Invacare® Typhoon SERVICE MANUAL
Contents
1. 7 14 W 54 Repairing a flat tyre GB motor CAUTION Danger of the wheelchair tipping over or rolling away e Secure the wheelchair from tipping over by propping it up with a wooden block under the battery box that is long and wide enough Using a wooden block that is too short or too high could cause the wheelchair to tip over e Switch the wheelchair off at the remote EXPLOSION HAZARD The wheel will explode if you do not let the air out of the tyre before removing the wheel e Always let the air out of the tyre before removing it press in the pin in the middle of the valve Injury hazard If the wheel has been insufficiently tightened or if the threaded holes in the rim have been damaged during assembly by excessive tightening then the wheel can loosen when driving e When reassembling the drive wheels position the screws in their holes by hand e Do not use electrical or pneumatic screw drivers e Tighten the Allen screws at a torque of 25 Nm e Make sure the Nordlock washers are replaced exactly the way they were removed Requirements e Allen key 6 mm Torque wrench Repair kit for tyre repair or a new inner tube Talcum powder Screw blocker Loctite e g Loctite 243 Note Pay attention to small pieces and the order in which the components are disassembled Arrange them in an orderly fashion so they can easily be assembled again in the right order e Prop up the wheelchair b2. 11 Page 7 6 7 7 7 8 7 9 7 10 7 11 Checking the cables Replacing the ACS Remote Updating the driving program Testing an actuator motor Adjusting and replacing the speed reduction switch Replacing the steering head bearings on the front or rear castor wheels 7 11 1 Front Castor Wheels 7 11 2 Rear Castor Wheels 7 12 7 13 7 14 7 15 7 16 Replacing the Anti Dive Spring Repairing a flat tyre conventional motor Repairing a flat tyre GB motor Replacing a drive wheel Replacing the safety belt 41 42 44 45 46 47 48 50 52 54 55 55 Introduction General information e All maintenance and overhaul work must be carried out in accordance with these repair instructions e Please observe all safety instructions e Information about operation or about general maintenance and care work should be taken from the electric vehicle Operating Manual e You can find information about ordering spare parts in the spare parts catalogue e Use only genuine Invacare spare parts Using parts from any other source will void the warranty e We reserve the right to make any alterations on the grounds of technical improvements e The electric vehicle may only be maintained and overhauled by qualified personnel e The minimum requirement for service technicians is relevant training such as in the cycle or orthopaedic mechanics fields or suitably long term job experience Experie
3. in the reverse order Please note The battery inserters can be inserted between the battery and the carrying belt They are thus easier to install Please note The battery poles on the rear battery must point backward and those on the front battery to the front The batteries cannot be connected in any other fitting direction 2 36 Assemble in accordance with this installation sequence Push the batteries 3 together with the carrying belt 5 and battery inserter 4 into the chassis Push the regulating motor 2 together with the nest into the chassis and allow to lock into place in the bottom plate Secure using lateral Allen screws Insert the connectors on the light circuit board in the correct order Apply the front panelling 1 and secure using lateral Allen Screws Please note The pole caps jam to a certain extent This is intentional so that water cannot reach the poles thus causing a short circuit Screw the battery cable onto the plus and minus pole Slide the pole caps over the poles Plug all cables into the electronic components Check that all connectors are fitted firmly Check the cable routing No cable should be able to protrude into the lifter area CAUTION Danger of crushing Please ensure that the regulating motor slides into the upper guiding device Move the regulating motor to the uppermost position and ensure that it slides into the upper guid
