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Invacare Zoom 300 & 400 Service Manual

1. Tie Wraps Tie Wraps Top View Top of Batteries Tie Wraps Tie Wraps 1 Tiller Wiring Harness Top View Rear Top of Batteries Tiller Wiring Harness Connector Rear Wiring Harness Rear Wiring Harness Connector FIGURE 8 14 Replacing the Tiller Wiring Harness Zoom 400 Part No 1122167 57 Zoom 300 and Zoom 400 SECTION 8 TILLER Changing to Left Handed Operation For this procedure refer to Changing to Left Handed Operation on page 80 Replacing the Throttle Assembly NOTE For this procedure refer to FIGURE 8 15 and FIGURE 12 2 on page 87 1 2 8 Turn power OFF and remove the key from the ignition Perform one 1 of the following to remove the batteries For Zoom 300 refer to Removing Installing the Batteries on Zoom 300 on page 86 For Zoom 400 refer to Removing Installing the Batteries on Zoom 400 on page 88 Remove the upper tiller shroud Refer to Removing Installing the Upper Tiller Shroud on page 44 Remove any RTV sealant from the throttle IDC connector on the PC board Detail A of FIGURE 8 15 Disconnect the throttle IDC from the header on the PC board Detail A of FIGURE 8 15 Remove the two 2 locknuts from the throttle mounting bracket and slide the existing throttle assembly out of the holes Detail B of FIGURE 8 15 Install the new throttle assembly into the mounting holes o
2. 1 2 Repair or 255 anrai a a RERE EEE EEEn 12 Operation Information S aec qa todecoeqe adi cip odios hoste lac pedro ure 12 Mire ope cee dics ovd tubae ce areas tela ee 13 Electrical NE ME 13 Grounding InstE ctiofis n cde angeben tg bean brit 13 Batteries ocio nece 13 Charging Batteries oen opa vios cista 14 D E ESEE 14 hil dici 14 SECTION 2 EMI INFORMATION 15 SECTION 3 SAFETY INSPECTION 17 Clhiecklist 5 bs ette cedem ena SEL ATE 17 SECTION 4 SEAT 19 Removirng lrnstalling th Seatern sinansa EAE E E EEE 19 eeii e darii a 19 Installirig odere eie p tele ng 19 Removing Installing the Seat Post eire tt
3. lt I AA BLACK Battery Connector BLACK Battery Connector wie ee NEGATIVE BLACK POSITIVE RED Battery Terminal Battery Terminal NOTE NEVER defeat or bypass any fuse Only replace with a fuse of the same rating NOTE DO NOT remove fuse or mounting hardware from the POSITIVE RED battery cable mounting screw DETAIL D REMOVING INSTALLING THE BATTERIES Right Battery Left Battery POSITIVE RED Battery Terminal NEGATIVE BLACK Battery Terminal Batteries Installed Battery Strap Battery Tray Battery Tray NOTE Seat and Rear Shroud not shown for clarity FIGURE 12 3 Removing Installing the Batteries on Zoom 400 Part No 1122167 89 Zoom 300 and Zoom 400 SECTION I2 BATTERIES AND CHARGER Connecting Disconnecting the Battery Cables on the Zoom 400 A WARNING On Zoom 400 only Battery terminal configuration shown below MUST be used Batteries that have the reversed terminal configuration MUST NOT be used otherwise serious injury or damage may occur POSITIVE DO NOT USE Battery Termina POSITIVE NEGATIVE Battery Battery Battery Terminal Termina Terminal NEVER allow any of your tools and or battery cable s to contact BOTH battery terminal s post s at the same time An electrical short may occur and seri
4. Throttle ThrottleIDC Assembly Header DETAIL B REPLACING THE THROTTLE ASSEMBLY Throttle Potentiometer Assembled Locknuts o i Shroud C a ATs A Y Throttle Bracket Throttle Bracket Lower Tiller Shroud Tiller Lever Throttle Assembly FIGURE 8 15 Replacing the Throttle Assembly Calibrating Throttle Potentiometer Mechanical Method NOTE For this procedure refer to Detail A of FIGURE 8 15 and FIGURE 8 16 NOTE This procedure should be performed only when one 1 of the following occurs Scooter does not drive and the Status LED blinks six 6 or seven 7 times After replacing the throttle assembly and the scooter does not drive the Status LED blinks six 6 or seven 7 times 1 Turn power off and remove the key from the ignition 2 Disengage the brake release lever Refer to Disengaging Engaging the Brake Release Lever on page 66 Part No 1122167 59 Zoom 300 and Zoom 400 SECTION 8 TILLER Put a block under the frame of the scooter to raise the drive wheels off the ground for testing purposes Remove the upper tiller shroud Refer to Removing Installing the Upper Tiller Shroud on page 44 Using a 5 64 allen head tool loosen the two 2 set screws slightly Refer to FIGURE 8 16 NOTE DO NOT remove the set screws 6 7 8 Turn the key to the ON position Locate the RED and WHITE wires f
5. Battery Motor Park Brake Park Brake Motor Forw Rev Inhibit Throttle Throttle Wiper Throttle Key Switch Buzzer Reduce Speed FIGURE 13 2 Controller NUMBER OF FAULT IMPACT ON NOTES FLASHES SCOOTER Battery needs Will Drive Battery charge is running low Recharge the batteries recharging as soon as possible 2 Battery voltage Drive Inhibited Battery charge is empty Recharge the batteries If the too low scooter is left off for a few minutes battery charge may recover sufficiently to allow driving for a short period of time 3 Battery voltage Drive Inhibited Battery charge is too high Scooter will charge batteries too high when traveling down slopes or decelerating Excessive charging in this manner may cause this fault Turn the scooter power off and then back on again 4 Current limit Drive Inhibited The scooter has drawn too much current for too time out long possibly because the motor has been over worked jammed or stalled Turn the scooter power off leave for a few minutes and then turn back on again Zoom 300 and Zoom 400 102 Part No 1122167 SECTION I3 MAINTENANCE AND TROUBLESHOOTING NUMBER OF FAULT IMPACT ON NOTES FLASHES SCOOTER 5 Brake fault Drive Inhibited Check that the park brake release lever is in the engaged position The park brake coil or wiring is faulty Check the park brake and wiring 6 Out of
6. FIGURE 8 11 Replacing the PC Board Part No 1122167 53 Zoom 300 and Zoom 400 SECTION 8 TILLER Removing Installing the Tiller Angle Adjustment Assembly NOTE For this procedure refer to FIGURE 8 12 Removing 1 Remove the tiller Refer to Removing Installing the Tiller on page 40 2 Remove the two 2 mounting bolts that secure the tiller angle adjustment assembly to the front fork Refer to FIGURE 8 12 Installing 1 Install the two 2 mounting bolts to secure tiller angle adjustment assembly to the front fork Securely tighten FIGURE 8 12 2 Install the tiller Refer to Removing Installing the Tiller on page 40 Tiller Angle Adjustment Assembly QA x PCIE Mounting Bolts Front Fork NOTE Zoom 300 shown Zoom 400 is the same FIGURE 8 12 Removing Installing the Tiller Angle Adjustment Assembly Zoom 300 and Zoom 400 54 Part No 1122167 SECTION 8 TILLER Replacing the Tiller Wiring Harness NOTE For this procedure refer to FIGURE 8 13 and FIGURE 8 14 1 Turn power off and remove the key from the ignition 2 Remove the seat Refer to Removing Installing the Seat on page 19 3 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 30 4 Perform one 1 of the following to remove the batteries For Zoom 300 Refer to Removing Installing the Batteries on Zoom 300 on page 86 For Zoom 400 Refer to Removing Installing the Batteries on Zoom
7. 37 37 Installing 37 Removing Installing the Caster Assemblies 38 REMOVING e 38 lie 38 Replacing Foam Filled Tires Onto Wheel Rims sentent 39 SECTION 8 TILLER 6646 Remoevihg lrstalling the Tieren tesoros 40 ao 40 ZOOMAOUE 41 Adjusting the Taller uicit eS tbe Pe TH obe ues SR IRR 43 Replacing Hand jg C 9 43 Zoom 300 and Zoom 400 4 Part No 1122167 TABLE OF CONTENTS TABLE OF CONTENTS Removing Installing the Upper Tiller Shroud seen 44 a ae anaa eei DI KU DRM NITE 44 Install Q 44 Removing Installing the Rear Tiller Shroud eese teen teetenta ttn ttannne 46 REMOVING ie T
8. Q 111 eare eiie EN Installing Removing Using the Walker Holder eene 112 Installing Removing the Walker Holder erret 112 Using the VValkerPIoldBE mr er be cine Dn a tou die 112 Installing Removing the Rear Mounted 2 113 I stalling cry cos suas aana aa Ra aai 113 Dri iem M 113 LIMITED WARRANTY 15 Part 1122167 7 Zoom 300 and Zoom 400 SPECIAL NOTES SPECIAL NOTES Signal words are used in this manual and apply to hazards or unsafe practices which could result in personal injury or property damage Refer to the table below for definitions of the signal words SIGNAL WORD MEANING DANGER Danger indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING Warning indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Caution indicates a potentially hazardous situation which if not avoided may result in property damage NOTICE THE INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE
9. 46 Istae bear a Mast Ad 46 Removing Installing the Headlight soiree tre ridere orlando oue dapi 47 MMO VINE cdit cidit tute ede ce eire ue iieii aseni d credi dera Maeda 47 hcl se 47 Removing Installing the Headlight Mounting Bracket Front Tiller Shroud 48 Removing rebels 48 hcl 48 Replacing the Ignition Switch eee eee eeeee entente entente entente nente nente nene nene 49 Replacing the Pobla tinte bonitate Donde peni 50 Replacing the Headlight Switch entere tid eee ed haee ede Reel det 5 Replacing PE Boat TR 52 Removing Installing the Tiller Angle Adjustment Assembly sse 54 epu RE 54 54 Replacing the Tiller Wiring Harness erret nne 55 Changing to poene respete entere Metodo ipee 58 Replacing the Throttle Assembly unsere ettet nte eek hueso 58 Calibrating Throttle Potentiombeter entretient ee ente detti eel esed eta ie eret tede obire eee 59
10. Battery 40 AMP Circuit Breaker qq te Cables Controller Bauey 4 Connector from Batteries p due DO NOT operate the scooter unless the tiller is in the locked position 75 Fuse 2 Slot Connectors BLACK Battery Cable DO NOT lean against or pull forward on the tiller while mounting or NO TE Warn ing Label 1 1 253 62 dismounting the scooter Otherwise injury may occur DO NOCT lift scooter up by the front or rear shroud Otherwise injury is located under the Tear shroud or damage to the scooter may occur 1118373 Rev A Rear Frame Assembly Pinch Point 1079203 Pinch Point 1079203 Part No 1122167 lI Zoom 300 and Zoom 400 SECTION I GENERAL GUIDELINES SECTION GENERAL GUIDELINES A WARNING SECTION GENERAL GUIDELINES contains important information for the safe operation and use of this product DO NOT use or service this product or any available optional equipment without first completely reading and understanding these instructions and any additional instructional material such as Owner s Manuals Service Manuals or Instruction Sheets supplied with this product or optional equipment If you are unable to understand the Warnings Cautions or Instructions contact a healthcare professional dealer or technical personnel before attempting to use or service this equipment otherwise injury or damage may occur Repair
11. IE mia M 69 Replacing the Controller ba HR 70 Zoom BOO 70 72 Removing Installing Rear Wiring Harness sssssscssessssssesssssssssssssesssssssseessssssesssssssssssssseesseseess 74 Replacing Resetting the Circuit Breaker eee eese tette tee tenton testen ta tita tonno 76 Replacing Se 76 Resetting Circuit Breaker eee eeeeeeeeen entente tetentente entente tenen 78 Replacing the FUSe 55 up adii 79 Changing to Left Handed 80 Programiming the Controller dolia 80 Plugging inthe FO Stab Ve Proinde mro Got Rt M ere etie eU 80 QE MEA 81 Set Up Men sor 81 Options Coni os n 82 Speed Lever in Neutral MRE nte dict 83 Controller Version Menta e nete tenet 83 SECTION I2 BATTERIES AND CHARGER
12. Tie Wraps aS Tiller Wiring Tie Wraps NOTE Transaxle not Harness V shown for clarity Top View Tiller Wiring ie Wrap Harness E D Be a 25 e mm ae i 1144 i O Y BE Q Top of Batteri Tie W Tie Wraps eae Top View Rear Top of Batteries ETT Tiller Wiring Harness Connector Rear Wiring Harness Connector Rear Wiring Harness FIGURE 8 13 Replacing the Tiller Wiring Harness 300 Zoom 300 and Zoom 400 56 Part No 1122167 SECTION 8 TILLER Buttom View Tiller Wiring Harness
13. Top View of Headlight Bottom View of Uppe Lower Tiller Switch Tiller Shroud Shroud Z FIGURE 8 10 Replacing the Headlight Switch Part No 1122167 51 Zoom 300 and Zoom 400 SECTION 8 TILLER Replacing the PC Board NOTE For this procedure refer to FIGURE 8 11 1 Disconnect the RED and BLACK controller connector from the RED and BLACK battery connector Refer to FIGURE 12 2 on page 87 for the Zoom 300 and FIGURE 12 3 on page 89 for the Zoom 400 2 Loosen the set screw not shown that secures the speed control knob and remove the knob Refer to Detail A of FIGURE 8 11 NOTE The set screw for the speed control knob can be reached through the access hole in the back of the speed control knob 3 Remove the upper tiller shroud Refer to Removing Installing the Upper Tiller Shroud on page 44 4 Disconnect the following from the PC board Detail B of FIGURE 8 11 Ignition switch Horn Throttle Controller Headlight Zoom 400 Only Headlight Switch Zoom 400 Only 5 Remove the six 6 locknuts that secure the PC board to the upper tiller shroud Refer to Detail C of FIGURE 8 11 Note the orientation of the PC board for proper installation of the new one Amos gt Remove the PC board from the upper tiller shroud and discard Install new PC board in the position noted in STEP 6 PN Oo Secure the new PC board to the upper tiller shroud with the existing six 6 mounting screws Refer
14. 84 Recommended Battery RU pie usi e n MIN UI o eq Tie pt 85 Removing Installing the Batteries on Zoom 300 222222 86 PEERS cm FUN UE 86 Installing Me 86 Removing Installing the Batteries on Zoom 400 2 2222 88 REMOVING a Gros hain oho hdd 88 Is CAM AN oxides eben on tete 88 Connecting Disconnecting the Battery Cables on the Zoom 400 90 IIPS CEN a den antag ees eta 90 DiSEORBeGEITIB aci Cos e LOL Ca notices 9 Replacing the Charger 92 c 92 TSO 400 en Dette 95 Zoom 300 and Zoom 400 6 Part No 1122167 Charging the Batteples oi s EP D T LN 97 On Board Battery ChaFBer iussit testate uet bend 97 Battery Charger Operation Charger Indicator Light on Tiller 98 SECTION 13 MAINTENANCE AND TROUBLESHOOTING 99 Storing the SCODELBE deco eto deus eine 99 Suggested Maintenance Procedures sissiu cs csscsssosssusectsnesssesco
15. Frame Post NOTE Seat post on Zoom 300 shown Seat post on Zoom 400 installs the same way FIGURE 4 2 Removing Installing the Seat Post Zoom 300 and Zoom 400 20 Part No 1122167 SECTION 4 SEAT Adjusting Seat Height NOTE For this procedure refer to FIGURE 4 3 NOTE The seat post has three 3 height settings 1 2 Remove the seat Refer to Removing Installing the Seat on page 19 Remove the mounting screw locknut and two 2 washers securing the seat 7 Mounting Seat Post post to the frame post Hole Align one 1 of the three 3 seat post 8 mounting holes with the frame post Mounting mounting hole to achieve desired seat Hole height FIGURE 4 3 Using the mounting screw locknut 9 Mounting and two 2 washers secure the seat Hole post to the frame post FIGURE 4 3 Adjusting Seat Height Install the seat Refer to Removing Installing the Seat on page 19 Removing Installing the Seat Pivot NOTE For this procedure refer to FIGURE 4 4 Removing 1 2 Remove the four 4 mounting bolts and washers that secure the seat pivot to the seat Installing 1 Install the four 4 mounting bolts and washers to secure the seat pivot to the seat Securely tighten 2 Install the seat Refer to Removing Remove the seat Refer to Removing Installing the Seat on page 19 Installing the Seat on page 19 Mounting Bolts FIGURE 4 4 Removing Installing the Seat Pivot Part No 1
16. B of FIGURE 12 2 A NEGATIVE BLACK battery cable from the NEGATIVE battery terminal post on the left battery B POSITIVE RED battery cable from POSITIVE battery terminal post on the right battery C WHITE Battery Cable Jumper from the POSITIVE battery terminal post on the left battery and the NEGATIVE battery terminal post on the right battery 8 Remove the existing batteries from battery tray by lifting the batteries out in the direction shown in Detail A of FIGURE 12 2 Installing 1 Place the powered scooter in a well ventilated area CAUTION Work should be performed in an area without risking damage to carpeting or floor covering 2 Turn power off and remove the key from the ignition 3 Remove the seat Refer to Removing Installing the Seat on page 34 4 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 44 Zoom 300 and Zoom 400 86 Part No 1122167 SECTION 12 AND CHARGER 5 Install two 2 batteries into the battery tray 6 Connect the wiring harness to the new batteries in the following order Detail of FIGURE 12 2 A NEGATIVE BLACK battery cable to the NEGATIVE battery terminal post on the LEFT battery B POSITIVE RED battery cable to POSITIVE battery terminal post on the right battery C WHITE Battery Cable Jumper to the POSITIVE battery terminal post on the left battery and the NEG
17. B Assemble the scooter Refer to Disassembling Assembling the Zoom 400 on page 105 Part No 1122167 69 Zoom 300 and Zoom 400 SECTION CONTROLLER 7 8 Install the batteries Refer to Removing Installing the Batteries on Zoom 300 on page 86 and Removing Installing the Batteries on Zoom 400 on page 88 Perform one 1 of the following e On Zoom 300 Connect the RED and BLACK controller connector to the RED and BLACK battery connector Refer to FIGURE 12 2 on page 87 On Zoom 400 Connect the two 2 BLACK battery connectors to the wiring harness connectors Refer to FIGURE 12 3 on page 89 Install the rear shroud Refer to Removing Installing the Rear Shroud on page 30 Install the seat Refer to Removing Installing the Seat on page 19 Replacing the Controller Tray Zoom 300 NOTE For this procedure refer to FIGURE 12 2 FIGURE 8 13 FIGURE 11 1 and FIGURE 11 2 1 2 3 4 Turn power OFF and remove the key from the ignition Remove the seat Refer to Removing Installing the Seat on page 19 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 30 Disconnect the RED and BLACK controller connector from the RED and BLACK battery connector Refer to FIGURE 12 2 on page 87 Remove the batteries Refer to Removing Installing the Batteries on Zoom 300 on page 86 and Removing Installing the Batteries on Zoom 400 on page 88 6 Remove the charger Refer to Replacing the Charger
