED s also will show faults in the system These chargers are normally found on scooters and low end consumer power chairs 24 Volt 5 Amp Battery Charger on board 5 amp On board battery chargers have a start up voltage of 18 22 VDC These chargers have no on off switch or fuses also it determines battery type
36. ctronic Temperature Gauge Eye Wash Wheelchair Scooter Lift Safety Glasses Computer with Internet Access Shop Apron Instant Camera or Digital Camera Rubber Gloves Cell Phone Antibacterial Cleaner Portable Van Ramps Lint Free Shop Rags Invacare IVS Software Back Support Devices 1 4 and 3 8 Torque Wrench Baking Soda RPM Gauge for Motors Anti Static Strap Line Amp Gauge for Motor Leads Sor 2 INVACARE SERVECE R FARTS Service amp Parts Education SERVICE MANUALS You can download a FREE copy of all manuals from our website at www invacare com or place an order with our parts department Service Manual Part Number Lynx Panther Scooters 1091860 Invacare Scooter 300 amp 400 HMV 1122167 Invacare Scooter 220 HMV 1125065 At m amp Atm QT 1125078 Pronto M41 1145724 Pronto M50 51 61 1125075 Pronto M71 1118377 Pronto M91 94 1125038 Pronto R2 amp R2 250 1098315 Formula PTO Plus 1125031 Formula TRE 1123820 Adjustable ASBA Seating 1143238 Power Mobility Guide Rev 1 09 TER 3 INVACARE INVACARE SERVECE R FARTS Service amp Parts Education WHAT CONSUMERS NEED TO KNOW ABOUT POWER MOBILITY PRODUCTS Recommendations courtesy of Invacare amp MK Battery Batteries EE X Chargin ALWAYS follow the manufacturers recommendations for battery type and size ALWAYS use Deep Cycle batteries due to the fact that they are designed to be discharged and recharged on a regular basis Cold Cranking Amp or Marine
37. d it may cause severe damage to the motor To inspect the coupler you will need to remove the motor refer to the service manual for motor removal instructions 1 Inspect gearbox output 2 Inspect the entire casing for shaft for damage and leaks including the area check keyway slot for where the motor coupler is damage located 4 Pole Gearbox Drive Ratios 18 1 High Speed Or 24 1 Heavy Duty High Speed GT CWD Power Mobility Guide Rev 1 09 TER 2 9 Service amp Parts Education DC MOTOR TESTING AND BRUSH INSPECTION 1 Turn the power OFF on the chair and disconnect the motor lead you wish to test 2 Setup your multimeter to take an Ohm reading 3 Measure the resistance on the two 2 motor contacts be sure to rotate motor and take at least two readings A normal reading is between 5 to 5 ohms Areading of O L Overload or in excess of 15 Ohms indicates a problem High readings are generally caused by bad contacts worn brushes and internal motor problems Most motor problems can be fixed by replacing motor brushes and completing the brush seating procedure see page 2 9 MK5 amp MK6I MKIV Motor Motor Test Point Test Point 4 Inspect brushes and the motor communtator for abnormal wear replace brushes if necessary After replacing brushes refer to page 2 7 for brush seating procedures 1 Remove brush cap with a flat screwdriver 2 Remove the brush and inspect it for wear When should you re
38. d with the charger and view the diagnostic codes printed on the charger for LED indicator explanation Power Mobility Guide Rev 1 09 TER 1 11 Service amp Parts Education 1 WIRING HARNESS TESTING Check the wiring harness for visible damage broken loose connections and corrosion If any damage is found replace harness If the damage is due to corrosion clean all connections thoroughly Corrosive connections can create high resistance which could cause problems with the electronics 2 Checkall fuses in the system including the fuses inside the battery boxes 3 When checking the wiring with your multi meter be sure to move the connection around while testing By moving the wiring around while your test leads are still in place you will notice intermediate connection problems TECHNICIANS NOTE Use your multi meter to perform an audible continuity test or take an Ohm reading should see less than 1 Ohm Check all connections for damage or corrosion if either is noticed replace wiring with OEM parts 3 TECH TIP If the wiring was damaged due to incontinence replace immediately Cut an old pneumatic tire tube into six inch sections and slip them over the new connections and tie wrap each end to protect the new connections Invacare Corporation has initiated a field correction involving certain Invacare power wheelchairs manu factured from 1988 through June 2000 Some of these power
39. damaged wiring 3 Inspect the 3 amp fuse on the P C B for a blown filament 4 Inspect the P C B for damage or loose connections 5 Make sure key switch and P C B attaching hardware is tight SCOOTER CONTROLLER INSPECTION 1 Remove the 6 push pins that secures the foot board mat to the base Then remove the 2 screws that secures the controller cover plate 2 Inspect wiring and controller for loose or broken connections damage and corrosion Replace if needed 3 Inspect the 5 amp fuse in line to the controller for a blown filament 4 Use programmer to check for error codes Power Mobility Guide Rev 2 08 page 5 9 4 Service amp Parts Education SCOOTER THROTTLE POT CALIBRATION PROCEDURE Manual Adjustment without DS100 Programmer This procedure should only be done if one of the following occurs Scooter will not drive and 6 flashes are noticed on the Status Indicator LED After Replacing a Throttle Assembly and the ocooter will not drive 6 flashes are noticed on the Status Indicator LED 1 Turn key off and disengage the brake lever at the back of the scooter Place an object under the frame to raise the drive wheels off of the ground for testing purposes Locate the 2 phillips head screws underneath the tiller display and remove them Locate and remove the 2 phillips head screws on the throttle handle the throttle handle base should remain 2 Using a 2mm hex head tool loosen th
40. ducation MK6i NX PERFORMANCE ADJUST MENU The first option in the main menu is Performance Adjust menu The Perform Adjustment menu is used to modify driving parameters of the power wheelchair These parameters are modified to enhance the performance of the power wheelchair for the end user Forward Speed Sets maximum forward speed Turning Speed Sets maximum turning speed Acceleration Fwd Sets how quickly the controller allows the chair to accelerate when the joystick is moved in a forward direction from neutral Acceleration Rev Sets how quickly the controller allows the chair to accelerate when the joystick is moved in a reverse direction from neutral Turn Acceleration Sets how quickly the controller allows the chair to accelerate when the joystick is moved in a left or right direction from neutral Turn Deceleration Sets how quickly the controller allows the chair to decelerate when the joystick is moved from a left or right direction to neutral Braking Forward Sets how quickly the controller allows the chair to decelerate when the joystick is moved from a forward direction to neutral Braking Reverse Sets how quickly the controller allows the chair to decelerate when the joystick is moved from a reverse direction to neutral Reverse Speed Sets maximum reverse speed Tremor Dampening Is used to adjust the sensitivity of the joystick out of the neutral position Often used to assist end users with Ataxia