4. sided wheel wear and can reduce driving power e The drive unit is installed in the reverse order 21 7 2 7 2 1 D 22 Replacing and calibrating a GB drive motor The next two sections describe how to replace a GB motor and then calibrate the new one We recommend reading through the instructions once before beginning work NOTE First check whether the vehicle is equipped with puncture proof tyres or pneumatic tyres Depending on whether the vehicle is equipped with puncture proof tyres or pneumatic tyres the process of disassembly and re assembly will be different You can recognise puncture proof tyres by the fact that they do not have a valve Replacing the motor CAUTION Danger of the wheelchair tipping over or rolling away e Secure the wheelchair from tipping over by propping it up with a wooden block under the battery box that is long and wide enough Using a wooden block that is too short or too high could cause the wheelchair to tip over e Switch the wheelchair off at the remote EXPLOSION HAZARD On a vehicle with pneumatic tyres the wheel will explode if you do not let the air out of the tyre before removing the wheel e Always let the air out of the tyre before removing it press in the pin in the middle of the valve Injury hazard The wheelchair will drive erratically if the GB Motors are not calibrated after being replaced e Make sure to calibrate the GB Motors after replacin
5. too far raise lifter in stages until the status display stops flashing If at all possible only drive when the seat is at driving height 3 x flashes Connection on the e Check plug in See Checking the left motor connections cables on page 41 loose defective Left motor e Check replace motor See Replacing and defective calibrating a GB drive motor on page 22 4x flashes Connection on the e Check plug in See Checking the right motor connections cables on page 41 loose defective Right motor e Check replace motor See Replacing and defective calibrating a GB drive motor on page 22 5 x flashes Fault brake fault e Check plug in See Checking the on left hand motor connections cables on page 41 Connection loose defective or motor defective Left motor e Engage motor Shut See User Manual disengaged GB electronics down and then motors switch on again Both motors e Engage motors Shut See User Manual disengaged electronics down and then standard motors switch on again 6 x flashes Fault brake fault e Check plug in See Checking the on right hand connections cables on page 41 motor Connection loose defective or motor defective Right motor e Engage motor Shut See User Manual disengaged GB electronics down and then motors switch on again 7 x flashes Battery dead e Pre charge battery See User Manual 16 Flash code _ Meaning Solution Notes 8 x flashes Battery voltage too e Switch l
6. 6 00 rites haa GmbH Fax 46 0 31 86 36 06 D 32457 Porta Westfalica ginvacare invacare com Deutschland LANDSKRONA a 46 0 418 285 40 Fax 46 0 418 180 89 linvacare invacare com OSKARSHAMN a 46 0 491 101 40 Fax 46 0 491 101 80 oinvacare invacare com Table of Contents Chapter 1 INTRODUCTION 1 1 General information 1 2 Notes on transport 1 3 Important symbols in this manual 2 SAFETY AND ASSEMBLY INSTRUCTIONS 2 1 Before any inspection or repair work 2 2 General safety information and notes on assembly disassembly 3 TIGHTENING TORQUES 4 LAYOUT OF COMPONENTS AND MODULES 5 SERVICE PLAN 1X ANNUALLY 6 TROUBLESHOOTING THE TYPHOON 6 1 Troubleshooting the Typhoon with ACS 6 1 1 Diagnosing driving faults 6 1 2 Diagnosing problems with electric actuators 6 1 3 REM24 Error Codes and Diagnostic Codes 7 REPAIR WORK 7 14 Replacing a conventional drive motor 7 2 Replacing and calibrating a GB drive motor 7 2 1 Replacing the motor 7 2 1 1 Disassembling the tyre and rim on a vehicle with pneumatic tyres 7 2 1 2 Disassembling the rim and the tyre on a vehicle with puncture proof tyres 7 2 1 3 Proceed with removing the motor 7 2 1 4 Reassembling the rim and the tyre on a vehicle with pneumatic tyres 7 2 1 5 Reassembling the rim and the tyre on a vehicle with puncture proof tyres 7 2 2 Calibrating GB motors 7 3 7 4 7 5 Replacing components of the electronics Replacing the batteries Replacing the main fuse 10
7. 9mm ring wrenches 8mm and 13mm open jawed wrenches 5mm and 10mm hexagon sockets Diagonal nosed cutting pliers Hammer Material for jacking up the vehicle End cap for the Bowden cable Self securing M12 nut Please note Please pay attention to the plain washers during dismantling Put small parts aside in such a way that they can be re fitted in the correct order e Jack up the vehicle for instance by placing a block of wood under the chassis e Loosen the wheel cap carefully using a small screwdriver e Usea 19mm ring wrench to loosen the wheel nut 1 e Pull the complete wheel from the wheel hub CAUTION Danger of injury e The open end of the Bowden cable can injure your hands After this work step you can for example protect the end by lagging it with insulating tape Please note It is easy to lose the small uncoupling parts It is wise to keep these in a safe place until they are required for reassembly e Cut off the end cap on the Bowden cable 1 using diagonal nosed cutting pliers In doing so please leave the Bowden cable as long as possible e Loosen the check screw 2 e Loosen the counternut 3 e Remove the tapped bush 4 e Pull the entire Bowden cable through both lugs on the drive unit e Press in the retaining clips 1 and in doing so pull the electronic panelling upward and to the rear applying slight pressure to the handle 2 e Pull the motor connector 1 out of th