18. NOTE Connectors to Controller not shown for clarity FIGURE 12 6 Replacing the Charger Zoom 300 Zoom 300 and Zoom 400 94 Part No 1122167 SECTION 12 AND CHARGER Zoom 400 NOTE For this procedure refer to FIGURE 12 7 and FIGURE 12 2 1 N Place the powered scooter in a well ventilated area where work be performed without risking damage to carpeting or floor covering Turn power off and remove the key from the ignition Remove the seat Refer to Removing Installing the Seat on page 19 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 30 Disconnect the two 2 BLACK battery connectors from the wiring harness connectors Refer to Detail C of FIGURE 12 3 Remove the two 2 mounting screws and locknuts that mount the AC receptacle to charger to the controller tray Refer to Detail B FIGURE 127 Disconnect the DC charger connector from the charger port 8 Cutthe tie wraps securing the DC charger connector cable to scooter frame refer to 10 11 12 13 14 15 16 17 18 19 Detail B of FIGURE 127 Cut the tie wraps securing the charger to the controller tray refer to Detail B of FIGURE 12 7 Remove the existing charger Place the new charger on the controller tray and secure it to the controller tray using tie wraps as shown in Detail B of FIGURE 12 7 Tie wrap the charger cables in three places as shown in Deta
19. Sew Drive Shaft Scooter Frame Drive Wheel Hex Nut ZOOM 400 DETAIL B Scooter Frame Transaxle Assembly Keystock Washer Drive Shaft Drive Wheel Removing Installing the Drive Wheels FIGURE 7 1 Zoom 300 and Zoom 400 35 Part No 1122167 SECTION 7 WHEELS AND CASTERS Removing Installing the Front Wheel NOTE For this procedure refer to FIGURE 7 2 NOTE Take note of position and orientation of wheel and mounting hardware before removing Removing 1 Turn power off and remove the key from the ignition 2 Place the front of the powered scooter up on blocks so that the front wheel is off the ground Remove the mounting screw locknut and two 2 spacers that secure the front wheel to the fork B Remove front wheel from fork Installing A WARNING Front wheel MUST be mounted in the lower mounting holes for both the Zoom 300 and Zoom 400 otherwise injury may result NOTE Before installing the front wheel check the fork for bending If bent replace the fork Refer to Removing Installing the Fork on page 37 1 Align front wheel with the lower fork mounting holes 2 Secure the front wheel to the fork using the mounting screw locknut and two 2 spacers e Securely tighten the front wheel mounting hardware Fork Lower Fork Mounting Screw Mounting Hole S S ad Locknut Front Wheel FIGURE 7 2 Remov
20. E o A Upper Tiller Mounting Shroud Tiller Harness Lower Tiller Screws Tiller Shroud Connector DETAIL B Headlight connects HERE Zoom 400 only Tiller Harness connects HERE Throttle IDC connects HERE FIGURE 8 4 Removing Installing the Upper Tiller Shroud Part No 1122167 45 Zoom 300 and Zoom 400 SECTION 8 TILLER Removing Installing the Rear Tiller Shroud NOTE This procedure is for the Zoom 400 only NOTE For this procedure refer to FIGURE 8 5 Removing 1 Remove the four 4 mounting screws that secure the rear tiller shroud to the front tiller shroud Installing 1 Secure the rear tiller shroud to the front tiller shroud using the four 4 mounting screws Securely tighten p Ne Mounting Screws Lower Tiller Shroud p udi M Ze M Mounting Screws Front Tiller Shroud FIGURE 8 5 Removing Installing the Rear Tiller Shroud Zoom 300 and Zoom 400 46 Part No 1122167 SECTION 8 TILLER Removing Installing the Headlight NOTE This procedure is for the Zoom 400 only NOTE For this procedure refer to FIGURE 8 6 Removing 1 Remove the rear tiller shroud Refer to Removing Installing the Rear Tiller Shroud on page 46 Disconnect the headlight connector from the PC board connector Detail A of FIGURE 8 6 Remove the locknut washer and mounting bolt that secure the headlight to the headlight mounting b
21. Floormat Tiller and Fork Assemblies and Scooter frame are not shown FIGURE 6 2 Removing Installing the Front Shroud Zoom 300 Part No 1122167 3l Zoom 300 and Zoom 400 S ECTION 6 SHROUDS Zoom 400 NOTE For this procedure refer to FIGURE 6 3 NOTE Reverse this procedure to install the front shroud on the scooter frame 1 2 3 Remove the seat Refer to Removing Installing the Seat on page 19 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 30 Remove the batteries Refer to Removing Installing the Batteries on Zoom 400 on page 88 Disconnect the tiller wiring harness from the rear wiring harness Refer to FIGURE 8 14 on page 57 Disengage the boot from the front shroud Refer to Removing Installing the Boot Assembly on page 33 6 Remove the tiller Refer to Removing Installing the Tiller on page 40 9 Remove the floormat the front shroud by pulling up and away Remove the four 4 mounting screws that secure the front shroud to the scooter frame Once the tiller is removed slide the boot off the tiller and front shroud off the scooter NOTE The boot will have to be slipped off the front basket bracket after disengaging the boot from the tabs 10 CC Boot Assembly SSS Front Basket Bracket goes through HERE Front Shroud NOTE Floormat tiller and fork assemblies and scooter frame are not shown FIGURE 6 3 Remo
22. Invacare products are specifically designed and manufactured for use in conjunction with Invacare accessories Accessories designed by other manufacturers have not been tested by Invacare and are not recommended for use with Invacare products Part No 1122167 8 Zoom 300 and Zoom 400 OVERALL DIMENSIONS BASE LENGTH BASE WIDTH STEP HEIGHT Floor Pan to Ground SEAT HEIGHT Floor Pan to Seat Cushion TYPICAL PRODUCT PARAMETERS TYPICAL PRODUCT PARAMETERS 44 in 22 5 in 3 5 in 17 19 in 46 in 24 in 4 5 in 17 19 in SEAT DIMENSIONS WIDTH DEPTH BACK HEIGHT 16 in 16 17 18 in 15 in 18 in 16 17 18 in 17 in 18 in 16 17 18 in 17 in 20 in 18 19 20 in 19 in ARM DIMENSIONS LENGTH HEIGHT BETWEEN SEAT AND ARMS WIDTH BETWEEN ARMS 13 in 7 9 in 16 in seat 16 22 in 18 in seat 18 24 in 13 in 7 9 in 18 in seat 18 24 in 20 in seat 20 26 in SPEED RANGE 0 4 5 m p h Factory setting 3 5 m p h 0 4 5 m p h Factory setting 5 5 m p h MAXIMUM WEIGHT LIMITATION 300 Ibs 400 Ibs MAXIMUM INCLINE CAPABILITY 8 Grade 8 Grade WHEELS FRONT WHEEL DRIVE WHEEL REAR CASTER 7 in x 2 in 8 in x 3 in in x 5 in 8 in x 2 in 10 in x 3 in l in x 5 in TURNING RADIUS 29 in 32 in WEIGHT OF PRODUCT FRONT BASE SECTION WITH BASKET REAR BASE SE
23. Mechanical Method eS nelle entere d uin 59 Prospamtming ERO NA EM av tees Iu Up v EP P REDE 6l SECTION 9 SWINGARMS ee eeee eese eee eesssssoseccsceccssscceccccocecccceccoos 62 Removing Installing the Swingarms eerte eese tentent ttn tontos 62 REMOVING Ree 62 IET eser EE ER IR MAUS 62 SECTION 10 5 cccccccccccccccccccccccccccccccccccccccccccccscocccccccees 64 Removing Installing the 64 REMOVINE 64 VANS AUN eee 64 Removing Installing the Brake Release Lever csscsssssssscssssssesseesssessesssssssessesssssessesseesesssssees 65 REMOVING aea UST TNT ROS UNS 65 lc D 65 Part No 1122167 5 Zoom 300 and Zoom 400 TABLE OF CONTENTS TABLE OF CONTENTS Disengaging Engaging the Brake Release Lever sss 66 SECTION I CONTROLLER 66 68 Removing Installing the Controller 68 REMOVING m 68 Installing 25a
24. not shown with those on the scooter frame 3 Install the seat Refer to Removing Installing the Seat on page 19 DETAIL A ZOOM 300 DETAIL ZOOM 400 Rear Shroud Seat Post Hook and Loop Strips of Slots Shroud Front Shroud FIGURE 6 1 Removing Installing the Rear Shroud Hook and Loop Strips Zoom 300 and Zoom 400 30 Part No 1122167 SECTION 6 SHROUDS Removing Installing the Front Shroud Zoom 300 NOTE For this procedure refer to FIGURE 6 2 NOTE Reverse this procedure to install the front shroud on the scooter frame 1 2 3 NA Remove the seat Refer to Removing Installing the Seat on page 19 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 30 Remove the batteries Refer to Removing Installing the Batteries on Zoom 300 on page 86 Disconnect the tiller wiring harness from the rear wiring harness Refer to FIGURE 8 13 on page page 56 Disengage the boot from the front shroud Refer to Removing Installing the Boot Assembly on page 33 Slide the boot up the tiller Remove the tiller Refer to Removing Installing the Tiller on page 40 Remove the floormat on the front shroud by pulling up and away Remove the four 4 mounting screws that secure the front shroud to the scooter frame 10 Once the tiller is removed slide the boot off the tiller and front shroud off the scooter Mounting Screws Boot Assembly Front Shroud NOTE
25. the wheels and tires should be checked periodically for cracks and wear and should be replaced Ensure powered scooter drives straight no excessive drag or pull to one side Check frame for damage and corrosion Ensure that the brake release lever is easy to engage disengage Ensure that tiller adjustment handle engages and disengages properly and securely Ensure that the scooter stops completely when throttle is released i e does not continue to roll as if the throttle is activated Clean upholstery and armrests Ensure adjustable height arms operate and lock securely Ensure armrest pad sits flush against arm tube Inspect the seat upholstery for rips and tears D OCC Inspect seat swivel for release and engagement seat locks into the determined swivel positions Inspect the seat positioning strap for signs of wear Replace if worn or damaged Ensure that the buckle on the seat positioning strap latches Replace if necessary Verify that the hardware that attaches the seat positioning strap to the seat frame is secure and undamaged Replace if necessary Ensure that the seat mounting hardware is securely tightened Inspect for excessive side movement or binding when the drive wheels raised and or turned Inspect front wheel fork assembly for proper tension by spinning the wheel front wheel should come to a gradual stop
26. 1 Remove the seat Refer to Removing Installing the Seat on page 19 2 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 30 3 Toreset do one 1 of the following For Zoom 300 P ress circuit breaker button located at rear of the controller tray For Zoom 400 Press circuit breaker button located at front of controller tray 4 Reverse STEPS 1 2 to reassemble the powered scooter Top View of Scooter DETAIL A ZOOM 300 Circuit Breaker Button Controller Tray DETAIL B ZOOM 400 Top View of Scooter Scooter Frame Controller E Tray Fall Rear Frame Assembly Circuit Breaker Button under scooter frame FIGURE 11 6 Replacing Resetting the Circuit Breaker Resetting Circuit Breaker Zoom 300 and Zoom 400 78 Part No 1122167 SECTION CONTROLLER Replacing the Fuse A WARNING NEVER defeat or bypass any fuse ONLY replace with a fuse with same rating If the fuse blows repeatedly DO NOT use the scooter This may indicate that a short circuit condition exists Investigate potential causes and correct before returning scooter to service NOTE For t
27. 400 on page 88 5 Remove the front shroud Refer to Removing Installing the Front Shroud on page 31 6 Disconnect the tiller wiring harness connector from the rear wiring harness FIGURE 8 13 for Zoom 300 FIGURE 8 14 for Zoom 400 7 Mark the positions of the tie wraps for replacing them later 8 Cut the tie wraps securing the tiller wiring harness to the frame NOTE For the Zoom 400 Refer to FIGURE 8 14 For the Zoom 300 Refer to FIGURE 8 13 NOTE The scooter may have to be elevated on blocks to access all tie wraps 9 Remove the tiller wiring harness from the scooter 10 Secure the new tiller wiring harness to the frame with tie wraps at the positions marked NOTE The scooter may have to be lifted to access all tie wrap points 11 Connect the tiller wiring harness connector to the rear wiring harness connector FIGURE 8 13 for Zoom 300 FIGURE 8 14 for Zoom 400 12 Replace the front shroud Refer to Removing Installing the Front Shroud on page 31 13 Perform one 1 of the following to install the batteries For Zoom 300 Refer to Removing Installing the Batteries on Zoom 300 on page 86 For Zoom 400 Refer to Removing Installing the Batteries on Zoom 400 on page 88 14 Replace the rear shroud Refer to Removing Installing the Front Shroud on page 31 15 Replace seat Refer to Removing Installing the Seat on page 19 Part No 1122167 55 Zoom 300 and Zoom 400 SECTION 8 TILLER Bottom View n
28. As a manufacturer of powered scooters Invacare endeavors to supply a wide variety of powered scooters to meet many needs of the end user However final selection of the type of powered scooter to be used by an individual rests solely with the user and his her healthcare professional capable of making such a selection TIE DOWN RESTRAINTS AND SEAT RESTRAINTS Powered scooter users should NOT be transported in vehicles of any kind while in the powered scooter As of this date the Department of Transportation has not approved any tie down systems for transportation of a user while in a powered scooter in a moving vehicle of any type It is Invacare s position that users of powered scooters should be transferred into appropriate seating in vehicles for transportation and use be made of the restraints made available by the auto industry Invacare cannot and does not recommend any powered scooter transportation systems SEAT POSITIONING STRAP It is the obligation of the dealers therapists and other healthcare professionals to determine if a seating restraint is required to ensure the safe operation of this equipment by the user Serious injury can occur in the event of a fall from a powered scooter A WARNING The seat positioning strap is a positioning belt ONLY It is not designed for use as a safety device withstanding high stress loads such as auto or aircraft safety belts If signs of wear appear belt must be replaced immediately
29. CAUTION When connecting the battery cables to the batteries the battery cables MUST be connected to the battery terminals posts as shown in FIGURE 12 2 for Zoom 300 and FIGURE 12 5 for Zoom 400 otherwise damage to the battery may result For proper battery connection batteries MUST use post style terminals with mounting holes through the terminal NOTE If there is battery acid in the bottom of the battery tray or on the sides of the battery ies apply baking soda to these areas to neutralize the battery acid Before reinstalling the existing or new battery ies clean the baking soda from the battery tray or battery ies being sure to avoid contact with skin and eyes Determine source of contamination Never install reinstall a battery with a cracked or otherwise damaged case Recommended Battery Type A WARNING The warranty and performance specifications contained in this manual are based on the use of deep cycle gel cell batteries Invacare strongly recommends their use as the power source for this unit CAUTION Failure to use the correct battery size and or voltage may cause damage to the powered scooter and give unsatisfactory performance Zoom 300 powered scooter uses two 2 12 volt 12 Amp hour 12AH batteries Zoom 400 powered scooter uses two 2 12 volt 31 Amp hour U1 batteries NOTE Recommended battery type is spill proof and requires no maintenance except routine charging NOTE Charge batteries
30. EMI up to a certain intensity This is called its immunity level The higher the immunity level the greater the protection At this time current technology is capable of achieving at least a 20 V m immunity level which would provide useful protection from the more common sources of radiated EMI There are a number of sources of relatively intense electromagnetic fields in the everyday environment Some of these sources are obvious and easy to avoid Others are not apparent and exposure is unavoidable However we believe that by following the warnings listed below your risk to EMI will be minimized The sources of radiated EMI can be broadly classified into three types 1 Hand held Portable transceivers transmitters receivers with the antenna mounted directly on the transmitting unit Examples include citizens band CB radios walkie talkie security fire and police transceivers cellular telephones and other personal communication devices NOTE Some cellular telephones and similar devices transmit signals while they are ON even when not being used 2 Medium range mobile transceivers such as those used in police cars fire trucks ambulances and taxis These usually have the antenna mounted on the outside of the vehicle and 3 Long range transmitters and transceivers such as commercial broadcast transmitters radio and TV broadcast antenna towers and amateur HAM radios NOTE Other types of hand held devices such a
31. INSTRUCTIONS A CHANGE IN OPERATING NOISE PARTICULARLY RELATIVE TO MOTORS AND GEARBOXES DOES NOT CONSTITUTE A FAILURE ALL SUCH DEVICES WILL EXHIBIT A CHANGE IN OPERATING NOISE DUE TO AGING THE FOREGOING EXPRESS WARRANTY IS EXCLUSIVE AND IN LIEU OF ANY OTHER WARRANTIES WHATSOEVER WHETHER EXPRESS OR IMPLIED INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND THE SOLE REMEDY FOR VIOLATIONS OF ANY WARRANTY WHATSOEVER SHALL BE LIMITED TO REPAIR OR REPLACEMENT OF THE DEFECTIVE PRODUCT PURSUANT TO THE TERMS CONTAINED HEREIN THE APPLICATION OF ANY IMPLIED WARRANTY WHATSOEVER SHALL NOT EXTEND BEYOND THE DURATION OF THE EXPRESS WARRANTY PROVIDED HEREIN INVACARE SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES WHATSOEVER THIS WARRANTY SHALL BE EXTENDED TO COMPLY WITH STATE PROVINCIAL LAWS AND REQUIREMENTS Part No 1122167 115 Zoom 300 and Zoom 400 Yes you can Invacare Corporation www invacare com USA One Invacare Way Elyria Ohio USA 44036 2125 800 333 6900 Canada 570 Matheson Blvd E Unit 8 Mississauga Ontario L4Z 4G4 Canada 800 668 5324 Invacare is a registered trademark of Invacare Corporation Teflon is a registered trademark of E l DuPont Nemours and Company Yes you can and HMV are trademarks of Invacare Corporation 2005 Invacare Corporation Part No 1122167 Rev B 06 05
32. Neutral Drive Inhibited Throttle is not in neutral position when turning the at power up key switch on Return the throttle to neutral turn power off and back on again Throttle may need to be re calibrated 7 Speed Pot Drive Inhibited The throttle or its wiring is faulty Check wiring error 8 Motor volts Drive Inhibited The motor or its wiring is faulty Check wiring error 9 Other internal Drive Inhibited errors Call Invacare Technical Services Department Part No 1122167 103 Zoom 300 and Zoom 400 SECTION 4 TRANSPORTING SECTION I4 TRANSPORTING A WARNING After ANY adjustments repair or service and BEFORE use make sure that all attaching hardware is tightened securely otherwise serious injury or damage may result Disassembling Assembling the Zoom 300 NOTE For this procedure refer to FIGURE 14 1 Disassembling 1 Ifinstalled on scooter remove the front basket Refer to Removing Installing the Front Basket on page 64 2 Remove the seat Refer to Removing Installing the Seat on page 34 3 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 44 Remove the batteries Refer to Removing Installing the Batteries on Zoom 300 on page 50 B g Fold tiller down to lowest locked position Refer to Adjusting the Tiller Angle on page 43 Assembling 1 Unfold tiller Refer to Adjusting the Tiller Angle on page 43 2 Install the batteries Refer to Rem