41. e 2 set screws slightly do not remove the screws 3 Turn the key to the on position and locate the throttle potentiometers red and white wires Use a multimeter to take a DC voltage reading from the red and white wires You should see a reading of 2 5 VDC 4 2 A normal reading is 2 Loosen the two 2mm hex around 2 3 VDC but if you are experiencing 6 head screws slightly flashes on the Status Indicator LED the throttle pot needs to be re calibrated 4 lore calibrate the throttle pot leave your digital multimeter hooked up to the red and white wires and use a small flat common screwdriver to adjust the throttle pot Turn the pot clockwise or counter clockwise until your multimeter reading is around 2 5 volts 2 When you have recalibrated the pot tighten the two set screws Engage the brake lever and turn the key off then back on Look at the Status Indicator LED you should notice a solid green LED if you do you should be able to drive the scooter Test drive the scooter while the wheels are still raised 3 amp 4 Using a digital multimeter re calibrate the throttle potentiometer Power Mobility Guide Rev 2 08 page ft 6 9 5 Service amp Parts Education SCOOTER THROTTLE POT CALIBRATION PROCEDURE Adjustment with DS100 Programmer This procedure should only be done if one of the following occurs Scooter will not drive and 6 flashes are noticed on the Status Indicator LED After Replacing
42. e default voltage for zero speed is 2 5 VDC Range After entering this menu option loosen the two set screws in the throttle pot assembly and rotate the throttle shaft slowly until the buzzer sounds If the controller version is 2 46 or higher the status light will also glow e Press ENTER to confirm the value when finished CONTROLLER VERSION 1 The CONTROLLER VERSION Menu Option will display the current version of software SCOOTER SPECIFICATIONS LYNX L 3 LYNX L 4 Base length 39 8 Base Width 20 Step Height floor pan to ground 4 Seat Height floor pan to seat 14 16 Overall Height 36 Width Depth Back Height Length 11 6 Height between seat amp arm 9 Width between arms 15 22 Tire Size Front 8 xX 2 Rear 8 xX 2 Turning Radius 39 4 Product Weight me Front base section Rear base section Seat Battery Charger Box Total Weight 103 Ibs 112 Ibs Power Mobility Guide 5 9 Rev 2 08 page 10 Service amp Parts Education SCOOTER ERROR CODES The scooter tillers are equipped with a status indicator LED that will flash diagnostic code information The status indicator LED will flash in burst separated by a pause to provide diagnostic information See page 5 3 for tiller faceplate status indicator light location Number Impact on of Flashes Scooter 1 Battery needs Will Drive recharging 2 Battery Voltage Drive too low Inhibited 9 Battery Voltage Drive
43. eason for this procedure is that if either battery is not FULLY charged it will begin to sulfate This happens because Lead Sulfate produced in the discharge process is not completely removed and begins to set up crystalline structures which will not return to acid and lead in the recharge process This typically is the reason for reduced capacity range in fairly new batteries Reduced capacity range can be due to a mechanical failure charger connection wiring etc or a consumer problem too short a charging routine incomplete charging Charging is also not a one time function A batteries depth of discharge resistance level less than 50 affects its ability to accept full charge current 10096 when in the initial charge process Also time of use does not correspond directly to recharge time requirements Source MK Battery Technical Manual www mkbattery com Power Mobility Guide Rev 1 09 TER 1 4 Service amp Parts Education BATTERY STATE OF CHARGE A battery state of charge or a static voltage reading is a test of the battery voltage while the power mobility product is at rest not driving Use a digital multimeter to check the static battery voltage by Inserting the multimeter leads into pins 1 and 2 of the charger programmer port on the front of the driver control see diagram below If you receive a negative reading on the meter switch the leads to the opposite pins Do not allow the leads to touch each
44. ect the current draw through the controller e The higher the Torque the faster the controller sends high current to the motors e The higher the Power Level the more current the controller will allow the motors to draw under load e The higher the Speed the more voltage the controller sends to the motors e The more Front Loaded the chair is the more power the motors need to move the chair through the resistance of the weight over the casters High Torque High Power Level High Speed Extended Driving Time Stress to the Motors Potential for Current Rollback Continuous driving with these high levels would be similar to a fighter jet continuously flying with the After Burners ON The controller may build up heat Current Rollback and the battery charge would be more quickly depleted There is no specific fault code for Current Rollback Users may complain of an intermittent cutout of their chairs operation or a sensation of loss of power If Current Rollback does occur the chair will still drive for a period of time before cutting out completely In a Current Rollback condition the controller cuts back on Current Voltage to the motors in an attempt to prevent a complete shut down or the wheelchair will shut down as the controller protects the power stage board e As the current counter inside the controller approaches a preset cut off value it cuts the power output to try and prevent complete shut down e f the user continues
45. enti opa qu ba ebbe min eee bt ete zen F uses saperet bude 4 21 Section 5 Scooter Troubleshooting Troubleshooting dfe mio Ree EE OO E T meds 5 1 Rear Base Assembly and Battery Charger Box Inspection rrrrrannrrrrrrnnnnnovnrnnnrnernnnnnnnennnnnanrrnnnnnnnee 5 2 Molor and Brak Testing MEE ET OO EO Om ORE 5 3 Front Console nd Controller Inspection ics wsaniceSusessccncasscecsieceesinedsdeng oeuet abide oppose tau densa Ubi tns Qt pen E rad o 5 4 Throttle Pot Calibration Procedure iccc tette niente Ian et eneeier np bux KU bibam cuudE 5 5 Programming SCHON NER TOO 5 7 Scooter ENN 5 10 Enor OOd EEE EN EN 5 11 Power Mobility Guide es Rev 1 09 TER pI N VACARE INVACARE SERVECE R FARTS Service amp Parts Education CONTACT LIST Technical Support Hotline Calling Tips 1 800 832 4707 M Please write down the model and serial number v Please write down the software version and error codes MI It is necessary that you are with the product before contacting technical support vi Before troubleshooting any chair make sure the batteries are in good condition Miscellaneous Contacts Phone and website MK Battery 1 800 372 9253 www mkbattery com TASH 1 800 463 5685 www tashinc com ASL 1 800 626 8698 www asl inc com Peachtree 1 830 693 6030 www asl inc com Magitek 1 800 347 9928 www magitek com New Abilities 1 800 829 8889 www newabilities com Therafin 1 800 843 7234 www therafin com U S Rehab 1 800 987 7342