8. Installation Manual of the ACS Electronics available from Invacare NOTE All ACS remotes are supplied with a standard drive programme If the driving programme has been customised then you will have to perform this customisation again after installing the new electronic module WARNING Every alteration to the drive programme can influence vehicle handling and the tipping stability of the wheelchair e Alterations to the drive programme must only be carried out by trained Invacare dealers e Invacare can only assume a warranty for the safe vehicle handling of the wheelchair in particular tipping stability for unaltered standard drive programmes e Switch off the remote e Pull the bus cable 1 out of the remote e Loosen the thumb screw 2 e Pull the remote and the remote holder out of the guiding device e Unscrew both remote holder screws 1 using the crosstip screwdriver Installation of the remote is carried out in reverse order Update the software in case a newer version is available Customise the driving programme with the programming software if required Check all vehicle functions 43 7 8 VU A4 Updating the driving program The driving programs for electric wheelchairs are continually updated and improved by Invacare For this reason you should check whether the version number is still up to date each time a wheelchair comes in for repairs and also durin
9. Invacare Typhoon SERVICE MANUAL This document contains information on Troubleshooting Maintenance Repair Version 26 11 09 43 6232 55 35 0 i Mobitec Mobilitatshilfen GmbH 4 Herzog Odilostrasse 101 Fax 43 6232 55 35 4 A 5310 Mondsee office mobitec austria com Austria austria invacare com WWW www mobitec austria com ri CR Invacare n v a 32 0 50 83 10 10 k A Autobaan 22 Fax 32 0 50 83 10 11 gt B 8210 Loppem Brugge belgium invacare com k A Belgium WWW www invacare be CH Mobitec Rehab AG a 41 0 61 48 77 08 0 tT Benkenstra e 260 Fax 41 0 61 48 77 08 1 7 CH 4108 Witterswil office mobitec rehab ch Switzerland switzerland invacare com WWW www mobitec rehab ch D Invacare Aquatec a 49 0 75 62 7 000 KM Alemannenstrae 10 Fax 49 0 75 62 7 00 66 88316 Isny info invacare aquatec com Deutschland WWW www invacare aquatec de Invacare A S Sdr Ringvej 37 T Kundeservice Fax Kundeservice 45 0 36 90 00 00 45 0 36 90 00 01 EE S DK 2605 Br ndby denmark invacare com Danmark WWW www invacare dk i Ej Invacare SA a 34 0 972 49 32 00 w c Aren s n Fax 34 0 972 49 32 20 8 Poligon Industrial de Celra contactsp invacare com E 17460 Celra Girona WWW www invacare es ESPA A E Invacare Poirier SAS a 33 0 247 62 64 66 TI Route de St Roch Fax 33 0 247 42 12 24 7 F 37230 Fondettes contactfr invacare com France WWW www inva
10. aining clips 1 and in doing so pull the electronic panelling upward and to the rear applying slight pressure to the handle 2 A CAUTION Electronics can be damaged e Disconnect all electronic components from the batteries before commencing work on the batteries e Disconnect all plugs from the electronic components Loi CAUTION Fire hazard Cables can be pinched and chafed e Please pay attention to the cable routing during dismantling so that the cables can be re fitted in this position The cable binders may only then be opened e Remove all pole caps from the poles e Unscrew the screws 1 on the minus poles using an 11mm open jawed wrench e Unscrew the screws 2 on the plus poles using an 11mm open jawed wrench Loi CAUTION Danger of crushing e The batteries are very heavy Please ensure that they do not hit the ground when being removed from the chassis 35 e Pull the battieres out to the front using the carrying belt e Remove the battery inserter and carrying belt from the battery Loi CAUTION Fire hazard Cables can be pinched and chafed e Please ensure correct cable layout They may not protrude into the lifter area Use cable binders if necessary When installing new batteries make sure there are no cables between the front batteries and the actuator of the lifter They could get damaged when the lifter is operated RIGHT e Installation is carried out