33. Q Check brake for binding or interference with travel Q Check the front fork for damage or corrosion Part No 1122167 17 Zoom 300 and Zoom 400 SECTION 3 SAFETY INSPECTION Q DODO D D OO Tighten locknut if the front wheel wobbles noticeably or loosen locknut if the wheel binds to a stop Ensure that the fork stem bearing set is tight Ensure that wheel bearings are clean and free of moisture Ensure that the bolts and fasteners on the caster assemblies are tight Inspect caster assembly for proper tension by spinning the caster The caster should come to a gradual stop Inspect tires for flat spots and wear Clean molded body shrouds Lubricate the top of the seat post using a Teflon lubricant Ensure that the anti roll safety feature is working properly The scooter should not free wheel downhill Zoom 300 and Zoom 400 18 Part No 1122167 SECTION 4 SEAT SECTION 4 SEAT A WARNING After ANY adjustments repair or service and BEFORE use make sure that all attaching hardware is tightened securely otherwise injury or damage may result Before performing any maintenance adjustment or service turn power OFF and remove key from ignition Removing Installing the Seat NOTE For this procedure refer to FIGURE 4 1 Removing 1 Fold down seat back 2 Pulling up on the seat lever lift the seat assembly off the seat post Installing 1 Align the seat pivot with the seat post 2 Pulling up
34. Repeat STEP 9 for the right connector Remove the locknut that secures the circuitbreaker to the controller tray Install the left connector using the two 2 screws as shown in Detail A of FIGURE 11 3 Repeat STEP 12 for the right connector Install the controller Refer to Removing Installing the Controller on page 68 Install the charger Refer to Replacing the Charger on page 92 Install the circuit breaker Refer to Replacing Resetting the Circuit Breaker on page 76 Install the controller tray on the scooter frame and secure with four 4 mounting bolts eight 8 washers and four 4 locknuts Securely tighten Refer to FIGURE 11 3 Install the rear wiring harness Refer to Removing Installing Rear Wiring Harness on page 74 Connect the tiller wiring harness to the rear wiring harness Refer to FIGURE 8 14 Assemble the scooter Refer to Disassembling Assembling the Zoom 400 on page 105 Zoom 300 and Zoom 400 72 Part No 1122167 SECTION CONTROLLER Mounting Bolts Washers Washers Controller Tray Scooter Frame Locknuts Locknut NOTE Wiring harness not shown REMOVE INSTALL WIRING HARNESS CONNECTORS DETAIL Controller Connector Tray Circuit Breaker NOTE Charger Controller and Wiring harness shown removed Zoom 400 FIGURE 11 3 Replacing the Controller Tray Zoom 300 and Zoom 400 73 Part No 1122167 SECTION CONTROLLER Removing Install
35. Zoom 400 NOTE For this procedure refer to FIGURE 12 3 Removing 1 Place the powered scooter in a well ventilated area CAUTION Work should be performed in an area without risking damage to carpeting or floor covering Turn power off and remove the key from the ignition 2 3 Remove the seat Refer to Removing Installing the Seat on page 34 4 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 44 5 Disconnect the two 2 BLACK battery connectors from the wiring harness connectors Detail C of FIGURE 12 3 Pull the hook and loop fastening battery strap apart D 7 Perform one 1 of the following to remove the battery from the battery tray Detail D of FIGURE 12 3 e Batteries with Built in Lifting Strap Use built in lifting strap to remove the battery from the battery tray Detail B of FIGURE 12 3 e Batteries without Built in Lifting Strap Use a battery lifting strap to remove the battery from the battery tray Detail A of FIGURE 12 3 8 Disconnect the battery cable Refer to Connecting Disconnecting the Battery Cables on the Zoom 400 on page 90 Installing 1 Connect the battery cable Refer to Connecting Disconnecting the Battery Cables on the Zoom 400 on page 90 2 Place the powered scooter in a well ventilated area where work can be performed without risking damage to carpeting or floor covering Turn power OFF and remove the key from the ignit
36. and or damage to the surrounding property may result NOTE For this procedure refer to FIGURE 15 4 Installing 1 Install the bracket into the accessory tube located on the back of the seat 2 Install mounting knob to secure the bracket in place Securely tighten 3 Install safety flag into bracket Removing 1 Remove the safety flag from the bracket 2 Remove the mounting knob that secures the bracket in place 3 Remove the bracket from the accessory tube located on the back of the seat Mounting Knob Safety Flag M a EIL eee Seat Bracket Accessory Tube FIGURE 15 4 Installing Removing the Safety Flag Part No 1122167 Zoom 300 and Zoom 400 SECTION 15 SCOOTER ACCESSORIES Installing Removing Using the Walker Holder A INSTALLATION WARNINGS After ANY adjustments repair or service and BEFORE use make sure that all attaching hardware is tightened securely The installation of the walker holder onto the back of the scooter seat significantly increases the length of the scooter When turning the scooter or swiveling the scooter seat it is important to take note of this increased length otherwise injury and or damage to the surrounding property may result Installing Removing the Walker Holder NOTE For this procedure refer to FIGURE 15 5 Mounting 7 Knob 57 NOTE Reverse this procedure to remove the walker holder 1 If necessary loosen but do not remove the moun
37. bearings of the front wheel checked to make sure they are clean and free from moisture Part No 1122167 99 Zoom 300 and Zoom 400 SECTION 13 AND TROUBLESHOOTING Lubrication Points NOTE For this procedure refer to FIGURE 13 1 1 Every six 6 months lubricate the top of the seat post using a Teflon lubricant Seat Post TOP Electrical SYMPTOM FIGURE 13 1 PROBABLE CAUSE Lubrication Points SOLUTIONS Batteries draw excessive current when charging Battery failure Electrical malfunction Check batteries Replace if necessary Contact Invacare for service Battery indicator flashes the charge level is low immediately after recharge Battery failure Malfunctioning battery charger Electrical malfunction Check batteries Replace if necessary Contact Invacare for Service Contact Invacare for Service Battery indicator flashes the charge level is low too soon after being recharged Batteries not charged Weak batteries Check charger Replace if necessary Replace batteries if necessary Contact Invac are for Service Motor chatters or runs irregu lar Electrical malfunction Contact Invacare for Service Powered scooter does not respond to commands Poor battery terminal con nection Clean terminals Power indicator off even after recharging Electrical malfunction Contact Invacare for Servic
38. daily Do not allow batteries to completely discharge NOTE Invacare recommends that both batteries be replaced if one 1 battery is defective DETAIL A BATTERY USED ON DETAIL B BATTERY USED ON ZOOM 400 ZOOM 300 12 Volt 12 Amp Hour 12 Volt 31 Amp Hour 12 AH Battery UI Battery FIGURE 12 1 Recommended Battery Type Part No 1122167 85 Zoom 300 and Zoom 400 SECTION I2 BATTERIES AND CHARGER Removing Installing the Batteries on Zoom 300 NOTE When removing or installing batteries ensure that the battery harness connectors completely erip the terminals of the battery Connection should be tight and secure Pliers can be used to gently crimp the contact to strengthen the connection Removing NOTE For this procedure refer to FIGURE 12 2 1 Place the powered scooter in a well ventilated area CAUTION Work should be performed in an area without risking damage to carpeting or floor covering Turn power OFF and remove the key from the ignition Remove the seat Refer to Removing Installing the Seat on page 34 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 44 Pull the hook and loop fastening battery strap apart amp WN Disconnect the RED and BLACK battery connector from the wiring harness assembly Detail B of FIGURE 12 2 7 Disconnect the wiring harness from the batteries by holding the connectors and pulling them in the following order Detail
39. in Detail B FIGURE 12 6 If necessary Connect the YELLOW metal connectors from the wiring harness to the metal connectors of the circuit breaker not shown Secure the AC receptacle to charger to the controller tray using the two 2 mounting screws and locknuts Insert the DC charger connector into the charger port Tie wrap the DC charger cable to the scooter frame as shown in Detail B of FIGURE 12 6 Connect the RED and BLACK controller connector to the RED and BLACK battery connector Refer to Detail B of FIGURE 12 2 Install the rear shroud Refer to Removing Installing the Rear Shroud on page 30 Install the seat Refer to Removing Installing the Seat on page 19 Insert the key into the ignition and turn the power on to drive the scooter Part No 1122167 93 Zoom 300 and Zoom 400 SECTION I2 BATTERIES AND CHARGER DETAIL A CHARGER REMOVED Charger 222 Charger Port gt 2227 DC Charger Connector 25 Y AC Receptacle 26 V A p C LJ to Charger N SH ABIT OW ae i iJ gt lt gt al Mounting Screws DETAIL B CHARGER INSTALLED Charger od EES SR Frame EX ye 22 Tie Wraps LON Se EB gt ct WY gt S e 555 2 Ve Tie Wrap Pe FO SINS d 7 2 Mo Charger Cable to X ipo je EY Lis ACR tacl coe Sate to Charger
40. locked into the forward position before and during operation of the scooter Otherwise injury to the user and or damage to the scooter may result CAUTION DO NOT use the seat swivel option when accessories are installed such as safety flag crutch cane holder etc and the seat is mounted in lowest height adjustment position Otherwise damage to the scooter may occur NOTE For this procedure refer to FIGURE 4 6 NOTE The seat lever is located just beneath the seat on the right side 8 Pull the seat lever up to rotate the seat NOTE The seat locks in position at 90 intervals The seat is locked when an audible click is heard 9 Rotate the seat to the desired position 10 Release seat lever to lock seat in desired position View From Back Top View Seat Seat EM 7 id Seat Lever FIGURE 4 6 90 Seat Swivel Adjustment Part No 1122167 23 Zoom 300 and Zoom 400 SECTION 4 SEAT Removing Installing the Seat Positioning Strap A WARNING The seat positioning strap is a positioning belt only It is not designed for use as a safety device withstanding high stress loads such as auto or aircraft safety belts If signs of wear appear belt must be replaced immediately ALWAYS wear your seat positioning strap NOTE For this procedure refer to FIGURE 4 7 1 N Remove the two 2 mounting screws and washers that secure the seat positionin
41. on page 92 Remove the controller Refer to Removing Installing the Controller on page 68 8 Remove the cricuit breaker Refer to Replacing Resetting the Circuit Breaker on 10 11 12 13 page 76 Disconnect the tiller wiring harness from the rear wiring harness Refer to FIGURE 8 13 Remove the rear wiring harness Refer to Removing Installing Rear Wiring Harness on page 74 Remove the brake release rod Refer to Removing Installing the Brake Release Lever on page 65 Remove the four 4 mounting bolts eight 8 washers and four 4 locknuts that secure the controller tray to the scooter frame Install the new controller tray on the scooter frame and secure with four 4 mounting bolts eight 8 washers and four 4 locknuts Securely tighten Refer to FIGURE 11 2 Zoom 300 and Zoom 400 70 Part No 1122167 SECTION CONTROLLER 14 Install the brake release rod Refer to Removing Installing the Brake Release Lever on page 65 15 Install the controller Refer to Removing Installing the Controller on page 68 16 Install the charger Refer to Replacing the Charger on page 92 17 Install the circuit breaker Refer to Replacing Resetting the Circuit Breaker on page 76 18 Install the rear wiring harness Refer to Removing Installing Rear Wiring Harness on page 74 19 Connect the tiller wiring harness to the rear wiring harness refer to FIGURE 8 13 20 Install the batteries Refer to Removing Install
42. or Service Information Set up of the electronic control unit is to be performed only by qualified technicians The final adjustments of the controller may affect other activities of the powered scooter Damage to the equipment could occur under these circumstances DO NOT service or adjust your powered scooter while occupied unless otherwise noted Operation Information Invacare products are specifically designed and manufactured for use in conjunction with Invacare accessories Accessories designed by other manufacturers have not been tested by Invacare and are not recommended for use with Invacare products Performance adjustments should only be made by professionals of the healthcare field or persons fully conversant with this process and the driver s capabilities Incorrect settings could cause injury to the driver bystanders damage to the scooter and to surrounding property After the powered scooter has been set up adjusted check to make sure that the powered scooter performs to the specifications entered during the set up procedure If the powered scooter does not perform to specifications turn the powered scooter off immediately and reenter set up specifications Repeat this section until the powered scooter performs to specifications Before using the scooter verify that the motor is plugged into the harness DO NOT connect any medical devices such as ventilators life support machines etc to the battery This could cause
43. s post s BLACK to NEGATIVE and red to POSITIVE with the provided 1 4 20 x 5 8 inch hex flange screw and hex flange locknut Securely tighten gt Verify all battery cable s ring terminal s are correctly installed and securely tightened pi Slide terminal cap s down battery cable s and onto battery clamps 6 Secure each terminal cap in place with a tie wrap use tie wraps 11 inches long Refer to Detail A of FIGURE 12 5 Remove the seat Refer to Removing Installing the Seat on page 34 8 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 44 Position the batteries on the scooter Refer to Removing Installing the Batteries on Zoom 400 on page 88 NOTE New Battery ies MUST be fully charged before using otherwise the life of the battery ies will be reduced N 10 If necessary charge the battery ies Refer to Charging the Batteries on page 97 11 Install the rear shroud Refer to Removing Installing the Rear Shroud on page 44 12 Install the seat Refer to Removing Installing the Seat on page 34 Disconnecting A WARNING The use of rubber gloves and chemical goggles and face shield is recommended when working with batteries NEVER allow any of your tools and or battery cable s to contact both battery ter minal s post s at the same time An electrical short may occur and serious per sonal injury or damage may occur 1 Remove the seat Refer
44. solenoid or the relay the problem is not with the throttle or inhibit circuitry If you can hear the solenoid but the motor does not turn look for an open circuit in the motor wiring Connect a voltmeter between Battery and the following Throttle pins Battery Throttle 0 50 1 V Battery Throttle Wiper 2 540 1 V Battery Throttle 4 50 1 V When the Throttle is moved in the forward and reverse directions the voltage on Throttle Wiper should increase and decrease by 2V If the throttle voltages are incorrect an incorrect throttle potentiometer is being used and or it is not correctly calibrated If the voltage swing does not occur check the potentiometer and wiring for open circuits Connect a voltmeter between Park Brake and Park Brake The voltmeter should measure 0V when the throttle is in neutral The voltmeter should measure 24V when the throttle is out of neutral If the voltages are incorrect check the park brake and park brake wiring Connect a voltmeter between Inhibit and Battery The voltmeter should measure 5V If the voltage is OV check that an inhibit switch is not engaged e g from the battery charger When OV is applied to this terminal driving will be inhibited Status light is FLASHING Check Error Codes chart on page 102 Part No 1122167 101 Zoom 300 and Zoom 400 SECTION 13 AND TROUBLESHOOTING Error Codes
45. the scooter powers down after 60 minutes of inactivity Options Menu NOTE Options Menu settings are either ON or OFF To change the current setting of the options A Press the VARY Key to change the current setting B Press the ENTER key to confirm the value when finished FACTORY OPTIONS DEFAULT DESCRIPTION SETTING Polarity of the Throttle Potentiometer is reversed Left Hand Drive POT REVERSE Normal polarity of the Throttle Potentiometer Right Hand Drive Sleep time is enabled ENABLE SLEEP Sleep time is disabled Zoom 300 and Zoom 400 82 Part No 1122167 SECTION CONTROLLER Speed Lever in Neutral Menu This menu is used to calibrate the throttle potentiometer for neutral such that when the throttle is at rest in neutral the controller reads a voltage that translates to zero speed The default voltage for zero speed is 2 3 VDC 20 2 1 Select the Speed Lever in Neutral menu option 2 Loosen the two 2 set screws in the throttle assembly 3 Rotate the throttle shaft slowly until the buzzer sounds NOTE If the controller version is 2 46 or higher the Status LED will also glow 4 Press ENTER to confirm the value when finished Controller Version Menu This menu is used to display the current version of the Controller software Part No 1122167 83 Zoom 300 and Zoom 400 SECTION I2 BATTERIES AND CHARGER SECTION I2 BATTERIES AND CHARGER A WAR
46. to Detail C of FIGURE 8 11 10 Connect the following to the PC board Detail of FIGURE 8 11 Ignition switch Horn Throttle Controller Headlight Zoom 400 Only Headlight Switch Zoom 400 Only Install the upper tiller shroud Refer to Removing Installing the Upper Tiller Shroud on page 44 Amos Pp 1 12 Align the flat side of the stem with the hash mark on the speed control knob Refer to Detail A of FIGURE 8 11 13 Tighten the set screw inside the speed control knob not shown to the stem Zoom 300 and Zoom 400 52 Part No 1122167 DETAIL Speed Control Stem S Knob Hash Mark on Stem Locknuts Locknuts NOTE Only upper tiller shroud shown for clarity SECTION 8 TILLER DETAIL unn si cm 29 ORF Er TeC 4 3 5 T 5 10 2 230 TL 5 TUM em DETAIL Ignition Switch connects HERE Throttle connects HERE Bottom View of Upper Tiller Shroud connects HERE Headlight connects HERE Horn connects Headlight Switch HERE connects HERE Zoom 400 Only PC Board Controller Zoom 400 Only Top View of Lower Tiller Shroud