46. g errors and verify that the Tilt Recline menu option is not OFF INVACARE SERVICE amp PARTS Service amp Parts Education MK6i NX TROUBLESHOOTING Charger Programmer Port BDI Lights Service Indicator The SPJ has limited programming that is contained in the Control Module There is No reprogramming necessary if replaced Charger Programmer Port Is the location where programmer plugs into for programing the Control Module which contains the fault log Service Indicator This Amber light informs the driver and technician when an error or fault occurs This light flashes a number of times with pause in between indicating the actual problem See error codes list Battery Display Indicator Lights will flash if in drive lockout informing the end user that the power wheelchair will not drive These indicator lights will also flash if charger is running MK6i Control Modules in NX level of electronics holds all programming aspects including any faults and error codes In the EX level of electronics all programming aspects are stored in the driver control Never open or modify control module Power Mobility Guide Rev 1 09 TER 4 10 Service amp Parts Education MK6i NX TROUBLESHOOTING Up Arrow Key Pwr Info Key Down Arrow Key MK6i Programmer gives diagonostic information in the control module On NX level of electronics this programmer will operate as a MK5 programmer and can not be utilized in conjunction wi
47. granted by later generations English physicist Michael Faraday had studied early experiments in electromagnetism with great interest In fact he had already created the world s first electric motor a crude model in which a wire rotated around a fixed magnet But if an electrical current could influence a magnetic field Faraday reasoned then perhaps the opposite was true as well He set a magnet spinning within an uncharged horseshoe shaped coil And true to his hypothesis the magnet s motion generated an electric charge in the coil What Faraday had discovered was the phenomenon of induced electromagnetism What he had created was the world s first electric generator GB Motors are Non Serviceable Heavy Duty GB Motors used on chairs after to February 2003 TECH NOTE When replacing a GB motor or controller you must calibrate the motors with your Remote Programmer See page 2 15 for the Calibration Procedure Power Mobility Guide Rev 1 09 TER 2 14 Service amp Parts Education GB MOTOR CALIBRATION PROCEDURE On chairs equipped with GB motors motor calibration must be done when the following conditions occur e When replacing a GB Motor e When replacing a GB Controller NOTE An Invacare Remote Programmer is necessary for this procedure 1 Raise both drive wheels off of the ground and block the front casters to prevent the chair form rolling forward The chair must be secure to prevent any injuries 2 Engage
48. gs north pole permanent magnets and the south pole of the windings are positioned next to the motor casings south pole permanent magnets Armature rotation is caused by like poles repelling and opposite poles attracting one another The direction speed torque and braking of the motor is controlled by the wheelchairs electronics North Pole Magnet Magnetic Field Lines Motor Brush i 17777 South Pole Armature End of motor shaft that connects to the gearbox i Motor Brush Magnetic Field Lines South Pole Magnet Power Mobility Guide Rev 1 09 TER 2 3 Service amp Parts Education DC MOTOR COMPONENT IDENTIFICATION 4 Pole Shown in Illustration Gearbox Motor Coupler Brush Housing Cap Motor Housing Motor Brush Brake Coil w Lever Brake Cover m ake H 9 O RCM Laminations may be straight or skewed Windings Bearings Motor Shaft Drive Nut Bearings Communtator Segments Power Mobility Guide Rev 1 09 TER 2 4 INVACARE SERVICE amp PARTS Service amp Parts Education GEARBOX AND COUPLER INSPECTION Power wheelchairs equipped with a conventional DC motor with a removable gearbox come equipped with a serviceable motor coupler The motor coupler provides a flexible connection between the motor and the gearbox it will eventually wear out over time If it is never service
49. h not recommended This charger has 4 led s that light up to inform the user that the power is on and the charging condition These led s also will show faults in the system OFF BOARD CHARGERS Advantages no switches to confuse user easier to see status lights easier transport stays with product faster charge times Disadvantages Disadvantages harder to see status lights heavier harder to transport slower charging times Power Mobility Guide Rev 1 09 TER user may notice charger heating up Service amp Parts Education BATTERY CHARGER TROUBLESHOOTING TIPS LA 24 Volt P INVACARE Fully Automatic Battery Charger Yes you can ORJ SPECIAL APPLICATION TYPE OF BATTERY CONVENTIONAL UF FOR CO 3 WET LEAD ACID ACID sl DONWHN FOR SEALED MAINTENANCE FREE GEL CELL GEL E Possible Cause Corrective Action No power Bad power cord Replace power cord Bad AC outlet Replace outlet Blown internal fuse Replace fuse owitch not turned ON Turn ON power switch Bad LED on panel Send in for repair Internal damage Send in for repair Charger ON batteries Static battery voltage too low Test batteries or not charging as a pair replace if necessary Charging cycle starts Bad Connection Replace connector then stops or replace wiring harness Short charge time One or both batteries Test batteries or may be bad replace if necessary NOTE Read all instructions provide