11. care fr Invacare Ltd Pencoed Technology Park T Customer Service Fax Customer Service 44 0 1656 776 200 44 0 1656 776 201 Pencoed uk invacare com Bridgend CF35 5HZ eire invacare com United Kingdom WWW www invacare co uk T3 Invacare Mecc San s r l a 39 0445 38 00 59 s_ Via Dei Pini 62 Fax 39 0445 38 00 34 8 36016 Thiene VI italia invacare com ITALIA WWW www invacare it Invacare Ireland Ltd a 353 18 10 70 84 Unit 5 Seatown Business Campus Fax 353 18 10 70 85 Seatown Rd Swords eire invacare com County Dublin WWW www invacare ie Ireland En Invacare AS Kundeservice 47 0 22 57 95 00 LAW Grensesvingen 9 Fax Kundeservice 47 0 22 57 95 01 Postboks 6230 norway invacare com Etterstad WWW www invacare no N 0603 Oslo Norge NL Invacare B V a 31 0 318 69 57 57 t Celsiusstraat 46 Fax 31 0 318 69 57 58 7 NL 6716 BZ Ede nederland invacare com Nederland WWW www invacare nl P Invacare Portugal Lda T 351 225 1059 46 sM Rua Estrada Velha 949 T 351 225 1059 47 P 4465 784 Le a do Balio Fax 351 225 1057 39 Portugal portugal invacare com WWW www invacare pt re terf rs ljare T Kundtj nst 46 0 8 761 70 90 K Invacare AB Fax Kundtj nst 46 0 8 761 81 08 Gi Fagerstagatan 9 sweden invacare com a 1 S 163 91 Spanga finland invacare com Sverige WWW www invacare se Tillverkare M LNDAL a 46 0 31 86 3
12. e 1 e Open the circlip protecting the pin using the circlip pliers and remove it Push the lower half of the walking beam down so that the tension on the spring 1 is released Remove the upper end of the spring from the hole in walking beam Use the Allen key 5mm to remove the bolt 1 that holds the retainer plate that secures the lower end of the spring The spring can now be replaced Reassembly is done in reverse order 51 7 13 d 52 Repairing a flat tyre conventional motor CAUTION Danger of the wheelchair tipping over or rolling away e Secure the wheelchair from tipping over by propping it up with a wooden block under the battery box that is long and wide enough Using a wooden block that is too short or too high could cause the wheelchair to tip over e Switch the wheelchair off at the remote CAUTION Injury hazard If the wheel has been insufficiently tightened during assembly it can become loosened during driving e When reassembling the drive wheels tighten the Allen screws at a torque of 30 Nm e Secure all screws using a suitable blocker e g Loctite 243 Requirements e Allen key spanner 5 mm Torque wrench Repair kit for tyre repair or a new inner tube Talcum powder Screw blocker Loctite e g Loctite 243 Note Pay attention to small pieces and the order in which the components are disassembled Arrange them in an orderly fashion so they can easi
13. e electronics 2 e The motor connector for the left hand drive unit is to be found in the electronics on the far left side Please note A great number of turns are required in order to unscrew the bolt e Secure the drive unit against falling out by placing a wooden block or styrofoam block underneath e Unscrew the bolt 1 in the drive unit suspension using a 10 mm hexagon socket 19 i Please note Make a note of the number of turns needed to loosen the nut This number of turns determines the wheel camber Incorrect wheel camber leads to one sided wheel wear and can reduce driving power e Insert a 17mm box wrench from the top through the opening in the chassis 1 e Loosen the nut e Remove the entire drive unit from the suspension in a downward direction e Remove the guiding lug for Bowden cables 1 using a 5mm hexagon socket e Unscrew the four screws 1 on the bedding plate using a 13mm open jawed or ring wrench A CAUTION Fire hazard Cables can be pinched and chafed e Please ensure correct cable layout The motor cable must be secured on the panelling by means of a plastic ring and may not protrude into the lifter area Loi CAUTION Risk of accident e Use a new Self securing wheel nut and tighten it applying 60 Nm 20 Please note Only tighten the suspension nut using the noted number of turns This sets the wheel camber Incorrect wheel camber leads to one
14. e Remove the plastic cap 5 e Loosen the bolt 3 and the associated nut in the figure this is covered with a 4 mm Allen key and a 10 mm socket spanner e Remove the nut incl the washer e Remove the screw incl the safety belt the washer 2 and the washer arranged behind Note Another nut is fixed between the two washers 2 and 4 as a spacer so that the belt mounting can rotate freely e Replace the safety belt 1 Refitting the safety belt e Refit the parts in reverse order