47. to FIGURE 15 2 Removing 1 Remove the front basket Refer to Removing Installing the Front Basket on page 108 2 Perform one 1 of the following On Zoom 300 Remove the two 2 mounting screws locknuts and washers that secure the front basket mounting bracket to the tiller On Zoom 400 Remove the two 2 mounting screws locknuts and washers that secure the front basket mounting bracket to the mounting tab in the scooter frame Installing 1 Perform one 1 of the following On Zoom 300 Install the front basket mounting bracket to the tiller using the two 2 mounting screws locknuts and washers e On Zoom 400 Install the front basket mounting bracket to the mounting tab in the scooter frame using the two 2 mounting screws locknuts and washers 2 Install the front basket Refer to Removing Installing the Front Basket on page 108 DETAIL A ZOOM 300 Washers Front Basket Mounting Bracket Locknuts NOTE Front Tiller basket not shown Assembly c Mounting Screws DETAIL B ZOOM 400 Front Basket Mounting Mounting Bracket Scooter Frame Tab Assembly Front Basket Mounting Screws FIGURE 15 2 Removing Installing the Front Basket Mounting Bracket Part No 1122167 109 Zoom 300 and Zoom 400 SECTION I5 SCOOTER ACCESSORIES Installing Removing the Crutch Cane Holder A WARNING The installation of the crutch cane holder onto the back of the scooter seat sign
48. wedge until the tiller angle adjustment cable is slack B Pull the tiller angle adjustment cable from the actuator wedge 13 Remove the tiller Zoom 300 and Zoom 400 40 Part No 1122167 SECTION 8 TILLER Zoom 400 NOTE For this procedure refer to FIGURE 8 1 FIGURE 8 14 and FIGURE 12 3 NOTE Reverse this procedure to install the tiller 1 2 3 4 Turn power off and remove the key from the ignition Remove the seat Refer to Removing Installing the Seat on page 19 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 30 Disconnect the two 2 BLACK battery connectors from the wiring harness connectors Refer to FIGURE 12 3 on page 89 Remove the rear tiller shroud Refer to Removing Installing the Rear Tiller Shroud on page 46 6 Remove the headlight Refer to Removing Installing the Headlight on page 47 Remove the headlight mounting bracket and front tiller shroud Refer to Removing Installing the Headlight Mounting Bracket Front Tiller Shroud on page 48 Disengage the boot and slide it up the tiller to expose the tiller angle adjustment assembly NOTE The boot will have to be slipped off the front basket bracket after disengaging the boot from the tabs 9 10 11 12 13 14 15 16 Disconnect the tiller wiring harness from the rear wiring harness Refer to FIGURE 8 14 on page 57 Cut the tie wrap securing the tiller harness cable and tiller angle adju
49. 00 shown Zoom 400 brake US release lever engages the same way FIGURE 10 3 Disengaging Engaging the Brake Release Lever Part No 1122167 67 Zoom 300 and Zoom 400 SECTION CONTROLLER SECTION CONTROLLER A WARNING After any adjustments repair or service and before use make sure that all attaching hardware is tightened securely otherwise injury or damage may result Before performing any maintenance adjustment or service turn power OFF and remove key from ignition Removing Installing the Controller NOTE For this procedure refer to FIGURE 11 1 Removing 1 Turn power off and remove the key from the ignition 2 Remove the seat Refer to Removing Installing the Seat on page 19 3 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 30 4 Perform one 1 of the following e On Zoom 300 Disconnect the RED and BLACK controller connector from the RED and BLACK battery connector Refer to FIGURE 12 2 on page 87 On Zoom 400 Disconnect the two 2 BLACK battery connectors from the wiring harness connectors Refer to FIGURE 12 3 on page 89 5 Remove the batteries Refer to Removing Installing the Batteries on Zoom 300 on page 86 and Removing Installing the Batteries on Zoom 400 on page 88 6 On Zoom 400 only A Disassemble the scooter Refer to Disassembling Assembling the Zoom 400 on page 105 B Remove the battery charger Refer to Replacing the Charger on page
50. 122167 21 Zoom 300 and Zoom 400 SECTION 4 SEAT Adjusting Seat Depth A WARNING DO NOT adjust the seat position outside the specifications recommended by the manufacturer Otherwise injury to user or damage to scooter may result NOTE For this procedure refer to FIGURE 4 5 1 Remove the seat assembly from the scooter Refer to Removing Installing the Seat on page 19 Remove the adjustable width arms Refer to Removing Installing Adjusting Arms on page 25 Remove the six 6 mounting screws located under the seat that secure the back assembly to the seat base Adjust back assembly to one 1 of three 3 mounting positions 5 Reinstall the six 6 mounting screws securing the back assembly to the seat base Securely tighten Reinstall the adjustable width arms Refer to Removing Installing Adjusting Arms on page 25 Reinstall the seat assembly onto the scooter Refer to Removing Installing the Seat on page 19 NOTE Mounting positions are in reverse order For example Depth Low is the highest position Mounting Positions Mounting Seat Base Screws Mounting Screws Back Assembly Seat Base Mounting Screws Back Assembly Seat Base Mounting Screws Mounting Holes Back pack Assembly Assembly Seat Base FIGURE 4 5 Adjusting Seat Depth Zoom 300 and Zoom 400 22 Part No 1122167 SECTION 4 SEAT 90 Seat Swivel Adjustment A WARNING Ensure that seat is
51. 87 for the Zoom 300 and FIGURE 12 3 on page 89 for the Zoom 400 Install the rear shroud Refer to Removing Installing the Rear Shroud on page 30 8 Install the seat Refer to Removing Installing the Seat on page 19 Part No 1122167 37 Zoom 300 and Zoom 400 SECTION 7 WHEELS AND CASTERS Tiller Angle Adjustment Assembly Scooter Frame Fork Stem Mount Front Fork NOTE Zoom 300 frame is shown Front fork mounts the same way to Zoom 400 FIGURE 7 3 Removing Installing the Fork Removing Installing the Caster Assemblies NOTE For this procedure refer to FIGURE 7 4 Removing 1 Use wrench to turn the hex nut on the caster assembly counter clockwise to loosen and remove the caster wheel 2 If necessary repeat STEPS 1 to remove the other caster Installing 1 Insert the caster wheel into the caster housing and turn the hex nut clockwise to securely tighten the caster wheel in place Caster Housing Hex Nut Swingarm Assembly Caster FIGURE 7 4 Removing Installing the Caster Assemblies Zoom 300 and Zoom 400 38 Part No 1122167 SECTION 7 WHEELS AND CASTERS Replacing Foam Filled Tires Onto Wheel Rims NOTE For this procedure refer to FIGURE 7 5 NOTE During initial use of scooter user may experience a flat spot on wheels Flat spot will disappear with continual use of scooter 1 Remove the wheel from the drive shaft Refer to Removing Installing the Drive Wheels on page 34 2 Perform
52. 92 7 Disconnect the following from the controller Detail C of FIGURE 11 1 e 6 way rear harness connector e 8 way rear harness connector 4 way motor connector 8 Remove the three 3 mounting screws and locknuts that secure the controller on the controller tray Zoom 300 and Zoom 400 68 Part No 1122167 SECTION CONTROLLER DETAIL B ZOOM 400 Locknuts DETAIL ZOOM 300 Mounting Screws Controller Controller Controller Mounting Screws Controller Tray DETAIL C LOCATION OF CONNECTORS 6 way Rear Harness 4 way Motor Connector 8 way Rear Harness Controller on Connector connects HERE Connector connects Zoom 400 id connects HERE HERE Controller on Zoom 8 way Rear Harness Connector connects HERE 4 way Motor Connector Connector connects HERE connects HERE FIGURE 11 1 Removing Installing the Controller Installing 1 Ensure that the power is off and the key is removed from the ignition 2 Install the controller on the controller tray using three 3 mounting screws and locknuts Securely tighten 3 Connect the following to the controller Detail C of FIGURE 11 1 e 6 way rear harness connector e 8 way rear harness connector e 4 way motor connector 4 On Zoom 400 only A Install the battery charger Refer to Replacing the Charger on page 92
53. ATIVE battery terminal post on the right battery 7 Connect the RED and BLACK battery connector to the wiring harness assembly Tighten securely 8 Secure batteries in the battery tray using the hook and loop battery strap Detail A of FIGURE 12 2 9 Reinstall the rear shroud Refer to Removing Installing the Rear Shroud on page 44 10 Reinstall the seat Refer to Removing Installing the Seat on page 34 NOTE New batteries MUST be fully charged BEFORE using otherwise the life of the batteries will be reduced 11 If necessary charge the batteries Refer to Charging the Batteries on page 97 DETAIL A REMOVING INSTALLING THE BATTERIES Batteries Batteries Removed Installed NOTE Seat and Rear Shroud not shown for clarity Battery Tray DETAIL B BATTERY 2 RED and BLACK WIRING HARNESS Battery Connector 50 Amp Fuse POSITIVE RED WHITE Battery Battery Cable LEFT Cable Jumper BATTERY NEGATIVE BLACK Battery Cable NEGATIVE BLACK Battery Terminal POSITIVE RED Battery Terminal POSITIVE RED Battery Terminal NEGATIVE BLACK Battery Terminal FIGURE 12 2 Removing Installing the Batteries on Zoom 300 Part No 1122167 87 Zoom 300 and Zoom 400 SECTION I2 BATTERIES AND CHARGER Removing Installing the Batteries on
54. CTION WITH SHROUDS ENTIRE BASE SECTION SEAT WITH ARMS BATTERIES QUANTITY 2 N A N A 71 Ibs 31 Ibs 18 Ibs 53 Ibs 48 Ibs 38 Ibs 46 Ibs TOTAL WEIGHT OF PRODUCT Including Batteries 120 Ibs 185 Ibs NOTE Zoom 300 parameters are based on an 18 inch wide seat Zoom 400 parameters are based on a 20 inch wide seat Part No 1122167 Zoom 300 and Zoom 400 LABEL LOCATIONS LABEL LOCATIONS On Zoom 300 NOTE Serial Number WEIGHT CAPACITY is located under the S J 300 LBS 136 kgs rear shroud REFER TO OWNER S MANUAL P N 1111016 WIRING DIAGRAM for Dual 12AH Batteries DO NOT REMOVE THIS LABEL The POSITIVE RED Battery Cable MUST connect to the POSITIVE 4 Battery Terminal s Post s The NEGATIVE BLACK Battery Cable MUST connect to the NEGATIVE Battery Terminal s Post s DO NOT allow Battery Cable s to contact the opposite Battery Terminal s Post s Replace cable s immediately if cable s insulation becomes damaged Failure to observe these warnings may result in an electrical short with serious personal injury and or damage to the electrical system See Owner s Manual WICEECENTO DO NOT operate the scooter unless the tiller is in the locked position 50 AMP FUSE MD Type Battery Cable Th TAH BATT 5 zstot Comer PUT DO NOT lean against or pull forward on the tiller while mounting or Wita ate cable a E B
55. HMV Highly Maneuverable Vehicle Zoom 300 and Zoom 400 DEALER Keep this manual The procedures in this manual must be performed by a qualified technician INVACARE Yes you can A WARNING THE PROCEDURES IN THIS SERVICE MANUAL MUST BE PERFORMED BY A QUALIFIED TECHNICIAN DO NOT SERVICE OR OPERATE THIS EQUIPMENT WITHOUT FIRST READING AND UNDERSTANDING 1 THE OWNER S OPERATOR AND MAINTENANCE MANUAL AND 2 THE SERVICE MANUAL IF YOU ARE UNABLE TO UNDERSTAND THE WARNINGS CAUTIONS AND INSTRUCTIONS CONTACT INVACARE TECHNICAL SUPPORT BEFORE ATTEMPTING TO SERVICE OR OPERATE THIS EQUIPMENT OTHERWISE INJURY OR DAMAGE MAY RESULT NOTE Updated versions of this manual are available on www invacare com Zoom 300 and Zoom 400 2 Part No 1122167 TABLE OF CONTENTS TABLE OF CONTENTS SPECIAL NOTES 8 TYPICAL PRODUCT PARAMETERS 9 LABEL LOCATIONS 10 On Zoom 300 o osea detti eate ab 10 2 400 E SECTION 1 GENERAL GUIDELINES
56. HT Battery LEFT Connectors Battery Rear Frame Assembly Battery Front Frame Assembly 3 Front Frame UP to Unlock Assembly Tiller Handle DOWN to Lock Mounting Frame Bracket Lock Mounting pu Lever Bracket lt a 5 22 CN Rear Frame i A igh EI 6 e FIGURE 14 2 Disassembling Assembling the Zoom 400 INSTALL FRONT FRAME FROM REAR FRAME ASSEMBLY Assembly Part No 1122167 107 Zoom 300 and Zoom 400 SECTION 15 SCOOTER ACCESSORIES SECTION 15 SCOOTER ACCESSORIES A WARNING After ANY adjustments repair or service and BEFORE use make sure that all attaching hardware is tightened securely otherwise injury or damage may result Before performing any maintenance adjustment or service turn power OFF and remove key from ignition Removing Installing the Front Basket NOTE For this procedure refer to FIGURE 15 1 1 To remove Lift up on the basket and remove it from the mounting clips 2 To install A Align the slots of the basket with the mounting clips on the tiller B Push down on the basket to secure it in place DETAIL A ZOOM 300 Slots Tiller Front Basket Front Basket FIGURE 15 1 Removing Installing the Front Basket Zoom 300 and Zoom 400 108 Part No 1122167 SECTION 15 SCOOTER ACCESSORIES Removing Installing the Front Basket Mounting Bracket NOTE For this procedure refer
57. ILLER Throttle Throttle IDC Potentiometer Wires from Throttle Potentiometer Lower Tiller Shroud DN Lever Set Screws FIGURE 8 16 Calibrating Throttle Potentiometer Programming Method NOTE For this procedure refer to FIGURE 8 16 NOTE Before performing this procedure review Programming the Controller on page 80 NOTE This menu is used to calibrate the throttle potentiometer for neutral such that when the throttle is at rest in neutral the controller reads a voltage that translates to zero speed The default voltage for zero speed is 2 3 VDC 0 2 1 Plug in the programmer Refer to Plugging in the Programmer on page 80 2 From the Main menu select the Speed Lever in Neutral menu option 3 Loosen the two 2 set screws in the throttle assembly refer to FIGURE 8 16 4 Rotate the throttle shaft slowly until the buzzer sounds NOTE If the controller version is 2 46 or higher the Status LED will also glow 5 Press ENTER to confirm the value when finished Part No 1122167 61 Zoom 300 and Zoom 400 SECTION 9 SWINGARMS SECTION 9 SWINGARMS A WARNING After any adjustments repair or service and before use make sure that all attaching hardware is tightened securely otherwise injury or damage may result Before performing any maintenance adjustment or service turn power OFF and remove key from ignition Removi
58. ILLER ANGLE ADJUSTMENT ASSEMBLY Angle Adjustment Removing Installing the Tiller Part No 1122167 SECTION 8 TILLER Adjusting the Tiller Angle A WARNING Ensure that tiller is properly adjusted before driving the scooter After making any tiller angle adjustments and before use the tiller MUST be securely locked into position Otherwise a fall from the scooter could occur causing bodily injury and or damage to the scooter Gently push pull against tiller to ensure that the tiller is securely engaged into the adjustment plate NOTE For this procedure refer to FIGURE 8 2 NOTE The powered scooter has an adjustable tiller The tiller locks into a position that is most Tiller Release Lever comfortable for you The tiller also folds down for transportation and storage D SP 1 Pull up on the tiller release lever Up to JPH 5 located under the right tiller handle Unlock 2 Push pull the tiller to the desired angle Right Tiller and release the tiller release lever Pande Down to 3 Gently push pull against tiller to Lock ensure that the tiller is securely engaged into the locking mechanism NOTE The tiller is locked in position when an audible click is heard FIGURE 8 2 Adjusting the Tiller Angle Replacing Handgrips NOTE For this procedure refer to FIGURE 8 3 1 Cut the hangrip along the tiller handle Handgrip TSA b AASSEMDIY 2 Remove the cuthandgrip from the tiller hand
59. NING Before performing any maintenance adjustment or service turn power OFF and remove key from ignition NEVER allow any of your tools and or battery cable s to contact BOTH battery terminal s post s at the same time An electrical short may occur and serious personal injury or damage may occur The use of rubber gloves and chemical goggles and face shield is recommended when working with batteries Always use a battery lifting strap when lifting a battery It is the most convenient method and assures that the battery acid will not spill It also helps to prolong the life of the battery DO NOT tip the batteries Keep the batteries in an upright position Invacare strongly recommends that battery installation and battery replacement always be done by a qualified technician All battery terminals caps two 2 on the LEFT battery and two 2 on the RIGHT battery MUST be installed prior to use DO NOT remove fuse or mounting hardware from the POSITIVE RED battery cable mounting screw On Zoom 400 only Battery terminal configuration shown below MUST be used Batteries that have the reversed terminal configuration MUST NOT be used otherwise serious injury or damage may occur POSITIVE DO NOT USE Battery Termina POSITIVE NEGATIVE Battery Battery Battery Terminal Termina Terminal Zoom 300 and Zoom 400 84 Part No 1122167 SECTION 12 5 AND CHARGER
60. card 7 Position the new ignition switch on the upper tiller shroud 8 Secure the new ignition switch with the locknut Securely tighten 9 Insert the ignition switch connector into the PC board 10 Apply a thin coating of RTV sealant to the ignition switch connector and PC board 11 Push the PC board into its slotted housing 12 Install the upper tiller shroud Refer to Removing Installing the Upper Tiller Shroud on page 44 Bottom View of Ignition Switch and Attached Wiring Ignition f DA 5 Ignition Switch L With p 3 CEB 4 v e A i B y o Top View of Lower Tiller Shroud Locknut connects HERE Bottom View of Upper Tiller Shroud FIGURE 8 8 Replacing the Ignition Switch Part No 1122167 49 Zoom 300 and Zoom 400 SECTION 8 TILLER Replacing the Horn NOTE For this procedure refer to FIGURE 8 9 NOTE RTV sealant is required for this prodcedure 1 Remove the upper tiller shroud Refer to Removing Installing the Upper Tiller Shroud on page 44 2 Remove the RTV sealant coating the horn connector CAUTION Remove any RTV sealant coating the connector on the PC board before disconnecting the connector from the PC board Otherwise the PC board could be damaged DO NOT use a chemical solvent to remove any RTV sealant from connectors as it may cause damage to the PC Board 3 Pull the