50. ing driving uses the values to generate a full speed command whenever that displacement is reached Exceeding this displacement does not provide further increase in speed The result of this method of calibration is a customized driving template The Joystick Throw in MK6i NX level of electronics is seperated into three level Normal full displacement of the inductive to access full programmed speed Short half displacement of the inductive to access full programmed speed Very Short quarter displacement of the inductive to access full programmed speed Fault Log shows the error codes that have been detected by the diagnostic system since the control module was built in the factory The Fault Log can be used by the service technician to uncover the cause of intermittent faults that may not be evident when the wheelchair is being serviced Usage Statistics displays how long the wheelchair has been on in hours minutes the total number of times the wheelchair has been powered up and how many times the wheelchair has been driven Power Mobility Guide Rev 1 09 TER 3 8 Service amp Parts Education MK6i NX ERROR CODES DESCRIPTION of Times Fault Log FaultLog Error Code Flashes Error Code Sub Code Description Details of Error Code 1 E01 00 User Fault Stall Time out 2 E02 00 Battery Fault Recharge Batteries or Replace 3 E03 00 Left Motor Fault Left Motor Short Circuit 01 Left Motor Open Circuit 02 Left Motor Connection Fault
51. minutes or more Check the Power Seating menu to verify Speeds Check Powered Seating menu to verify proper programing and Diagnostics menu for version Check for 24 VDC when switch is activated with a multimeter at the actuator connector Switch actuator leads from a functioning actuator to the one that is not working activate switch to verify if the actuator is bad or the power seating control module is bad Check all Mecury switch on the chair make adjustments or replace Replace joystick or send in for repair Return to seat back to upright position Possible bad wiring harness check pins 2 and 3 on charger connector for 5 VDC reference when seat is below 20 degrees and 0 VDC when seat is tilted beyond 20 degrees Check cables for wiring damage inhibit line or charger plug faulty Check the control module for programming errors and verify the Version through the Diagnostics Menu INVACARE SERVICE amp PARTS Service amp Parts Education MK6i PTO PLUS AND SUPER LOW TROUBLESHOOTING GUIDE SYMPTOM Wheelchair Power ON but does not drive Seating System not functioning or working intermittently E28 Error code System not operating through the driver control Power Mobility Guide Rev 1 09 TER PROBABLE CAUSE System tilted beyond drive lock out angle 20 degrees Low battery voltage Bad Mode switch on MPJ Communication Error in TRAM or SANODE Bad 4 way switch or QPB Actuator HOT
52. mp up to the available power Power Level A common demonstration of the Torque setting was to set the value high and have someone stand behind the chair and try and hold the chair back while someone sitting in the chair tried to drive forward The result being that no matter how hard the person tried the chair would pull from their grip Then turn the Torque setting down and try the same thing The result would have been the same if the second attempt is done for 10 seconds or so The problem was that most people would be able to hold that chair back for 3 or 4 seconds If they would have counted to 10 they would have noticed the power ramping up and the chair would have push them across the room as if the Torque setting was set high in the first demonstration The higher the setting the more responsive the chair becomes to the joystick commands If the Torque value is set too high the chair can have a jerky or jumpy feel If the user complains their power chair is too jerky too responsive too jumpy etc Try reducing the Torque value in the Performance Adjustment Menu with your MK6i Programmer It is common that someone may have previously increased the Torque value in an attempt to give the chair more power a common misunderstanding If the chair is still too responsive the turn down the Speed and Sensitivity or Turn Acceleration and Deceleration A good general rule to follow Low Speeds often require High Torque Values
53. n the positive plate in all lead acid batteries recombines with the hydrogen given off by the negative plate The recombination of the hydrogen and oxygen produces water H 0 which replaces the moisture in the battery Therefore the battery is maintenance free as it never needs water replenishment Source MK Battery Technical Manual www mkbattery com TO CHARGER 24 VOLT How does a Series Connection work with two 12V Batteries Circuit Series Acircuit which has only one path for the current flow Batteries arranged in series are connected with negative of the first to positive of the second negative of the second to positive of the third etc If two 12 volt batteries of 50 ampere hours capacity each are connected in series the circuit voltage is equal to the sum of the two battery voltages or 24 volts and the ampere hour capacity of the combination is 50 ampere hours Power Mobility Guide Rev 1 09 TER 1 2 Service amp Parts Education CYCLE OF DEEP CYCLE BATTERIES DISCHARGE RECHARGE A battery CYCLE is a discharge and recharge of a battery Once a recharging part of the cycle begins the charger must be able to reach its cut off voltage Frequent short charges will decrease the life of batteries by reducing the number of cycles in them ALL SEALED LEAD ACID AND GEL CELL DEEP CYCLE BATTERIES DO NOT HAVE A MEMORY DOES THE DEPTH OF THE DISCHARGE AFFECT BATTERY LIFE YES The greater the load on
54. ndicate a dam aged brake or an open or poor connection respectively 4 Checkthe motor leads for damage or corrosion if corroded or damaged clean or repair connection and re test 5 The controllers will store an E09 or an E10 error code for brake problems try switching the motor leads to ensure that problem is the brake or the controller If you have an E09 error code present switch the motor leads If the error code changes to an E10 the problem is the brake If the error code does not change and still states E09 then the problem is in the controllers brake output section 6 One last test point will be the micro switch that allows the motor to be in the drive mode or the free wheel mode Place your meter leads on the two brake contacts with your meter set up to read Ohms or Continuity Engage and disengage the brake lever and watch your meter you should see a resistance value then a near zero reading as the switch opens and closes If you have a meter that has an audible continuity feature perform the same steps but you will hear and audible come ON then OFF as you open and close the switch If the switch fails this test you must replace the brake or the motor Brake Lever Micro Switch MP Brake Coil IMPORTANT NOTE A bad electromechanical brake will damage the brake output section in the controller DO NOT connect a bad electromechanical brake to a good controller module A bad electromechanical brake MUST be replaced Powe