61. directly to the battery terminals DO NOT attempt to recharge the batteries and operate the wheelchair at the same time DO NOT operate wheelchair with extension cord attached to the AC cable DO NOT attempt to recharge the batteries when the wheelchair has been exposed to any type of moisture DO NOT attempt to recharge the batteries when the wheelchair is outside DO NOT sit in the wheelchair while charging the batteries Read and carefully follow the manufacturer s instructions for each charger supplied or purchased If charging instructions are not supplied consult a qualified technician for proper procedures When using an extension cord use only a three 3 wire extension cord having at least 16 AWG American Wire Gauge wire and the same or higher electrical rating as the device being connected Use of improper extension cord could result in risk of fire and electric shock Ensure the pins of the extension cord plug are the same number size and shape as those on the charger DO NOT under any circumstances cut or remove the round grounding plug from the charger AC cable plug or the extension cord plug Three 3 prong to two 2 prong adapters should not be used Use of three 3 prong adapters can result in improper grounding and present a shock hazard to the user Rain Test Invacare has tested its powered scooters in accordance with ISO 7176 Rain Test Passing this test means that the end user or his her attendant s
62. e Zoom 300 and Zoom 400 100 Part No 1122167 Controller SECTION I3 MAINTENANCE AND TROUBLESHOOTING NOTE For this procedure refer to FIGURE 13 2 SYMPTOM Status light is OFF PROBABLE CAUSE Programmer is plugged in Battery supply voltage may not be present on the controller terminals Key may be off or the wiring and fuses may not be intact Status LED may not be fitted correctly SOLUTIONS Unplug programmer Connect a voltmeter between Battery and Battery negative probe on Battery The voltmeter should measure between 23 and 27 volts If the voltage is negative check for correct battery wir ing polarity If the voltage is OV check the circuit breaker and for open circuit wiring Connect a voltmeter between the Key Switch terminal and Battery The voltmeter should read at least 20 volts If the voltage is OV use the voltmeter to check the wiring from Battery to the key switch itself and back to the Key Switch terminal Status light is perma nently ON but the scooter does not move Park brake solenoid or relay may not be working Voltage on the Throttle terminals may be incorrect when Throttle is in neutral Voltage on the Motor terminals may be incorrect Inhibit status may be incorrect Move the throttle to the full speed position and listen carefully for the operation of the park brake solenoid or the relay in the controller If you can hear the
63. e Drive Wheels on page 34 8 Remove both swingarms and viscous elements from the frame Refer to Removing Installing the Swingarms on page 62 9 Once the swingarm and viscous elements are removed the transaxle will be free to be removed Installing 1 Align the transaxle along the bottom of the frame 2 Install the viscous element on drive shaft of the transaxle 3 Install both swingarms and viscous elements Refer to Removing Installing the Swingarms on page 62 4 Install both drive wheels Refer to Removing Installing the Drive Wheels on page 34 5 Install the batteries 6 Reconnect the 4 way motor connector to the controller Refer to FIGURE 11 1 Zoom 300 and Zoom 400 64 Part No 1122167 SECTION 0 5 On Zoom 400 only Assemble the scooter Refer to Disassembling Assembling the Zoom 400 on page 105 8 Install the rear shroud Refer to Removing Installing the Rear Shroud on page 30 9 NOTE Zoom 300 shown Zoom 400 transaxle removes installs the same way Install the seat Refer to Removing Installing the Seat on page 19 Swingarm and Caster Assembly Swingarm Assembly Viscous Element Cotter Pin 3 Viscous Element Assembly P Base Frame FIGURE 10 1 Removing Installing the Transaxle Removing Installing the Brake Release Lever NOTE For this procedure refer to FIGURE 10 2 Removing 1 Remove the seat Refe
64. e PC board Otherwise the PC board could be damaged DO NOT use a chemical solvent to remove any RTV sealant from connectors as it may cause damage to the PC Board 8 Disconnect the following from the PC board Detail A of FIGURE 8 4 A Throttle IDC B Headlight connector Zoom 400 only C Tiller harness connector Installing 1 Connect the following to the PC board Detail B of FIGURE 8 4 A Throttle IDC B Headlight connector Zoom 400 only C Tiller harness connector Zoom 300 and Zoom 400 44 Part No 1122167 SECTION 8 TILLER 2 Apply a thin coating of RTV sealant to the connectors 3 Rotate the upper tiller shroud forward 4 Secure the upper tiller shroud to the lower tiller shroud using the four 4 mounting screws 5 Perform one 1 of the following e On Zoom 300 Connect the RED and BLACK controller connector to the RED and BLACK battery connector Refer to FIGURE 12 2 on page 87 On Zoom 400 Connect the two 2 BLACK battery connectors to the wiring harness connectors Refer to FIGURE 12 3 on page 87 6 Install the rear shroud Refer to Removing Installing the Rear Shroud on page 30 7 Install the seat Refer to Removing Installing the Seat on page 19 Zoom 300 DETAIL A Zoom 400 Shown Headlight Connector to PC Shown Board Zoom 400 only Lower Throttle Upper Tiller ba Tiller Shroud i i Shroud
65. e Tiller Zoom 300 NOTE For this procedure refer to FIGURE 8 1 FIGURE 8 13 and FIGURE 12 2 NOTE Reverse this procedure to install the tiller 1 Turn power off and remove the key from the ignition Remove the seat Refer to Removing Installing the Seat on page 19 2 3 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 30 4 Disconnect the controller from the batteries by pulling the RED and BLACK controller connector from the RED and BLACK battery connector Refer to FIGURE 12 2 on page 87 5 Remove the basket Refer to Removing Installing the Front Basket on page 108 6 Disengage the boot and slide it up the tiller to expose the tiller angle adjustment assembly 7 Disconnect the tiller wiring harness from the rear wiring harness Refer to FIGURE 8 13 on page 56 8 Remove the upper tiller shroud Refer to Removing Installing the Upper Tiller Shroud on page 44 9 Remove the mounting screw and P clip securing the tiller harness cable to the tiller Detail C of FIGURE 8 1 10 Pull the tiller harness cable through the hole in the lower tiller shroud 11 Remove the two 2 locknuts mounting screws tube clamps and cable bracket that secure the tiller to the tiller angle adjustment assembly Detail A of FIGURE 8 1 12 Disconnect the tiller angle adjustment cable from the actuator wedge by performing the following Detail D of FIGURE 8 1 A Lift up the actuator
66. e arm width can be adjusted between 18 inches and 22 inches NOTE Changing the width of the arms may also affect the overall width of the powered scooter Use caution when traveling through doorways 1 Loosen the adjustment knob on one 1 arm located beneath the seat frame on the arm support bracket Refer to FIGURE 5 1 CAUTION The arm can be adjusted to a maximum distance of 4 4 inches from the inside of the arm to the top of the mounting shaft If the arm is adjusted beyond the maximum 47 inches the arm will fall out 2 Move arm in or out to the desired position 3 Retighten adjustment knob securely 4 Measure distance between back and inside of arm NOTE For proper balance adjust both arms to the same distance away from the back 5 Repeat STEPS 1 4 for opposite arm setting it at the distance determined in STEP 4 Adjusting Arm Angle NOTE For this procedure refer to FIGURE 5 2 NOTE Arm angle can be adjusted between 8 and 10 1 Lift up the arm Loosen the jam nut Adjust the adjustment screw up or down to the desired arm angle Tighten the jam nut e To position the opposite arm at the same angle count the exposed threads after the jam nut has been tightened D Set the opposite arm to position determined in STEP 5 Zoom 300 and Zoom 400 26 Part No 1122167 SECTION 5 ARMS Arm Adjustment Count Exposed Threads STEP 5 Mounting Tube Jam Nut FIGURE 5 2 Adjusti
67. ed wheelchair is turned ON 2 Be aware of nearby transmitters such as radio or TV stations and try to avoid coming close to them 3 If unintended movement or brake release occurs turn the powered wheelchair OFF as soon as it is safe 4 Be aware that adding accessories or components or modifying the powered wheelchair may make it more susceptible to EMI NOTE There is no easy way to evaluate their effect on the overall immunity of the powered wheelchair and 5 Report all incidents of unintended movement or brake release to the powered wheelchair manufacturer and note whether there is a source of EMI nearby Important Information 1 20 volts per meter V m is a generally achievable and useful immunity level against EMI as of May 1994 the higher the level the greater the protection 2 This device has been tested to a radiated immunity level of 20 volts per meter Modification of any kind to the electronics of this wheelchair as manufactured by Invacare may adversely affect the RFI immunity levels Zoom 300 and Zoom 400 16 Part No 1122167 SECTION 3 SAFETY INSPECTION SECTION 3 SAFETY INSPECTION Checklist These adjustments should be made whenever you service this product especially as a part of the initial set up Follow these maintenance procedures A WARNING Before performing any maintenance adjustment or service turn power OFF and remove key from ignition CAUTION As with any vehicle
68. g straps to the arm frame Remove the halves of the seat positioning strap from the arm frame 3 Reposition the halves of new seat positioning strap underneath arm frame B Reinstall the two 2 mounting screws and washers that secure the seat positioning straps to the arm frame Securely tighten Arm Frame One Half 2 of Seat Positioning Strap One Half 2 of Seat i Positioning Strap T Mounting Screw eee Screw FIGURE 4 7 Removing Installing the Seat Positioning Strap Washer Zoom 300 and Zoom 400 24 Part No 1122167 SECTION 5 ARMS SECTION 5 ARMS A WARNING After ANY adjustments repair or service and BEFORE use make sure all attaching hardware is tightened securely otherwise injury or damage may result Before performing any maintenance adjustment or service turn power off and remove key from ignition Removing Installing Adjusting Arms Removing Installing NOTE For this procedure refer to FIGURE 5 1 NOTE Reverse this procedure to install the arms 1 Loosen adjustment knob that secures the arm to the arm support bracket 2 Remove the arm from the arm support bracket 3 If necessary repeat STEPS 1 2 to remove the remaining arm Arm Adjustment Knobs Arm Support Bracket FIGURE 5 1 Removing Installing Adjusting Arms Part No 1122167 25 Zoom 300 and Zoom 400 SECTION 5 ARMS Adjusting Arm Width NOTE For this procedure refer to FIGURE 5 1 NOTE Th
69. g the Seat on page 19 Zoom 300 and Zoom 400 62 Part No 1122167 GE eo 59 SECTION 9 SWINGARMS Swingarm Assembly Glide Bearings Washer Transaxle Assembly Viscous Element NOTE Swingarm on Zoom 300 shown Swingarm on Zoom 400 removes installs the same way FIGURE 9 1 Removing Installing the Swingarms Part No 1122167 63 Zoom 300 and Zoom 400 SECTION I0 TRANSAXLE SECTION 10 TRANSAXLE A WARNING After any adjustments repair or service and before use make sure that all attaching hardware is tightened securely otherwise injury or damage may result Before performing any maintenance adjustment or service turn power off and remove key from ignition Removing Installing the Transaxle NOTE For this procedure refer to FIGURE 10 1 and FIGURE 11 1 Removing 1 Turn power off and remove the key from the ignition Remove the seat Refer to Removing Installing the Seat on page 19 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 30 2 3 4 Disconnect the 4 way motor connector from the controller Refer to FIGURE 11 1 5 On Zoom 400 only disassemble the scooter Refer to Disassembling Assembling the Zoom 400 on page 105 6 Remove the batteries Refer to Removing Installing the Batteries on Zoom 300 on page 86 or Removing Installing the Batteries on Zoom 400 on page 88 7 Remove both drive wheels Refer to Removing Installing th
70. his procedure refer to FIGURE 11 7 1 Remove the seat Refer to Removing Installing the Seat on page 19 2 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 30 NOTE Two 2 fuse holders are located on the wiring harness NOTE Replace existing blown fuse with a new fuse of the same rating 3 Pull fuse out and install new fuse Detail A of FIGURE 11 7 4 Reverse STEPS 1 4 to reassemble the powered scooter Fuse Holder Rear Wiring Harness DETAIL A To Batteries Fuse Holder Controller FIGURE 11 7 Replacing the Fuse Part No 1122167 79 Zoom 300 and Zoom 400 SECTION CONTROLLER Changing to Left Handed Operation NOTE For this procedure refer to FIGURE 11 8 NOTE The default factory is setting is OFF NOTE For more information refer to Programming the Controller on page 80 1 Plug in the programmer to the programmer port on the controller 2 Press the MENU key to access the Options Menu 3 From the Options Menu select Pot Reverse menu 4 Press the VARY key to change the current setting to ON NOTE The default factory is setting is OFF 5 Press the ENTER Key to confirm the value when finished 6 Unplug the programmer from the programmer port Programming the Controller Plugging in the Programmer A WARNING Disengage the brake release lever before making any programming changes The scooter will drive if the brake release leve
71. horn switch connector to disconnect the horn switch from the PC board 4 Push the horn switch with the attaching wires through upper tiller shroud in the direction of the arrow shown in Detail B of FIGURE 8 9 and discard 5 Install the new horn switch into the upper tiller shroud by inserting the wiring first then the horn 6 Push the horn switch into place until the housing is snug against the upper tiller shroud Refer to Detail A of FIGURE 8 9 7 Insert the horn switch connector into the PC board Refer to Detail of FIGURE 8 9 8 Apply a thin coating of RTV sealant to the horn switch connector and PC board 9 Install the upper tiller shroud Refer to Removing Installing the Upper Tiller Shroud on page 44 DETAIL B DETAIL A PC Board Horn Switch should be snug Upper Tiller against Upper Tiller Shroud Shroud Horn Switch Pull Horn Switch and Wires out in this direction Top View of Lower Tiller Shroud Horn Switc connects Horn Switch and Wiring SOY HERE Bottom View of Upper Tiller Shroud FIGURE 8 9 Replacing the Horn Zoom 300 and Zoom 400 50 Part No 1122167 SECTION 8 TILLER Replacing the Headlight Switch NOTE This procedure is for the Zoom 400 only NOTE For this procedure refer to FIGURE 8 10 NOTE RTV sealant is required for this prodcedure 1 Remove the upper tille
72. hould have sufficient time to remove his her powered scooter from a rain storm and retain powered scooter operation DO NOT leave powered scooter in a rain storm of any kind DO NOT leave powered scooter in a damp area for any length of time Weight Limitation The weight limitation for the Zoom 300 is 300 Ibs The weight limitation for the Zoom 400 is 400 Ibs If so equipped the front basket is rated for a maximum loading capacity of 10 Ibs Zoom 300 and Zoom 400 14 Part No 1122167 SECTION 2 EMI INFORMATION SECTION 2 EMI INFORMATION A WARNING CAUTION IT IS VERY IMPORTANT THAT YOU READ THIS INFORMATION REGARDING THE POSSIBLE EFFECTS OF ELECTROMAGNETIC INTERFERENCE ON YOUR POWERED WHEELCHAIR Electromagnetic Interference EMI From Radio Wave Sources Powered wheelchairs and motorized scooters in this text both will be referred to as powered wheelchairs may be susceptible to electromagnetic interference EMI which is interfering electromagnetic energy EM emitted from sources such as radio stations TV stations amateur radio HAM transmitters two way radios and cellular phones The interference from radio wave sources can cause the powered wheelchair to release its brakes move by itself or move in unintended directions It can also permanently damage the powered wheelchair s control system The intensity of the interfering EM energy can be measured in volts per meter V m Each powered wheelchair can resist
73. hown for clarity FIGURE 12 7 Replacing the Charger Zoom 400 Zoom 300 and Zoom 400 96 Part No 1122167 SECTION 12 5 AND CHARGER Charging the Batteries A WARNING NEVER attempt to recharge the batteries by attaching cables directly to the battery terminals or clamps DO NOT attempt to recharge the batteries and operate the powered scooter at the same time If the circuit breaker trips repeatedly IMMEDIATELY unplug charger and contact Invacare Technical Service Department CAUTION New batteries MUST be fully charged prior to initial use of the powered scooter Always charge new batteries before initial use or battery life will be reduced As a general rule you should recharge your batteries nightly to assure the longest possible life and to minimize required charging time Plan to recharge them when you do not anticipate using the powered scooter On Board Battery Charger NOTE For this procedure refer to FIGURE 12 8 NOTE The powered scooter is designed with an electrical lockout to prevent it from being driven while the charger is plugged into an outlet 1 Plug AC power cord into on board battery charger port located on the rear bumper 2 Plug AC power cord into 110 volt wall outlet 3 Refer to Battery Charger Operation Charger Indicator Light on Tiller on page 98 NOTE Charger port on Zoom 300 shown Charger port on Zoom 400 is similar FIGURE 12 8 Charging the Batteries Pa
74. ifi cantly increases the length of the scooter When turning the scooter or swiveling the scooter seat it is important to take note of this increased length otherwise injury and or damage to the surrounding property may result NOTE For this procedure refer to FIGURE 15 3 NOTE The Crutch Cane Holder Safety Flag and Oxygen Holder all install into the accessory tube ONLY one 1 of these may be installed at a time Installing 1 Install the crutch cane holder into the accessory tube located on the back of the seat 2 Install the mounting knob to secure the crutch cane holder in place Securely tighten 3 Alignthesloton the base with the hook on the crutch cane holder and slide base down into position Removing 1 Remove the crutch cane holder from the accessory tube 2 Remove the mounting knob that secures the crutch cane holder in place 3 Remove the crutch cane holder from the accessory tube Crutch Cane Holder Mounting Knob Seat Hoek Accessory Tube CID Base FIGURE 15 3 Installing Removing the Crutch Cane Holder Zoom 300 and Zoom 400 110 Part No 1122167 SECTION 15 SCOOTER ACCESSORIES Installing Removing the Safety Flag A WARNING The installation of the safety flag onto the back of the scooter seat significantly increases the length of the scooter When turning the scooter or swiveling the scooter seat it is important to take note of this increased length otherwise injury