55. ocated in battery charger box and reset if necessary If circuit breaker continues to trip an electrical problem is present contact Invacare Technical Support Ohm reading should be less than 1 Ohm Replace if circuit breaker has tripped multiple times 110AC Charger Connection Charger LED Circuit Breaker 3 Amp Charger 12 volt Battery Front to Rear Connection Rear Base Assembly Power Mobility Guide Rev 2 08 page 3 5 2 Service amp Parts Education SCOOTER MOTOR AND BRAKE TESTING Motor and Brake Ohm Testing Procedures 1 Before testing begins you will need to remove the seat and battery charger box Then remove rear motor section Tip the rear section on the anti tipper wheels to locate 4 clip connection Inspect these connections for damage or loose connections and corrosion 2 lotestthe motor circuit for proper resistance insert meter leads into M and M Normal motor Ohm range is 5 5 Ohms High Ohms reading may be cause by bad motor brushes 3 lotest parking brake circuit for proper resistance insert meter leads into B and B Normal brake coil Ohm range is 40 50 Ohms Test and inspect the brake coil micro switch for damage Motor Brake Coil Brake Coil Micro Switch Power Mobility Guide Rev 2 08 page 4 5 3 Service amp Parts Education SCOOTER FRONT CONSOLE INSPECTION 1 Remove the 2 screws at the base of the front console faceplate 2 Look for loose connections or
56. onnectors The red and black connectors are for the motor and the two black connectors are for the brake You will need to separate the individual housings from the contacts as shown in the picture to the right The new brake coil will have new contacts already crimped to the wire leads 6 Upon completing step 5 slide the Anderson housing mmm off of the motor lead and remove the protective sleeve to expose the wires coming out of the motor housing 9 Caution Do not cut this protective cover slide it off of the wires unless you have replacement protective covering for the wires If you are cutting off the protective covering be careful not to damage the original motor wiring If you do cut into the insulation of the motor wiring it must be repaired before putting the protective covering back onto the wiring Power Mobility Guide Rev 1 09 TER 2 12 Service amp Parts Education 4 POLE DC MOTOR BRAKE COIL REPLACEMENT continued 7 With the wiring loose and the brake coil screws removed begin to remove the brake coil from the motor housing Pull up on the brake coil and pull the brake coil wires through the opening on the motor housing Mark the brake coil defective and discard it Install the new brake coil and pull the brake coil wiring through the motor housing opening NOTE Before going onto step 8 make sure that the brake coil pad is mated with the hex drive nut on the end of the motor sh
57. or open or short circuits Out of Neutral Drive Throttle is not in neutral position at power up Inhibited when turning the key switch on Return throttle to neutral turn power off and back on again Throttle may need to be re calibrated Check Throttle wiring opeed Pot Drive The throttle or its wiring is faulty Error Inhibited Check for open or short circuits Throttle may not be correctly set up Motor Volts Drive The motor or its wiring is faulty Error Inhibited Check for open or short circuits Other Internal Drive Call Invacare Technical Services at Errors Inhibited 1 800 832 4707 NOTE If the SOUND FAULT ability is enabled the scooter will alarm the same number as the flashing LED Power Mobility Guide Rev 2 08 page 12 9 11 Roadrunner Mobility Corporate Office 717 Lingco Drive Suite 211 Richardson TX 75081 1 800 467 2668 www roadrunnermobility com
58. orarily connect the motor plug to the controller and test the motor before putting it back on the chair Make sure that there are no E09 or E10 error codes when testing motor When testing is complete reattach motor to the chair and test drive chair Power Mobility Guide Rev 1 09 TER 2 10 Service amp Parts Education 4 POLE DC MOTOR BRAKE COIL REPLACEMENT 1 Itis best if you remove the entire motor from the chair Hefer to the Service Manual for motor removal instructions Once the motor is removed from the chair remove the cap on the end of the motor to expose the brake coll 2 Remove the screws that attach the coil to the motor housing 3 The motor lead has a protective sleeve and a strain relief that needs to be removed in order to replace the brake coil Some motors have a plastic threaded nut and others have a plastic connector that prevent the motor leads from being damaged Use caution when removing the strain relief and the protective sleeve due to the fact that they will have to be reused when putting the brake assembly back together Power Mobility Guide Rev 1 09 TER 2 11 Service amp Parts Education 4 POLE DC MOTOR BRAKE COIL REPLACEMENT continued 4 Begin to disassemble the motor connector by removing the roll pin at the top of the connector Then remove the two screws and clamp at the base of the connector 5 Slide the Anderson housing back to expose the individual motor and brake c
59. other while connected this will cause damage to the multimeter and driver control A relatively good reading of a set of gel batteries should display at least 25 0 volts or higher 75 Charger Connector V Static Battery Voltage Test Point Pin 1 positive 4 Pin 2 z negative GEL SEALED Lead Acid Type Deep Cycle Charge Level Specific Gravity Static Reading On Charge 100 N A 25 6 VDC 28 8 VDC 15 N A 25 0 VDC 28 2 VDC 50 N A 24 6 VDC 27 8 VDC 25 N A 24 4 VDC 2 4 VDC DISCHARGED N A 24 2 VDC 27 0 VDC If the batteries are not fully charged or appear weak recharge them overnight before performing a load test Severely discharged batteries could take up to 10 16 hours to recharge back up to 10096 Severely discharged batteries could also rise rapidly giving the charger a false reading causing the charger to shut off too soon Power Mobility Guide Rev 1 09 TER 1 5 Service amp Parts Education FIELD LOAD TEST PROCEDURE Old batteries lose their ability to store release power due to increased internal resistance This means that as you try to take power from the battery some of that power is used up in the process of passing through the battery resulting in less voltage at the posts The more power drawn the lower the voltage available When this lost voltage drops as a pair 0 2 volts the batteries are GOOD 2 2 5 their POOR and 2 5 or higher BAD Testing under a load is the only way to spot this problem
60. place brushes Brushes should be replaced before the tamped shunt wire has a chance to score the communtator and before the brush is at the end of the spring travel When a brush has less than a 1 4 of material remaining it should be replaced Also check the shunt wire for any discoloring and check the spring for damage If either is noticed replace the brush Make sure the brush housing is clean so the brush can travel freely without any resistance Power Mobility Guide Rev 1 09 TER 2 6 Service amp Parts Education 2 POLE MOTOR BRUSH REMOVAL AND REPLACEMENT please order replacement brushes by model Please refer to the specific model power wheelchair p service manual for motor removal procedures if necessary 1 Locate the two phillips head screws at the front of the motor and remove these two screws Remove the long plastic cap and locate the brush assembly on each side of the motor 2 Before removing brushes review these technical tips a The brush spring retainer is not available as a service part caution should be used when removing brushes b The screw and washer that attaches the shunt wire to the motor is not available as a service part caution should be used when removing this screw 3 Remove the screw that attaches the shunt wire to the motor assembly please keep the screw and washer to attach the new motor brush 4 Release the tension on the brush spring retainer with a small screwdrive
61. r and position the screwdriver in place to hold the spring tension Remove the brush and inspect the commutator for damage Place the new brush into the brush housing and release the tension on the spring to hold the brush in place Attach the shunt wire to the motor housing by reusing the small screw and washer to secure the shunt wire Repeat this procedure for the opposite brush 5 Replace the motor cap and screws and the test motor Please review page 2 9 for the brush seating procedure Power Mobility Guide Rev 1 09 TER 2 7 Service amp Parts Education 2 POLE SCHMITT amp 4 POLE MOTOR BRUSH REMOVAL AND REPLACEMENT Brush Seating Procedure 1 Disengage the motors and make sure the poweris off on the display or driver control With a flat screwdriver locate the brush cap and remove the brush cap by turning the screwdriver counter clockwise 2 Before removing the brush for inspection place a temporary mark on the motor casting and on the top of the brush If not replacing the brush with a new one it must be put back Gy ES into the brush holder in its original M S position Remove the brush from p OS the brush holder and inspect the CA brush thoroughly Look for excessive wear or chips in the brush and any discoloration in the shunt wire EPlace temporary narks here 3 Install the new brush or original brush back into the Make sure the chair is brush holder and replace the brush cap turn
62. r Mobility Guide Rev 1 09 TER 2 9 Service amp Parts Education OLDER 2 POLE MOTOR BRAKE COIL REPLACEMENT Please refer to the specific model power wheelchair j service manual for motor removal procedure 1 Locate the two phillips head screws at the front of the motor and remove these two screws Remove the long plastic cap to expose the brake coil assembly on the end of the motor 2 Locate the two white wires on the brake coil and cut off the shrink wrap to expose the wire connectors Cut the wires just below the connector to retain the length of the two black wires on the motor leads 3 Locate and remove the two phillips head screws that attach the brake coil to the motor assembly Remove the brake coil clapper plate with springs friction disk and reaction plate The new brake coil kit will include all of these items to complete the repair 4 Remove the contents of the new brake coil and begin to replace the brake coil assembly The new brake coil is spring loaded so the clapper plate will need to be held together to hold the springs in place Line up the brake coil assembly with the screw holes and tighten the screws to secure the brake coil to the motor assembly 5 Connect the two white wires to the two black wires with an insulated connector and cover the two connections with heat shrink to protect the connections Reverse step 1 and reattach the long plastic cap and two screws to the motor assembly Temp
63. rk Brake Fault Right Park Brake Drive Time Test Failed 01 Right Park Brake Output Enabled When Chair Idle 02 Right Park Brake Output Did Not Enable When Entering Drive Mode 03 Right Park Brake Fault During Power Up Testing 04 Right Park Brake Feedback Low During Drive Park Brake Short 7 E07 00 Remote Fault Local SR Fault CPU EEPROM ect 01 Joystick Fault at the Remote 02 Speed Pot Fault at the Remote 8 E08 00 Controller Fault 01 RAM Fault 02 ROM Fault 03 CPU Fault 04 EEPROM Fault 05 Watchdog Fault 06 Stack Fault 07 Software Fault 08 Power up Testing Fault 09 Relay Fault or Precharge Fault 10 Bridge Fault or Disable All Fault 11 Electronics Fault Thermistor 12 Calibration Setting Fault 9 E09 00 Communication Fault Remote Connection Lost 01 Low Communication Mode 10 E10 00 General Fault General Fault 11 E11 00 Incorrect Remote Incompatible Remote Power Mobility Guide Rev 1 09 TER 4 12 INVACARE SERVICE amp PARTS Service amp Parts Education UNDERSTANDING CURRENT ROLLBACK Current Rollback is a protective condition the controller goes into when heat builds up if the motors ever draw excessive amounts of current through the controller for extended periods of time This condition is protecting the power stage board in the controller This part is approximately a 500 00 value and would be costly to replace The programming values for Torque and Power Level as well as the Center of Gravity setup of the chair do aff
64. seconds with switch depressed Refer to LOAD TEST ANALYSIS CHART AUN LOAD TEST ANALYSIS CHART Meter Action gt 10Seconds Battery Condtion Needle in Green GOOD Needle in Yellow WEAK CHARGE amp TEST Needle in Red BAD REPLACE NOTE Read all of the supplied instructions for analyzer before use Power Mobility Guide 1 7 Rev 1 09 TER 7 Service amp Parts Education RULES FOR CHARGING BATTERIES Rule 1 New batteries MUST be fully charged prior to initial use There have been occasions when new batteries have failed out of the box This will also help in verifing that the charging system is functioning properly Save yourself an unnecessary service call and charge the batteries the night before your delivery or before the customer is scheduled to pick up their chair Rule 2 New batteries DO have a break in period of 20 cycles Regardless of use re charge the batteries every night for the first 20 days After the 20 day break in period re charge the batteries on a regular basis Rule 3 Be aware that if your customer had lead acid batteries and you are replacing them with gel batteries please double check their battery charger If they have a dual mode charger then make sure the switch Schauer and Lester models only is in the correct position prior to initial use permanent damage can be done to a set of batteries if not set correctly see the Owner s Manual or call Invacare Technical Support if not sure If the c