75. il B FIGURE 127 Secure the AC receptacle to charger to the controller tray using the two 2 mounting screws and locknuts Insert the DC charger connector into the charger port Tie wrap the DC charger cable to the scooter frame as shown in Detail B of FIGURE 12 7 Connect the two 2 BLACK battery connectors to the wiring harness connectors Refer to Detail C of FIGURE 12 3 Install the rear shroud Refer to Removing Installing the Rear Shroud on page 30 Install the seat Refer to Removing Installing the Seat on page 19 Insert the key into the ignition and turn the power on to drive the scooter Part No 1122167 95 Zoom 300 and Zoom 400 SECTION I2 BATTERIES AND CHARGER AC Receptacle DC to Charger Charger d Connector X DETAIL A CHARGER REMOVED DETAIL CHARGER INSTALLED AC Receptacle to Charger Locknuts Controller Tray Mounting Screws DC Charger Connector Tie Wrap Charger Port hidden from view NOTE Connectors to Controller not s
76. ing Installing the Front Wheel Zoom 300 and Zoom 400 36 Part No 1122167 SECTION 7 WHEELS AND CASTERS Removing Installing the Fork NOTE For this procedure refer to FIGURE 7 3 FIGURE 12 2 and FIGURE 12 3 Removing 1 Remove the seat Refer to Removing Installing the Seat on page 19 2 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 30 3 Disconnect the RED and BLACK battery connector from the wiring harness assembly Refer to FIGURE 12 2 on page 87 for the Zoom 300 and FIGURE 12 3 on page 89 for the Zoom 400 4 Remove the boot assembly Refer to Removing Installing the Boot Assembly on page 33 5 Remove the tiller Refer to Removing Installing the Tiller on page 40 6 Remove the two 2 mounting bolts that secure the tiller angle adjustment assembly to the front fork Refer to FIGURE 7 3 Slide front fork out of the fork stem mount on the scooter frame Installing 1 2 3 Slide front fork into the fork stem mount Place the tiller angle adjustment assembly on the front fork Install the two 2 mounting bolts to secure tiller angle adjustment assembly to the front fork Securely tighten FIGURE 7 3 Install the tiller assembly Refer to Removing Installing the Tiller on page 40 5 Install the boot assembly Refer to Removing Installing the Boot Assembly on page 33 6 Connect the RED and BLACK battery connector to the wiring harness assembly Refer to FIGURE 12 2 on page
77. ing Rear Wiring Harness NOTE For this procedure refer to FIGURE 11 4 NOTE To install the rear wiring harness reverse this procedure 1 Disconnect the following from the controller e 6 way rear harness connector 8 way rear harness connector 4 way motor connector Disconnect the batteries Refer to Removing Installing the Batteries on Zoom 300 on page 86 or refer to Removing Installing the Batteries on Zoom 400 on page 88 Disconnect the circuit breaker Refer to Replacing Resetting the Circuit Breaker on page 76 On Zoom 400 only A Remove the four 4 mounting screws securing the battery connectors to the frame B Remove the rear harness connector from controller tray Remove the two 2 screws and locknuts securing the charger connector to the controller tray Lift the wiring harness from the controller tray Zoom 300 and Zoom 400 74 Part No 1122167 SECTION CONTROLLER Battery Connector Battery Connector Q Circuit i 7 1 N 7 Mounting Screws DETAIL ZOOM 400 m Breaker Screws Charger Connector Rear Harness Connector Locknuts 6 Way 4 Way 8 Way Connector Connector Connector Screws DETAIL B ZOOM 300 Battery Connector 6 Way 4 Connector TOE Se z Charger j Connector 4 Way Connector Rear Harness Connector 8 Way Connector C Controller Tray Locknuts Circuit Breaker FIGURE 11 4 Removing Installing Rear Wiring Harness Par
78. ing the Batteries on Zoom 300 on page 86 or Removing Installing the Batteries on Zoom 400 on page 88 21 Install the rear shroud Refer to Removing Installing the Rear Shroud on page 30 22 Install the seat Refer to Removing Installing the Seat on page 19 Mounting Bolts Brake Release Rod Controller Tray Scooter Frame Locknuts FIGURE 11 2 Replacing the Controller Tray Zoom 300 Part No 1122167 71 Zoom 300 and Zoom 400 SECTION CONTROLLER Zoom 400 NOTE For this procedure refer to FIGURE 8 14 FIGURE 11 1 FIGURE 11 3 and FIGURE 12 2 1 2 Turn power OFF and remove the key from the ignition Disassemble the scooter Refer to Disassembling Assembling the Zoom 400 on page 105 3 Remove the charger Refer to Replacing the Charger on page 92 Remove the controller Refer to Removing Installing the Controller on page 68 5 Disconnect the tiller wiring harness from the rear wiring harness Refer to 10 11 12 13 14 15 16 TZ 18 19 20 FIGURE 8 14 Remove the rear wiring harness Refer to Removing Installing Rear Wiring Harness on page 74 Remove the circuit breaker Refer to Replacing Resetting the Circuit Breaker on page 76 Remove the four 4 mounting bolts eight 8 washers and four 4 locknuts that secure the controller tray to the scooter frame Remove the two 2 screws that mount the left connector to the controller tray Detail A of FIGURE 11 3
79. ion Remove the seat Refer to Removing Installing the Seat on page 34 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 44 Perform one 1 of the following to position the battery into the battery tray Detail D of FIGURE 12 3 Batteries with Built in Lifting Strap Use built in lifting strap to position battery onto the battery tray Detail B of FIGURE 12 3 Batteries without Built in Lifting Strap Use a battery lifting strap to position battery onto battery tray When battery is in proper position remove lifting strap Detail A of FIGURE 12 3 7 Connect the two 2 BLACK battery connectors to the wiring harness connectors Detail C of FIGURE 12 3 oO 9 Zoom 300 and Zoom 400 88 Part No 1122167 SECTION 12 5 AND CHARGER 8 Secure batteries in the battery tray using the battery strap 9 Reinstall the rear shroud Refer to Removing Installing the Rear Shroud on page 44 10 Reinstall the seat Refer to Removing Installing the Seat on page 34 NOTE New batteries MUST be fully charged BEFORE using otherwise the life of the batteries will be reduced DETAIL A BATTERY LIFTING STRAPS DETAIL B BUILT IN LIFTING STRAPS Battery Built in Lifting Straps LTRS 55 Lifting Straps DETAIL C BATTERY WIRING HARNESS Wiring Harness Connectors es u Cn j
80. le 3 Spray the inside of the new handgrip with hairspray 4 Slide the new handgrip onto the tiller handle Tiller Handle 5 Repeat STEPS 1 and 4 for the other Under the Handgrip handgrip FIGURE 8 3 Replacing Handgrips Part No 1122167 43 Zoom 300 and Zoom 400 SECTION 8 TILLER Removing Installing the Upper Tiller Shroud NOTE For this procedure refer to FIGURE 8 4 Removing 1 Turn power off and remove the key from the ignition Remove the seat Refer to Removing Installing the Seat on page 19 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 30 Perform one 1 of the following e On Zoom 300 Disconnect the RED and BLACK controller connector from the RED and BLACK battery connector Refer to FIGURE 12 2 on page 87 On Zoom 400 Disconnect the two 2 BLACK battery connectors from the wiring harness connectors Refer to FIGURE 12 3 on page 87 g Remove the four 4 mounting screws that secure the upper tiller shroud to the lower tiller shroud CAUTION Carefully rotate the upper tiller shroud backward to avoid damaging the internal wiring otherwise scooter will not operate properly 6 Gently rotate the upper tiller shroud backward exposing the internal wiring 7 Remove the RTV sealant coating the connectors to the PC board CAUTION Remove any RTV sealant coating the connector on the PC board before disconnecting the connector from th
81. mrest 28 Removing Installing Arm Support 2 4 28 SECTION 6 SHROUDS ccccccccccccccccccccccccccccccccccccccccsccccccccccscocccccccees Removing Installing the Rear 30 30 IE 30 Removing lnstalling the Front Shroud uie 3l ZOOI 3l Zoom 400 m 32 Removing Installing the Boot 2 2 8 0 33 SECTION 7 WHEELS AND CASTERS 34 Removing Installing the Drive Wheels ssssssssssssssessesssssessessssssessssssssssesssssssssessssssssssessesesseese 34 34 34 Removingllristalling the Front 36 Removilig cucina ptio suba Sdn a ed acd PP 36 sta SEU d 36 Removing Installing the
82. n Zoom 400 brake release lever removes installs the same way FIGURE 10 2 Removing Installing the Brake Release Lever Disengaging Engaging the Brake Release Lever A WARNING Ensure that the brake release lever is in the engaged position before driving There should be an audible click when stopping and starting NOTE For this procedure refer to FIGURE 10 3 The brake release lever manually engages and disengages the brake The brake release lever is located under the shroud near the left caster assembly 1 Perform one 1 of the following To Disengage Pull the brake release lever out in the direction shown in FIGURE 10 3 NOTE When the brake release lever is disengaged lever pulled out and the key is removed the powered scooter can be pushed The powered scooter cannot be driven with the brake in the disengaged lever pulled out position To Engage Push the brake release lever in in the direction shown in FIGURE 10 3 Zoom 300 and Zoom 400 66 Part No 1122167 SECTION I0 TRANSAXLE NOTE The brake MUST be engaged lever pushed in in normal driving conditions Activation of the throttle control lever automatically releases the brake so that the powered scooter can drive Releasing the throttle control lever automatically engages the brake so as to prevent the powered scooter from rolling on its own Controller Tray Transaxle Push Lever In Disengaged Pull Lever Out NOTE Zoom 3
83. n the throttle mounting bracket Detail B of FIGURE 8 15 Replace the two 2 locknuts Tighten to 25 inch Ibs 20 Detail B of FIGURE 8 15 NOTE Ensure that the lower tiller shroud fits in between the throttle bracket and tiller lever Refer to Detail B of FIGURE 8 15 9 10 11 12 13 14 15 Connect the throttle IDC into the throttle IDC header Detail A of FIGURE 8 15 Apply sealant to the throttle IDC header Replace the upper tiller shroud Refer to Removing Installing the Upper Tiller Shroud on page 44 Perform one 1 of the following to replace the batteries For Zoom 300 Refer to Removing Installing the Batteries on Zoom 300 on page 86 For Zoom 400 Refer to Removing Installing the Batteries on Zoom 400 on page 88 Reinstall the rear shroud Refer to Removing Installing the Rear Shroud on page 30 Reinstall the seat Refer to Removing Installing the Seat on page 19 Insert the key into the ignition and turn it to the ON position NOTE The Status LED light on the control panel should be solid GREEN If the Status LED light is not solid refer to Error Codes on page 102 or call Invacare Technical Service Department Zoom 300 and Zoom 400 58 Part No 1122167 SECTION 8 TILLER DETAIL A DISCONNECT CONNECT THE THROTTLE IDC TOP View of Lower Tiller Shroud BOTTOM View of Throttle IDC Upper Tiller Shroud
84. ng Arm Angle Adjusting Arm Height NOTE For this procedure refer to FIGURE 5 3 NOTE The arm height can be adjusted between 1 inch and 3 inches 1 Remove the lock knob that secures the arm to the arm mounting tube 2 Adjust the arm to desired height 3 Reinstall the lock knob that secures the arm to the arm mounting tube and tighten securely 4 Repeat STEPS 1 3 for opposite arm if necessary y d Lock Knob Arm Mounting Tube EN FIGURE 5 3 Adjusting Arm Height Part No 1122167 27 Zoom 300 and Zoom 400 SECTION 5 ARMS Replacing Armrest Pads NOTE For this procedure refer to FIGURE 5 4 Arm Pad 1 Remove the two 2 mounting screws that secure the armrest pad to arm 2 Remove the old armrest pad 3 Install new armrest pad and securely tighten with existing mounting screws 4 If necessary repeat STEPS 1 3 to replace the other armrest pad Mounting Screws FIGURE 5 4 Replacing Armrest Pads Removing Installing Arm Support Bracket NOTE For this procedure refer to FIGURE 5 5 NOTE Reverse this procedure to install the arm support bracket 1 Remove the seat from the scooter Refer to Removing Installing the Seat on page 19 2 Remove the arms from the seat assembly Refer to Removing Installing Adjusting Arms on page 25 3 Turn the seat over and remove the six 6 mounting screws washers and spacers that secure the arm support bracket to the seat a
85. ng Installing the Swingarms NOTE For this procedure refer to FIGURE 9 1 Removing 1 Turn power OFF and remove the key from the ignition Remove the seat Refer to Removing Installing the Seat on page 19 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 30 Remove the batteries Refer to Removing Installing the Batteries on Zoom 300 on page 86 and Removing Installing the Batteries on Zoom 400 on page 88 Remove the drive wheel Refer to Removing Installing the Drive Wheels on page 34 Support the transaxle Remove the cotter pin on the swingarm Slide out the two 2 washers two 2 glide bearings and swingarm assembly Remove the viscous element from the drive shaft 10 If necessary repeat STEPS 5 8 for the other swingarm assembly Installing 1 Install the viscous element on the drive shaft 2 Install the two 2 washers two 2 bearing glides and swingarm assembly as shown in FIGURE 9 1 Install the cotter pin on the swingarm Install the drive wheel Refer to Removing Installing the Drive Wheels on page 34 If necessary repeat STEPS 1 4 for the other swingarm assembly Install the batteries Refer to Removing Installing the Batteries on Zoom 300 on page 86 and and Removing Installing the Batteries on Zoom 400 on page 88 7 Install the rear shroud Refer to Removing Installing the Rear Shroud on page 30 8 Install the seat Refer to Removing Installin
86. nsouostssuecnscusnscsuesdcassusst ensssnnsayessonbsdustochocase 99 L brication ao 1 cT 100 100 NORTON RR 101 ND 102 SECTION 14 TRANSPORTING 66 104 Disassembling Assembling the Zoom 300 2 2222222 104 ISAS SOM DIAG zac caosa che Wand tie oie DAS md UM 104 Tor Pee eR REP cC c 104 Disassembling Assembling the Zoom 400 seen ttnntnentenn 105 DisassembliN E 105 Assembling iod atat pier aries bu 106 SECTION 15 SCOOTER ACCESSORIES 108 Removing Installing the Front Basket sese tettettententntententnntene 108 Removing Installing the Front Basket Mounting Bracket sse 109 aee 109 Iristalling sense RR aun penati umque EUST 109 Installing Removing the Crutch Cane Holder eene 110 deer 110 EPOR PT 110 Installing Removing the Safety Flag ssiinsccsesissssvoncseidesnsctvvessoasonoduoncossndonsncononndedensusuebuvonsotvnedngssodonerstny ci se
87. nt frame assembly from the rear frame assembly A Use the one hand to firmly hold the tiller handle B Using the other hand firmly hold the YELLOW frame lock lever located under marker label 2 and pull UP to the Unlocked position as shown in Detail C of FIGURE 14 2 NOTE The frame lock lever remains in the unlocked position when the front frame assembly is separated from the rear frame assembly C Lift the front frame assembly so that the mounting brackets disengage from the rear frame assembly as shown in Detail C of FIGURE 14 2 D Separate the front frame assembly from the rear frame assembly 7 Fold tiller down to lowest locked position Refer to Adjusting the Tiller Angle on page 43 Assembling 1 Unfold tiller Refer to Adjusting the Tiller Angle on page 43 2 Ensure that the tiller is in the highest locked position 3 Perform the following to connect the front frame assembly to the rear frame assembly Detail C of FIGURE 14 2 A Use the one hand to firmly hold the tiller handle B Using the other hand firmly hold the front frame assembly and align with the REAR frame assembly NOTE The frame lock lever remains in the unlocked position when the front frame assembly is separated from the rear frame assembly A WARNING When reassembling scooter ensure the frame lock lever is in the LOCKED position securing the FRONT and REAR frame assemblies together Otherwise injury and or damage may resul
88. on the seat lever lower the seat assembly onto the seat post NOTE If necessary slightly twist seat assembly back and forth to lock in place 3 Release seat lever and lift up on seat assembly to ensure the seat is secure Seat Back Seat Seat Pivot Located under the Seat Seat Post FIGURE 4 1 Removing Installing the Seat Part No 1122167 19 Zoom 300 and Zoom 400 SECTION 4 SEAT Removing Installing the Seat Post A WARNING Ensure that the seat post mounting screw is properly engaged and locked Other wise injury and or damage may result NOTE For this procedure refer to FIGURE 4 2 NOTE Take note of position and orientation of the seat post and seat post mounting screw before removing Removing 1 Remove the seat Refer to Removing Installing the Seat on page 19 2 Remove the mounting screw locknut and two 2 washers securing the seat post to the frame post refer to FIGURE 4 2 Lift seat post up and remove from frame post d Installing 1 Insert the seat post into the frame post and align the frame post mounting hole with the desired seat post mounting hole refer to FIGURE 4 2 N Using the mounting screw locknut and two 2 washers secure the seat post to the frame post Install the seat Refer to Removing Installing the Seat on page 19 Seat Post Seat Post Mounting Holes A Washer Mounting T ZN Washer gt Frame Post Mounting Hole
89. one 1 of the following Replacing Existing Tire Rim Discard existing tire and hub Proceed to STEP 3 Replacing Existing Rim Only Perform the following i Remove the four 4 existing mounting screws lock washers and nuts that secure the existing outer rim inner rim and hub to the existing tire ii Discard existing mounting hardware rims and hub 3 When installing the new two piece hub into a new pneumatic tire if necessary place the inner tube into the tire 4 Insert the outer rim and inner rim into the new existing tire 5 Insertthehub into the inner rim and align the four 4 mounting holes of the hub inner rim and outer rim 6 Using the four 4 mounting screws lock washers and hex nuts secure the outer rim to the inner rim and hub Torque hex nuts to 160 200 in lbs 20 7 Install the drive wheel on the drive shaft Refer to Removing Installing the Drive Wheels on page 34 Washers Outer Rim Locknuts Wheel Hub Mounting Screws Cutout Inner Rim FIGURE 7 5 Replacing Foam Filled Tires Onto Wheel Rims Part No 1122167 39 Zoom 300 and Zoom 400 SECTION 8 TILLER SECTION 8 TILLER A WARNING After any adjustments repair or service and before use make sure that all attaching hardware is tightened securely otherwise injury or damage may result Before performing any maintenance adjustment or service turn power OFF and remove key from ignition Removing Installing th