65. t is detected discontinue and call dealer Storing Batteries All batteries should be fully charged before putting the unit away for storage regardless of storage lengthof time It is also recommended that you disconnect the main power source to avoid the possibility of discharging the batteries which could cause perma nent damage Power Mobility Guide Rev 1 09 TER 4 INVACARE INVACARE SERVECE R FARTS Service amp Parts Education WHAT CONSUMERS NEED TO KNOW ABOUT POWER MOBILITY PRODUCTS Recommendations courtesy of Invacare amp MK Battery Pine important information Check all air tires often to ensure proper level of inflation This will result in better product performance DO NOT engage or disengage motor locks clutches with the power in the ON position DO NOT operate power mobility products on roads streets or highways DO NOT travel up or down ramps inclines or slopes greater than 9 degrees DO NOT attempt to traverse inclines with water ice or oil film on it DO NOT enter or exit a power mobility product with power in the ON position Injury may occur DO NOT expose any power mobility product to any liquids or leave in a damp area for prolonged time This could cause rusting and corrosion that will damage the product and void the limited warranty DO NOT lift power mobility products by any removeable parts Damage or injury may occur Power Mobility Guide m 5 INVACARE Rev 1 09
66. th a SD Memory Card Pwr Powers programmer On Off Up amp Down Arrow Keys scrolls through the Others Menu options to access the Fault Log Select Key allows selection into highlighted and modified value Other functions when prompted Tthe first 3 faults are the most recent Error Codes To operate turn ON power wheelchair plug MK6i Programmer into joystick charger pro gramming port press power key on programmer and wait for communication If communi cation error is present disconnect programmer verify power is ON and or test joystick charger programmer port for proper voltage 25 0 dcv or higher then retry The Others menu provides calibration changes and the diagnostic menu that can be utilized to assist in troubleshooting and repair of consumer power wheelchair Motor Balance is a calibration used to correct veer when going straight When performing motor balance you change the value to slower side If major changes to Motor Balance is needed check motors for possible issues Joystick Throw is a calibration used to calibrate the neutral and the full speed travel of the proportional joystick This can be used to recalibrate joystick if relative error code is present Fault Log shows the error codes that have been detected by the diagnostic System since the control module was built in the factory The Fault Log can be used by the service technician to uncover the cause of intermittent faults that may not be evident when the
67. th power ON Heset breaker and check wiring Replace fuse Replace brushes if necessary or replace motor if internal damage is determined Replace controller or send to Invacare for repair Leave the power ON and allow the controller to count down recharge overnight with power ON With key power OFF position wait 10 seconds and turn power back ON Service amp Parts Education MK6i FORMULA TRE amp CG TROUBLESHOOTING GUIDE SYMPTOM Wheelchair Power ON but does not drive Seating System not functioning or working intermittently E28 Error code System not operating through the driver control Power Mobility Guide Rev 1 09 TER PROBABLE CAUSE System tilted beyond drive lock out angle 20 degrees Low battery voltage Blown 15 amp fuse Faulty Connections Communication Error Actuator HOT due to heavy load for an extended period of time Communication Error in TRAM 4WSB SANODE and S4WSB Bad Actuators Bad or Loose Mercury switches Bad mode switch on the MPJ System tilted beyond drive lock out angle 20 degrees Damaged wiring on joystick or 24 VDC power adapter Communication Error SOLUTIONS Return to seat back to upright position Limit switch faulty or out of adjustment Charge batteries and verify load test Replace Fuse on Power adapter Check all connections Save proper 4W STD PRGM in the Calibrations Menu Check turn power OFF to allow electronics to cool down 2
68. the batteries the sooner they will have to be replaced Typical Gel Cell Cycling Ability vs Depth of Discharge Capacity Discharged Typical Life Cycles 500 15 mo 750 2 yrs 1100 3 yrs 75 is the average capacity withdrawn for an active user NOTE Consumers may experience longer or shorter battery life depending on driving charging habits terrain temperature programming values and 24 volt accessories in the system Instructing the consumer is IMPORTANT for maintaining the batteries Power Mobility Guide 1 3 Rev 1 09 TER i Service amp Parts Education SEALED BATTERY BREAK IN PROCEDURE A battery CYCLE is a discharge and a complete recharge A new battery out of the box has 2 cycles completed prior to initial use and about 60 65 capacity while continuing to grow in capacity in as many as 20 cycles Though after 10 cycles a gel battery should reach 9096 capacity or higher When educating your customers about their new batteries it is very important that you inform them about the Break in Procedure and recharge cycle Break in Procedure All deep cycle gel batteries require a complete recharging regardless of use for the first 20 days of use in any power mobility product Failure to do this could shorten the driving range and may effect the overall life of the batteries 12096 Peak Capacity Ca Pacity Wil 100 20 Cycles 9096 10 Cycles Overall Battery Life 6096 2 Cycles The r
69. the motors and plug in the Remote Programmer into the chairs controller 3 Turnonthe chair then the Remote Programmer Select the Calibration Menu and arrow down to Calibrate Motor The programmer screen will prompt you with the following questions 1 WHEELS WILL MOVE DRIVE WHEELS RAISED YES OR NO 2 CHAIR WILL DRIVE ARE DRIVE WHEELS RAISED YES OR NO 4 Pressthe Select button on the programmer to begin the Calibration procedure To CANCEL the Calibration press the MENU button 5 When the calibration is complete the screen will display the following COMPLETED TEST SAVING NEW VALUES TECH NOTE Make sure the rear drive wheels are clearly off of the ground they will begin to MOVE when calibration begins Place an object in front of the two casters to prevent the chair from rolling forward off of the stationary 4 stand Power Mobility Guide Rev 1 09 TER 2 15 INVACARE SERVICE amp PARTS MK6i Consumer NX Electronics Visit the Technical Zone at www invacare com or Call us Toll FREE at 1 800 832 4707 Service amp Parts Education MK6i CONSUMER NX ELECTRONICS Consumer or NX electronics are Invacare s basic electronics that are intended for the basic power mobility product These systems cannot usually be expanded through the electronics and have very limited programming ability All lower end consumer power wheelchairs use a form of these NX electronics Power Mobility Guide