90. oud Position the headlight mounting bracket and the front tiller shroud onto the tiller assembly Secure the front tiller shroud and the headlight mounting bracket using the two 2 mounting screws Install the headlight Refer to Removing Installing the Headlight on page 47 Install the rear shroud Refer to Removing Installing the Rear Tiller Shroud on page 46 Zoom 300 and Zoom 400 48 Part No 1122167 SECTION 8 TILLER Replacing the Ignition Switch NOTE For this procedure refer to FIGURE 8 8 NOTE RTV sealant is required for this procedure 1 Remove the upper tiller shroud Refer to Removing Installing the Upper Tiller Shroud on page 44 N Pull up the PC board from its slotted housing in order to gain easier access to the components and to allow the weight of the upper tiller shroud to be supported by the lower tiller shroud ad Remove the RTV sealant coating the ignition switch connector CAUTION Remove the RTV sealant coating the connector on the PC board before disconnecting the connector from the PC board Otherwise the PC board could be damaged DO NOT use a chemical solvent to remove any RTV sealant from connectors as it may cause damage to the PC Board Pull the ignition switch connector to disconnect the ignition switch from the PC board Loosen and remove the locknut that secures the ignition switch in place 4 5 6 Push the ignition switch through the upper tiller shroud and dis
91. ous personal injury or damage may occur The use of rubber gloves and chemical goggles and face shield is recommended when working with batteries Do not remove fuse or mounting hardware from the POSITIVE RED battery cable mounting screw NEVER defeat or bypass any fuse ONLY replace with a fuse of the same rating NOTE For this procedure refer to FIGURE 12 4 and FIGURE 12 5 Connecting 1 Install battery terminal cap s onto battery cable s as follows FIGURE 12 4 A RED battery terminal cap onto RED battery cable B GREY battery terminal cap onto BLACK battery cable Battery Terminal Cap Battery Cable NOTE Only battery cable and terminal cap shown Both caps install in the same manner FIGURE 12 4 Connecting Disconnecting the Battery Cables on the Zoom 400 Installing Battery Terminal Caps Zoom 300 and Zoom 400 90 Part No 1122167 SECTION 12 5 AND CHARGER A WARNING When connecting the battery cables to the batteries the battery cables MUST be connected to the battery terminals posts as shown in FIGURE 12 5 otherwise dam age to the battery cable may result when installing battery terminal caps N Connect battery cable s to battery ies terminal s post s A NEGATIVE BLACK battery cable to NEGATIVE battery terminal post B POSITIVE RED battery cable to POSITIVE battery terminal post Secure the battery cable s ring terminal s to the battery terminal
92. oving Installing the Batteries on Zoom 300 on page 50 3 Install the rear shroud Refer to Removing Installing the Rear Shroud on page 44 4 Install the seat Refer to Removing Installing the Seat on page 34 5 If desired install the front basket Refer to Removing Installing the Front Basket on page 64 Zoom 300 and Zoom 400 104 Part No 1122167 SECTION 4 TRANSPORTING Refer to Removing Installing the Seat on page 34 Refer to Removing Installing the Rear Shroud on page 44 Refer to Removing Installing the Front Basket on page 64 Refer to Removing Installing the Batteries on Zoom 300 on page 50 Refer to Adjusting the Tiller Angle on page 43 FIGURE 14 1 Disassembling Assembling the Zoom 300 Disassembling Assembling the Zoom 400 NOTE For this procedure refer to FIGURE 14 2 Disassembling 1 If installed on scooter remove the front basket Refer to Removing Installing the Front Basket on page 64 Remove the seat Refer to Removing Installing the Seat on page 34 3 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 44 Remove the batteries Refer to Removing Installing the Batteries on Zoom 400 on page 53 Disconnect the 4 housing motor located under marker label 1 connector from the controller Detail B of FIGURE 14 2 Part No 1122167 105 Zoom 300 and Zoom 400 SECTION 4 TRANSPORTING 6 Perform the following to separate the fro
93. procedure refer to FIGURE 7 1 Removing 1 Turn power off and remove the key from the ignition Remove the seat Refer to Removing Installing the Seat on page 19 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 30 2 3 4 Place the scooter frame up on blocks so that the drive wheels are off the ground 5 Remove the hex nut and washer that secure the drive wheel to the drive shaft Discard hex nut 6 Usea wheel puller if necessary to remove the existing drive wheel from the drive shaft 7 Remove keystock from drive shaft Set aside 8 If necessary repeat STEPS 1 6 to remove other drive wheel Installing 1 Place keystock in cutout on drive shaft as shown in FIGURE 7 1 NOTE The keystock in the drive shaft MUST lineup with the cutout in the wheel hub 2 Install the drive wheel onto the drive shaft NOTE If necessary use a rubber hammer to gently tap drive wheel completely into position on the drive shaft 3 Secure wheel to drive shaft using the washer and new hex nut Securely tighten NOTE A new hex nut should be used when reinstalling the wheel 4 Repeat STEPS 1 3 to install the other drive wheel 5 Install the rear shroud Refer to Removing Installing the Rear Shroud on page 30 6 Install the seat Refer to Removing Installing the Seat on page 19 Zoom 300 and Zoom 400 34 Part No 1122167 SECTION 7 WHEELS AND CASTERS ZOOM 300 DETAIL Keystock
94. r Volume Sleep Time OPTION MENU Change two factory preset values Potentiometer Reverse Enable Sleep SPEED LEVER IN NEUTRAL MENU Calibrate the throttle about neutral CONTROLLER VERSION MENU Set Up Menu Displays the version of Controller software On the Set Up menu display press the NEXT key to scroll through the options To change the current setting of the options A Press the VARY key to change the current setting B Press the ENTER key to confirm the value when finished Part No 1122167 81 Zoom 300 and Zoom 400 SECTION CONTROLLER FACTORY OPTIONS DEFAULT DESCRIPTION SETTING Slowest acceleration to maximum forward speed ACCELERATION Fastest acceleration to maximum forward speed Slowest deceleration from maximum forward speed DECELERATION Fastest deceleration from maximum forward speed Slowest forward speed FORWARD SPEED Fastest forward speed Slowest reverse speed REVERSE SPEED Fastest reverse speed Slowest limit of maximum forward speed and maxi mum reverse speed REDUCE SPEED Fastest limit of maximum forward speed and maxi mum reverse speed Turns the horn buzzer OFF BUZZER VOLUME Turns the horn buzzer ON 10 being the highest volume setting Fastest sleep time setting for the scooter the scooter powers down after 5 minutes of inactivity SLEEP TIME Slowest sleep time setting for the scooter
95. r is engaged NOTE For this procedure refer to FIGURE 11 8 Turn power off and remove the key from the ignition Remove the seat Refer to Removing Installing the Seat on page 19 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 30 1 2 3 4 Insert the key in the ignition and turn power on 5 Locate the programmer port on the controller and remove the black protective cap 6 Plug in the DS100 programmer into the programmer port NOTE After a few seconds if a fault is indicated on the display refer to the back of the programming card provided with the programmer for details 7 Press the MENU key to scroll through all of the menus available with the programmer Zoom 300 and Zoom 400 80 Part No 1122167 DETAIL A ZOOM 300 Controller Programmer Port with Protective End Cap DETAIL ZOOM 400 Controller Rear View of Scooter SECTION CONTROLLER Front of Scooter Top View of Scooter Programmer Port with Protective End Cap FIGURE 11 8 Changing to Left Handed Operation Programming the Controller Main Menu MAIN MENU OPTIONS PROGRAMMABLE PARAMETERS SET UP MENU Customize scooter for the user s driving preferences or environ ment by adjusting features such as Acceleration Deceleration Forward Speed Reverse Speed Reduce Speed Buzze
96. r shroud Refer to Removing Installing the Upper Tiller Shroud on page 44 2 Remove the RTV sealant coating the headlight switch connector CAUTION Remove any RTV sealant coating the connector on the PC board before disconnecting the connector from the PC board Otherwise the PC board could be damaged DO NOT use a chemical solvent to remove any RTV sealant from connectors as it may cause damage to the PC Board 3 Pull the headlight switch connector to disconnect the headlight switch from the PC board 4 Push the headlight switch with the attaching wires through upper tiller shroud Detail B of FIGURE 8 10 5 Install the new headlight switch into the upper tiller shroud by inserting the wiring first then the headlight switch 6 Push the headlight switch into place until the housing is snug against the upper tiller shroud Refer to Detail B of FIGURE 8 10 7 Insert the headlight switch connector into PC board Refer to Detail B of FIGURE 8 10 8 Apply a thin coating of RTV sealant the headlight switch connector and the PC board 9 Install the upper tiller shroud Refer to Removing Installing the Upper Tiller Shroud on page 44 DETAIL DETAIL Headlight Switch should be snug against Upper Tiller Shroud PC Board Upper Tiller Shroud Headlight Switch connects Headlight Switch
97. r to Removing Installing the Seat on page 19 2 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 30 3 On Zoom 400 only Disassemble the scooter Refer to Disassembling Assembling the Zoom 400 on page 105 4 Remove the cotter pin and washer that attach the brake release lever to the lever mounting bracket on the transaxle 5 Twist off the rubber tip from the end of the brake release lever 6 Remove the brake release lever by sliding it out of the controller tray Installing 1 2 Slide the brake release lever through the slot in the controller tray Slide the brake release lever into the slot on the lever mounting bracket on the transaxle 3 Install the rubber tip onto the end of the brake release lever Install the washer and cotter pin to secure the brake release lever to the transaxle Part No 1122167 65 Zoom 300 and Zoom 400 SECTION 10 5 5 On Zoom 400 only Assemble the scooter Refer to Disassembling Assembling the Zoom 400 on page 105 6 Install the rear shroud Refer to Removing Installing the Rear Shroud on page 30 7 Install the seat Refer to Removing Installing the Seat on page 19 DETAIL A BRAKE RELEASE Slot on Controller Tray LEVER INSTALLED Cotter Pin c for Brake Release Lever Brake Release AA Controller gt Lever Tray Washer Washer Transaxle Lever Mounting Brake Bracket Release Lever Cotter Pin NOTE Zoom 300 show
98. racket Detail B of FIGURE 8 6 Remove the headlight Installing 1 Insert the headlight cable and connector through the hole in the upper tiller shroud Detail B of FIGURE 8 6 Install the headlight on the headlight mounting bracket using the locknut washer and mounting bolt Securely tighten 3 Plug the headlight connector to the PC board connector Detail A of FIGURE 8 6 Install the rear tiller shroud Refer to Removine Installine the Upper Tiller Shroud on page 44 DETAIL DETAIL B PC Board Hole in Upper Headlight Tiller Shroud G t onnector Headlight Mounti pus Headlight Cable and Connector FIGURE 8 6 Removing Installing the Headlight Part No 1122167 47 Zoom 300 and Zoom 400 SECTION 8 TILLER Removing Installing the Headlight Mounting Bracket Front Tiller Shroud NOTE This procedure is for the Zoom 400 only NOTE For this procedure refer to FIGURE 8 7 Removing 1 Remove the headlight Refer to Removing Installing the Headlight on page 47 Remove the two 2 mounting screws that secure the headlight mounting bracket and the front tiller shroud to the tiller assembly Remove the headlight mounting bracket and the front tiller shroud Installing 1 Front Tiller Shroud Headlight Mounting Bracket Be Assembly 3 Mounting Screws FIGURE 8 7 Removing Installing the Headlight Mounting Bracket Front Tiller Shr
99. reaker dismounting the scooter Otherwise may occur jumper co 2Stot connector CHT Controller TN 12H BATT BE DO NOT lift scooter up by the front or rear shroud Otherwise injury BLACK Battery Cable or damage to the scooter may occur 1118373 Rev A NOTE Warning Label 1118359 is located under the rear shroud Scooter Pinch Point 1079203 NOTE Warning Label 1079203 is also located on the other swingarm Part No 1122167 10 Zoom 300 and Zoom 400 LABEL LOCATIONS On Zoom 400 NOTE Serial Number L X WEIGHT CAPACITY is located under the ies yt 400 LBS 182 kgs _ NS REFER TO OWNER S MANUAL rear shroud DO NOT REMOVE THIS LABEL The POSITIVE RED Battery Cable MUST connect to the POSITIVE Battery Terminal s Post s The NEGATIVE BLACK Battery Cable MUST connect to the NEGATIVE Battery Terminal s Post s Install protective caps on POSITIVE and NEGATIVE battery terminals DO NOT allow Battery Cable s to contact the opposite Battery Terminal s Post s Replace cable s immediately if cable s insulation becomes damaged DO NOT remove fuse or mounting hardware from POSITIVE RED battery cable mounting screw Failure to observe these warnings may result in an electrical short with serious personal injury and or damage to the electrical system See Owner s Manual 1125362 Rev A 404 75 AMP Fuse 2 Slot Connectors RED Battery Cable
100. rinflate the tires Failure to follow these recommendations may cause the tire to explode and cause bodily harm The recommended tire pressure is listed on the side wall of the tire Electrical Grounding Instructions DO NOT under any circumstances cut or remove the round grounding prong from any plug used with or for Invacare products Some devices are equipped with three prong grounding plugs for protection against possible shock hazards Where a two prong wall receptacle is encountered it is the personal responsibility and obligation of the customer to contact a qualified electrician and have the two prong receptacle replaced with a properly grounded three prong wall receptacle in accordance with the National Electrical Code If you must use an extension cord use only a three wire extension cord having the same or higher electrical rating as the device being connected In addition Invacare has placed RED ORANGE warning tags on some equipment DO NOT remove these tags Batteries The warranty and performance specifications contained in this manual are based on the use of deep cycle gel cell batteries Invacare strongly recommends their use as the power source for this unit Part No 1122167 13 Zoom 300 and Zoom 400 SECTION GENERAL GUIDELINES Carefully read battery battery charger information prior to installing or servicing the powered scooter Charging Batteries NEVER attempt to recharge the batteries by attaching cables
101. rom the throttle potentiometer Using a digital volt meter take a DC voltage reading from the RED and WHITE wires A reading of 2 3 VDC 0 2 should be displayed If the reading does not fall within this range go to STEP 9 NOTE A normal reading is around 2 3 VDC 40 2 but if the Status LED continues to blink six 6 times the throttle pot needs to be re calibrated 9 10 11 12 13 14 15 To re calibrate the throttle pot perform the following A Leave the digital multimeter hooked up to the red and white wires B Using a small flat screwdriver adjust the throttle potentiometer by turning the potentiometer clockwise or counter clockwise until the multimeter reading is around 2 3 Volts 0 2 When the throttle potentiometer is re calibrated and the reading falls within the recommended range tighten the two 2 set screws Replace the upper tiller shroud Refer to Removing Installing the Upper Tiller Shroud on page 44 Engage the brake release lever Refer to Disengaging Engaging the Brake Release Lever on page 66 Turn the power to the scooter off then on again Look at the Status LED A solid GREEN LED should be displayed and the scooter can be driven Test drive the scooter NOTE If the scooter does not drive repeat this procedure If the scooter still does not drive call Invacare at the number listed on the back cover of this manual Zoom 300 and Zoom 400 60 Part No 1122167 SECTION 8 T
102. rt No 1122167 97 Zoom 300 and Zoom 400 SECTION I2 BATTERIES AND CHARGER Battery Charger Operation Charger Indicator Light on Tiller NOTE If the scooter is turned on while charging the battery charge indicator will show the batteries at FULL charge The charger must be unplugged and the powered scooter must be ON to show actual battery charge level NOTE For this procedure refer to FIGURE 12 9 1 The charging indicator will illuminate Solid RED indicating that the charger is ON 2 If the charger is plugged in and the charger indicator is OFF the charger is disconnected Check that all connections are secure If Charge LED indicator is still OFF unplug AC power cord from the on board battery charger and wall outlet Contact dealer or a qualified technician DETAIL A ZOOM 300 CONTROL PANEL DETAIL ZOOM 400 CONTROL PANEL BATTERY LEVEL BATTERY LEVEL Aoli m RUA ON f We STATUS INDICATOR STATUS Solid GREEN Normal Blinking GREEN Refer to Error Codes on page 102 CHARGING INDICATOR STATUS Solid RED Charger Plugged In LED Off Not Charging FIGURE 12 9 Battery Charger Operation Charger Indicator Light on Tiller Zoom 300 and Zoom 400 98 Part No 1122167 SECTION I3 MAINTENANCE AND TROUBLESHOOTING SECTION 13 MAINTENANCE AND TROUBLESHOOTING A WARNING After ANY adjustments repair or service and BEFORE
103. s cordless phones laptop computers AMIFM radios TV sets CD players cassette players and small appliances such as elec tric shavers and hair dryers so far as we know are not likely to cause EMI problems to your powered wheelchair Part No 1122167 15 Zoom 300 and Zoom 400 SECTION 2 EMI INFORMATION A WARNING Powered Wheelchair Electromagnetic Interference EMI Because EM energy rapidly becomes more intense as one moves closer to the transmitting antenna source the EM fields from hand held radio wave sources transceivers are of special concern It is possible to unintentionally bring high levels of EM energy very close to the powered wheelchair s control system while using these devices This can affect powered wheelchair movement and braking Therefore the warnings listed below are recommended to prevent possible interference with the control system of the powered wheelchair Electromagnetic interference EMI from sources such as radio and TV stations amateur radio HAM transmitters two way radios and cellular phones can affect powered wheelchairs and motorized scooters FOLLOWING THE WARNINGS LISTED BELOW SHOULD REDUCE THE CHANCE OF UNINTENDED BRAKE RELEASE OR POWERED WHEELCHAIR MOVEMENT WHICH COULD RESULT IN SERIOUS INJURY 1 Do not operate hand held transceivers transmitters receivers such as citizens band CB radios or turn ON personal communication devices such as cellular phones while the power