70. the secure the wheels will move screwdriver clockwise to tighten cap DO NOT av OVERTIGHTEN the brush cap tighten and loosen the cap a couple of times to ensure proper seating of the brush in the brush housing After inspecting all brushes on the chair raise the drive wheels off of the ground and block the front casters to secure the chair Do not leave the chair unattended when performing STEP 4 4 Beginthe brush seating process by turning the power on and verify again that the drive wheels are off of the ground Engage the motors and use a rubber band to hold the joystick in the forward position Allow the motors to run in the forward direction for at least one hour After one hour allow the motors to cool off for a half hour and repeat this procedure in the reverse direction After completing this procedure test drive the chair and you should notice an increase in performance Power Mobility Guide Rev 1 09 TER 2 8 Service amp Parts Education ELECTROMECHANICAL PARKING BRAKE TESTING E09 and E10 Error Code Problems 1 Turn the power OFF and disconnect the motor lead you wish to test 2 Setup your multimeter to take an Ohm reading make sure the motor is in the drive mode 3 Measure the resistance in the brake coil by placing your meter leads on the two brake contacts Anormal reading is in the range of 40 80 Ohms depending on type and manufacturer of motor Areading of zero or a very high reading could i
71. ue applied at Power Level the control has more output at a faster time Power Mobility Guide j Rev 1 09 TER 4 14 INVACARE z P INVACARE SERVICE amp PARTS INVACARE SERVICE amp PARTS Scooter Troubleshooting LYNX L 3 amp L 4 Visit the Technical Zone at www invacare com or Call us Toll FREE at 1 800 832 4707 Service amp Parts Education SCOOTER TROUBLESHOOOTING PROCEDURE 1 Check the static battery voltage with a digital multimeter 25 0 VDC or higher OK Battery Voltage VDC 2 lestthe battery charger to ensure that it is functioning properly Plug in the charger and check the on charge voltage at the batteries with a digital multimeter 27 0 VDC or higher OK 3 Checkall fuses and connections for damage loose or broken connection and corrosion e Front Console Fuse 3 Amp OK e Controller Fuse 5 Amp OK e Battery amp Motor Connections OK e Tiller Connections OK e Circuit Breaker Connections OK e Charger Connections OK 4 Test Motor and Brake Connections and measure motor brake resistance e Test Motor Connection M and M 5 to 5 Ohms Good higher Ohm readings indicate internal problems Ohms Motor Brushes OK e Test Brake Coil on B1 and B2 40 50 Ohm Ranges Good O L indicates a shorted Brake Coil Ohms e Check Micro Switch on Brake OK 5 Check the control module for any error codes see error code list on 5 2 amp 5 3
72. ustomer does NOT HAVE a dual mode charger then they will need to upgrade to a newer style dual mode charger Rule 4 Allow at least eight 8 hours for normal charging Larger batteries greater than 55 ampere hours or severely discharged batteries may require up to sixteen 16 hours to be properly charged and equalized If the charger operates for sixteen 16 hours and is unable to fully charge the batteries an internal timer turns the charger off Perform a load test on the batteries to determine if replacements are needed Rule 5 The range per battery charge using recommended batteries should be approximately 5 to 9 hours of typical operation Extensive use on inclines may substantially reduce per charge mileage A good rule of thumb is for every hour of actual drive time you should equal that amount of time or exceed it when recharging Rule 6 Charge the batteries through the power mobility product with the power ON to help eliminate current rollback at start up This resets overheat timer and thermastat to normal levels Refer to the Electronics Service Manuals for further explanation Power Mobility Guide Rev 1 09 TER 1 8 Service amp Parts Education ON BOARD FULLY AUTOMATIC BATTERY CHARGERS All power wheelchairs Invacare delivers today have some form of Fully Automatic Battery Charger as standard equipment The term Fully Automatic means that once a recharge cycle begins the charger will stay on until it rea
73. wheelchair is being serviced Usage Statistics displays how long the wheelchair has been on in hours minutes the total number of times the wheelchair has been powered up and how many times the wheelchair has been driven Power Mobility Guide Rev 1 09 TER 4 11 Service amp Parts Education MK6i NX ERROR CODES DESCRIPTION of Times Fault Log FaultLog Error Code Flashes Error Code Sub Code Description Details of Error Code 1 E01 00 User Fault Stall Time out 2 E02 00 Battery Fault Recharge Batteries or Replace 3 E03 00 Left Motor Fault Left Motor Short Circuit 01 Left Motor Open Circuit 02 Left Motor Connection Fault B 03 Motor Terminal Connected to B 04 Left Motor Voltage Fault 05 Left Motor Bridge Fault 06 Too Many Hardware Current Limit Events 07 Current Offset Out of Range 08 Hardware Current Limit Fault 4 E04 00 Right Motor Fault Right Motor Short Circuit 01 Right Motor Open Circuit 02 Right Motor Connection Fault B 03 Motor Terminal Connected to B 04 Right Motor Voltage Fault 05 Right Motor Bridge Fault 06 Too Many Hardware Current Limit Events 07 Current Offset Out of Range 08 Hardware Current Limit Fault 5 E05 00 Left Park Brake Fault Left Park Brake Drive Time Test Failed 01 Left Park Brake Output Enabled When Chair Idle 02 Left Park Brake Output Did Not Enable When Entering Drive Mode 03 Left Park Brake Fault During Power Up Testing 04 Left Park Brake Feedback Low During Drive Park Brake Short 6 E06 00 Right Pa
74. www usrehab com Motion Concepts 1 888 433 6818 www motionconcepts com The Aftermarket Group TAG 1 888 824 8200 www aftermarketgroup com Invacare 1 800 333 6900 www invacare com Need access to Invacare s Tech Zone for helpful tips and more login using Username techzone Password invacare Power Mobility Guide P ue Rev 1 09 TER 1 LINVACARE INVACARE SERVECE R FARTS Service amp Parts Education RECOMMENDED TOOL LIST Remote Programmer PN 1109091 Digital Multimeter Scooter Programmer PN 1124242 Flashlight Remote Programmer Mk6i PN 1142215 Pitch Angle Gauge Professional SD Card PN 1144515 Basic SD Card PN 1144516 Wire Crimping Pliers Electrical Connector Assortment Tire Tools available from TAG Hex T Handle Wrenches Metric SAE 1 4 Socket Set Metric SAE 3 8 Socket Set Metric SAE 1 2 Socket Set Metric SAE 3 8 amp 1 2 Torque Wrench SAE Wrench Set 1 Metric Wrench Set 4mm 19mm Channel Locking Pliers Vise Grip Pliers Dead Blow Hammer Screw Driver Set Small Pry Bar Set Tape Measures Tie Wrap Assortment shrink Wrap Assortment Brush Chalk Scissors Razor Blade Knife 6 amp 12 Crescent Wrench Tire Gauge Hacksaw Bench with Vise and Bench Grinder Compressed Air Source Drill with Drill Bits Hemote Battery Charger 12 volts Hemote 8 amp 24 Volt Charger Wire Brush Heat Gun omall Files Assorted Fasteners Soldering Iron Glue Gun Safety Items Optional Items for Service Tech s First Aid Kit Ele

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