104. ssembly 4 Remove the arm support bracket Zoom 300 and Zoom 400 28 Part No 1122167 SECTION 5 ARMS Side View Seat Assembly Arm Spacers Arm Support Bracket Washers Mounting Screws Bottom View Arm 9 Arm Arm Support Bracket Mounting Screws Mounting Screws Spacers and Wash Pacers and VVasners Spacers and Washers FIGURE 5 5 Removing Installing Arm Support Bracket Part No 1122167 29 Zoom 300 and Zoom 400 SECTION 6 SHROUDS SECTION 6 SHROUDS A WARNING After ANY adjustments repair or service and BEFORE use make sure that all attaching hardware is tightened securely otherwise injury or damage may result Before performing any maintenance adjustment or service turn power OFF and remove key from ignition Removing Installing the Rear Shroud NOTE For this procedure refer to FIGURE 6 1 Removing 1 Remove the seat Refer to Removing Installing the Seat on page 19 2 Disengage the hook and loop strips securing the rear shroud to the frame by pulling up on the shroud 3 Lift the rear shroud off the seat post Installing 1 Align the tabs on the rear shroud with the slots in the front shroud 2 Place rear shroud on the frame and press down slightly to engage the hook and loop strips on the rear shroud
105. stment cable to the tiller Remove the upper tiller shroud Refer to Removing Installing the Upper Tiller Shroud on page 44 Remove the mounting screw and P clip securing the tiller harness cable to the tiller Detail C FIGURE 8 1 Pull the tiller harness cable through the hole in the lower tiller shroud Remove the two 2 locknuts mounting screws tube clamps and cable bracket that secure the tiller to the tiller angle adjustment assembly Detail B of FIGURE 8 1 Disconnect the tiller angle adjustment cable from the actuator wedge by performing the following Detail D of FIGURE 8 1 A Liftup the actuator wedge until the tiller angle adjustment cable is slack B Pull the tiller angle adjustment cable weight from the actuator wedge Remove the tiller Part No 1122167 41 Zoom 300 Zoom 400 SECTION 8 TILLER DETAIL A ZOOM 300 Cable Bracket Coved Mounting Screws S ashers RC aan a Ne fel Tiller Angle Adjustment Assembly DETAIL B ZOOM 400 E Coved Mounting Washers Screws Cable 5 i Locknuts Tiller Angle Adjustment Assembly DETAIL C INTERIOR CONTROL BOX Tiller Harness Cable P Clip Angle Adjustment L oq Br Cable Sh Mounting If Actuator 0 Wedge V Hole in Lower Tiller Shroud hidden from view FIGURE 8 1 Zoom 300 and Zoom 400 42 DETAIL D T
106. t C Lower the front frame assembly so that the mounting brackets engage with the rear frame assembly NOTE The mounting brackets are engaged when an audible click is heard The YELLOW frame lock lever automatically locks in place 4 Connect the 4 housing motor connector located under marker label 1 to the controller Detail B of FIGURE 14 2 Install the batteries Refer to Removing Installing the Batteries on Zoom 400 on page 53 Install the rear shroud Refer to Removing Installing the Rear Shroud on page 44 D Zoom 300 and Zoom 400 106 Part No 1122167 SECTION 4 TRANSPORTING 7 Install the seat Refer to Removing Installing the Seat on page 34 8 If desired install the front basket Refer to Removing Installing the Front Basket on page 64 DETAIL ASSEMBLE DISASSEMBLE ZOOM 400 DETAIL DISCONNECT MOTOR AND BATTERY CONNECTORS Refer to Removing Installing the Seat on page 34 Motor Connector Refer to Removing Installing the Rear Shroud on page 44 Controller Refer to Removing Installing the Batteries on Zoom 400 on page 53 REN a 1 Lk anb Refer to Removing Installing the Front Basket on page 64 E OFE ji rH I2I 3 3E sl J f i SZ BAD BLACK RIG
107. t Invacare s option This warranty does not include any labor or shipping charges incurred in replacement part installation or repair of any such product Invacare s sole obligation and your exclusive remedy under this warranty shall be limited to such repair and or replacement For warranty service please contact the dealer from whom you purchased your Invacare product In the event you do not receive satisfactory warranty service please write directly to Invacare at the address on the bottom of the back cover Provide dealer s name address date of purchase indicate nature of the defect and if the product is serialized indicate the serial number Do not return products to our factory without our prior consent LIMITATIONS AND EXCLUSIONS THE FOREGOING WARRANTY SHALL NOT APPLY TO SERIAL NUMBERED PRODUCTS IF THE SERIAL NUMBER HAS BEEN REMOVED OR DEFACED PRODUCTS SUBJECT TO NEGLIGENCE ACCIDENT IMPROPER OPERATION MAINTENANCE OR STORAGE COMMERCIAL OR INSTITUTIONAL USE PRODUCTS MODIFIED WITHOUT INVACARE S EXPRESS WRITTEN CONSENT INCLUDING BUT NOT LIMITED TO MODIFICATION THROUGH THE USE OF UNAUTHORIZED PARTS OR ATTACHMENTS PRODUCTS DAMAGED BY REASON OF REPAIRS MADE TO ANY COMPONENT WITHOUT THE SPECIFIC CONSENT OF INVACARE OR TO A PRODUCT DAMAGED BY CIRCUMSTANCES BEYOND INVACARE S CONTROL AND SUCH EVALUATION WILL BE SOLELY DETERMINED BY INVACARE THE WARRANTY SHALL NOT APPLY TO PROBLEMS ARISING FROM NORMAL WEAR OR FAILURE TO ADHERE TO THESE
108. t No 1122167 75 Zoom 300 and Zoom 400 SECTION CONTROLLER Replacing Resetting the Circuit Breaker Replacing NOTE For this procedure refer to FIGURE 11 5 FIGURE 12 2 and FIGURE 12 3 1 2 3 4 9 ND 10 11 12 13 Turn power OFF and remove the key from the ignition Remove the seat Refer to Removing Installing the Seat on page 19 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 30 Perform one 1 of the following On Zoom 300 Disconnect the controller from the batteries by pulling the RED and BLACK controller connector from the RED and BLACK battery connector Refer to FIGURE 12 2 On Zoom 400 Disconnect the controller from the batteries by pulling the two 2 BLACK battery connectors from the BLACK wiring harness connectors Refer to FIGURE 12 3 Remove the YELLOW metal connectors of the wiring harness from the circuit breaker Remove the two 2 locknuts that secure the circuit breaker to the controller tray Remove the circuit breaker Position the new circuit breaker so that it passes through the mounting hole on the controller tray Position the locknuts on the end of the circuit breaker and securely tighten Connect the YELLOW metal connectors from the wiring harness to the metal connectors of the circuit breaker Perform one 1 of the following On Zoom 300 Connect the controller from the batteries by pulling the RED and BLACK con
109. ter in a well ventilated area CAUTION Work should be performed in an area without risking damage to carpeting or floor covering 2 Turn power off and remove the key from the ignition 3 Remove the seat Refer to Removing Installing the Seat on page 19 Zoom 300 and Zoom 400 92 Part No 1122167 SECTION 12 5 AND CHARGER Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 30 5 Disconnect the controller from the batteries by pulling the RED and BLACK controller 10 11 12 13 14 15 16 17 18 19 20 21 connector from the RED and BLACK battery connector Refer to Detail of FIGURE 12 2 Remove the two 2 mounting screws and locknuts that mount the AC receptacle to charger to the controller tray Refer to Detail B FIGURE 12 6 Disconnect the DC charger connector from the charger port If the AC receptacle wire runs below the circuit breaker remove the YELLOW metal connectors of the wiring harness from the circuit breaker not shown Cut the tie wraps securing charger to controller tray Detail A of FIGURE 12 6 Cut the tie wrap securing the DC charger connector cable to scooter frame Detail A of FIGURE 12 6 Remove the existing charger Place the new charger on the controller tray and secure it to the controller tray using a tie wrap as shown in Detail A of FIGURE 12 6 Tie wrap the charger cables in three places as shown
110. the welded nut on the accessory tube Securely tighten 4 Align the mounting clips on the bracket with the slots on the basket and slide the basket DOWN securely into position Removing 1 Remove the basket from the bracket 2 Loosen the mounting knob 3 Remove the basket bracket from the accessory tube 4 Tighten the mounting knob Mounting Knob Rear Basket vm MS dt AAAI 4 Xe d e a EAN A a 2200 s ANA A OUR d 596 Accessory Tube EN 5 Slots Mounting Clips Basket Bracket FIGURE 15 7 _Installing Removing the Rear Mounted Basket Part No 1122167 113 Zoom 300 and Zoom 400 SECTION 15 SCOOTER ACCESSORIES NOTES Zoom 300 and Zoom 400 114 Part No 1122167 LIMITED WARRANTY LIMITED WARRANTY PLEASE NOTE THE WARRANTY BELOW HAS BEEN DRAFTED TO COMPLY WITH FEDERAL LAW APPLICABLE TO PRODUCTS MANUFACTURED AFTER JULY 4 1975 This warranty is extended only to the original purchaser user of our products This warranty gives you specific legal rights and you may also have other legal rights which vary from state to state Invacare warrants this product to be free from defects in materials and workmanship for a period of eighteen 18 months on electrical and transaxle and three 3 years on frame from date of purchase If within such warranty period any such product shall be proven to be defective such product shall be repaired or replaced a
111. ti bete cedet UR PRESA 20 REMOVINE fe 20 Installing ocu tetti 20 Adjusting Seat 21 Removing Installing the Seat Pivot esee esten ttenta nta tta ton tontoa tontos tentata oa ons 21 asia ee ied tastes 21 Installilig toas b eb MR dep codon d 21 Adjusting Seat D 22 920 Seat Swivel Adjustment o as 23 Removing Installing the Seat Positioning Strap seen 24 SECTION 5 ARMS 25 Part 1122167 3 Zoom 300 and Zoom 400 TABLE OF CONTENTS TABLE OF CONTENTS Removing Installing Adjusting Arms 25 Reimoving Installitig 25 52 lo bag LUCRO 25 Adij sting Artu Width ceto cuero rrt ettet rtt a Debe ea erint 26 Adjusting Arm Angl eiennenn irere o pepe lee pee 26 Adj stine Arm ogame 27 Replacing Ar
112. ting knob 2 Install the walker holder into the accessory tube 3 Thread the mounting knob into the welded nut on the accessory tube Securely tighten FIGURE 15 5 Installing Removing the Walker Holder Accessory Tube Holder Using the Walker Holder NOTE For this procedure refer to FIGURE 15 6 1 Fold walker Refer to walker ay 1 instructions o Heak NOTE Walker MUST be folded before using Hookarid walker holder Loop Strap 2 Hang folded walker on walker holder hooks T p 3 Secure walker with hook and loop straps FIGURE 15 6 Using the Walker Holder Zoom 300 and Zoom 400 112 Part No 1122167 SECTION I5 SCOOTER ACCESSORIES Installing Removing the Rear Mounted Basket A WARNING The rear mounted basket is rated for a maximum capacity of ten 10 Ibs After ANY adjustments repair or service and BEFORE use make sure that all attaching hardware is tightened securely The installation of the basket and basket bracket onto the back of the scooter seat increases the length of the scooter When turning the scooter or swiveling the scooter seat it is important to take note of this increased length otherwise injury and or damage to surrounding property may occur NOTE For this procedure refer to FIGURE 15 7 Installing 1 If necessary loosen but do not remove the mounting knob 2 Install the basket bracket into the accessory tube 3 Thread the mounting knob into
113. to Removing Installing the Seat on page 34 Remove the rear shroud Refer to Removing Installing the Rear Shroud on page 44 Remove the batteries Refer to Removing Installing the Batteries on Zoom 400 on page 88 N Part No 1122167 91 300 2 400 SECTION I2 BATTERIES AND CHARGER 4 Cutthe tie wrap that secure each the battery terminal cap in place 5 Slide terminal cap s UP on the battery cable s 6 Disconnect battery cable s from battery ies terminal s post s A POSITIVE RED battery cable from the POSITIVE battery terminal post B NEGATIVE BLACK battery cable from NEGATIVE battery terminal post DETAIL TERMINAL CAPS onnector NEGATIVE TIE WRAPS x Terminal Cap Battery POSITIVE NEGATIVE Terminal Caps Termina Battery Battery Handle Terminal UI Batt X Locknut BLACK Battery Cable Locknut POSITIVE p Tie Wraps Battery Terminal RED Battery Cable with Bracket UI Battery NOTE Only battery cable and terminal cap shown Both caps install in the same manner NOTE DO NOT remove fuse or mounting hardware from the POSITIVE RED battery cable mounting screw FIGURE 12 5 Connecting Disconnecting the Battery Cables on the Zoom 400 Replacing the Charger Zoom 300 NOTE For this procedure refer to FIGURE 12 6 and FIGURE 12 2 1 Place the powered scoo
114. troller connector from the RED and BLACK battery connector Refer to FIGURE 12 2 On Zoom 400 Connect the controller from the batteries by pulling the two 2 BLACK battery connectors from the BLACK wiring harness connectors Refer to FIGURE 12 3 Install the rear shroud Refer to Removing Installing the Rear Shroud on page 30 Install the seat Refer to Removing Installing the Seat on page 19 Zoom 300 and Zoom 400 76 Part No 1122167 SECTION CONTROLLER LLOW Metal Connectors Y DETAIL A ZOOM 300 from Wiring Harness Circuit Breaker Mounting Hole Controller Tray LLOW Metal Connectors M gt S en O Yn N E I E E d o gt N i lt gt a Locknuts Breaker Circuit Breaker Mounting Hole FIGURE 11 5 Replacing Resetting the Circuit Breaker Replacing Zoom 300 and Zoom 400 77 Part No 1122167 SECTION CONTROLLER Resetting Circuit Breaker A WARNING NEVER defeat or bypass the circuit breaker ONLY replace with a circuit breaker with same rating If a circuit breaker repeatedly trips DO NOT use the scooter This may indicate that a short circuit condition exists Investigate potential causes and correct before returning scooter to service NOTE For this procedure refer to FIGURE 11 6 NOTE Key must be removed from ignition before resetting circuit breaker
115. unexpected failure of the device and the powered scooter DO NOT attempt to lift the powered scooter by any removable detachable parts Lifting by means of any removable detachable parts of a powered scooter may result in injury to the user or damage to the powered scooter DO NOT attempt to lift the powered scooter by its tiller seat or shrouds Zoom 300 and Zoom 400 12 Part No 1122167 SECTION GENERAL GUIDELINES DO NOT stand on the frame of the powered scooter DO NOT stand on the shroud s of the powered scooter DO NOT adjust the seat position outside the specifications recommended by the manufacturer After making any tiller angle adjustment and before use the tiller must be securely locked into position Otherwise the user may fall from the scooter resulting in bodily harm and or damage to the scooter Gently push pull the tiller to ensure that the tiller is securely engaged On Zoom 400 only Before use ensure that the frame lock lever is in the locked position securing the front and rear frame assemblies together Otherwise injury and or damage may occur DO NOT use an escalator to move a powered scooter between floors Serious bodily injury may occur DO NOT overtighten hardware attaching to the frame This could cause damage to the frame tubing Avoid storage or use near external flame or combustible products Tire Pressure Ensure that the powered scooter has the proper tire pressure P S I DO NOT ove
116. use make sure that all attaching hardware is tightened securely otherwise injury or damage may occur Before performing any maintenance adjustment or service turn power OFF and remove key from ignition DO NOT overtighten hardware attaching to the frame This could cause damage to the frame Storing the Scooter A WARNING Use care in storage DO NOT allow any metallic objects to contact the exposed terminals 1 Before storing the scooter for prolonged periods of time perform the following A Charge the batteries Refer to Charging the Batteries on page 97 B Remove the batteries Refer to Removing Installing the Batteries on Zoom 300 on page 86 or refer to Removing Installing the Batteries on Zoom 400 on page 88 2 Before use recharge batteries Refer to Charging the Batteries on page 97 Suggested Maintenance Procedures 1 Before using the powered scooter make sure all nuts and bolts are tight Check any parts for damage or wear and replace Check all parts for proper adjustment 2 Ensure that batteries are properly maintained and charged as required 3 The wheels and tires should be checked periodically for cracks and wear and should be replaced by a qualified technician if damaged 4 Regularly check for loose nuts and or bolts in the front and drive wheels If loose have them adjusted by a qualified technician 5 Clean dirt dust and grease from exposed components 6 Periodically have the
117. ving Installing the Front Shroud Zoom 400 Zoom 300 and Zoom 400 32 Part No 1122167 SECTION 6 SHROUDS Removing Installing the Boot Assembly NOTE For this procedure refer to FIGURE 6 4 NOTE Reverse this procedure to install the boot assembly 1 Remove the front shroud Refer to Removing Installing the Front Shroud on page 31 2 Remove the tiller Refer to Removing Installing the Tiller on page 40 3 4 Remove the boot assembly from the front shroud by disengaging the boot from the Remove the front shroud and boot assembly from the scooter tabs on the front shroud NOTE On the Zoom 400 the boot will have to be slipped off the front basket bracket after disengaging the boot from the tabs Refer to Detail A of FIGURE 6 4 Tab DETAIL A Boot Assembly Front Basket Bracket Shroud N Front Basket Bracket NOTE The Zoom 400 is shown The Zoom 300 is the same without the front basket bracket FIGURE 6 4 Removing Installing the Boot Assembly Part No 1122167 33 Zoom 300 and Zoom 400 SECTION 7 WHEELS AND CASTERS SECTION 7 WHEELS AND CASTERS A WARNING After any adjustments repair or service and before use make sure that all attaching hardware is tightened securely otherwise injury or damage may result Before performing any maintenance adjustment or service turn power Off and remove key from ignition Removing Installing the Drive Wheels NOTE For this

Invacare Zoom 300 & 400 Service Manual

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Invacare Zoom 300 &amp; 400 Service Manual

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Invacare Zoom 300 & 400 Service Manual