15. g Fixing Action Notes See Replacing the batteries on page 33 for Safety Information on working with batteries Clean contacts and terminals Evaluate flash code gt Tighten replace gt Replace Cable connecting plug Replace joystick Joystick function Power supply Check spring for damage e Check correct function e Check function of the Stability Lock e Check the programme version of the driving electronics Is there a newer version available Replace cable connector plug or console Replace if damaged See Replacing the Anti Dive Spring on page 50 KE RS Kaz e Update the software See Updating the on page 44 Troubleshooting the Typhoon Troubleshooting the Typhoon with ACS If a problem occurs with the wheelchair then please proceed as follows e Identify the possible cause of the fault by using the troubleshooting tables below e Check the Status Display on the remote Identify the error code if it is flashing e Perform the necessary checks and repairs as recommended in the table below Note For more information on troubleshooting the Typhoon with GB motors please see the Dynamic DX GB AS Power Module Installation Manual Order Nr 1441533 Diagnosing driving faults PROBLEM OTHER Wheelchai r will not drive POSSIBLE SOLUTION REFERENCE SYMPTOMS CAUSE Status display Drive motors e Engage See User Manual on remote may be the drive ligh
16. g regular inspections If a newer version is available the driving program must be updated The procedure for updating the driving program is described in the user manual of the Wizard software NOTE The electronic system is supplied with a standard drive program If the driving program has been customised you have to perform this customisation again after installing the new driving program WARNING Every alteration to the drive program can influence vehicle handling and the tipping stability of the wheelchair e Alterations to the drive program must only be carried out by trained Invacare dealers e Invacare can only assume a warranty for the safe vehicle handling of the wheelchair in particular tipping stability for unaltered standard drive programs Pre requisites e Dynamic Wizard software e User manual for the Wizard software e For further information on other requirements such as the minimum system configuration of the PC to be used for programming necessary programming cables see the user manual of the Wizard software You find the latest version of the user manual in the download area on http www dynamiccontrols com 7 9 i Testing an actuator motor Requirements e Multimeter e Check the electrical resistance of the actuator If it is close to infinite then the motor is likely to be burnt out If it is less than 1Q then motor has a short circuit In either case t
17. g them Injury hazard If the bolts that hold the wheel have been insufficiently tightened or if the threaded holes in the rim have been damaged during assembly by excessive tightening then the wheel can loosen when driving e When reassembling the drive wheels position the screws in their holes by hand e Do not use electrical or pneumatic screwdrivers e Tighten the Allen screws at a torque of 25 Nm e Make sure the Nordlock washers are replaced exactly the way they were removed NOTE CONCERNING WARRANTY ON GB MOTORS If within such warranty period motors are proven to be defective the motors will be repaired or replaced at Invacare s absolute discretion This warranty does not include labour or shipping charges Neither does the warranty apply to physical damage nor unauthorised repairs Invacare s sole obligation and your exclusive remedy under this warranty is limited to such repair and or replacement 7 2 1 1 Requirements Wooden block to prop up the vehicle Allen key 6mm Allen key 4mm Small flat bladed screwdriver Circlip pliers Loctite 243 2x combination wrench 13mm Hammer Chisel Torque wrench One new hexagonal dome headed bolt M8 20mm long 5mm key size Additional parts and tools for working on puncture proof tyres e Tyre lubrication soap based e 3 screws M8 x 30 mm for preliminary positioning of the rim during assembly Note Pay attention to small pieces and the order in whic
18. h the components are disassembled Arrange them in an orderly fashion so they can easily be assembled again in the right order e Prop up the wheelchair by lifting it up on the side that you want to work on and then placing the wooden block underneath the battery box on that side e Use the small flat bladed screwdriver to loosen the screws that hold the motor cable connection and disconnect the cable Disassembling the tyre and rim on a vehicle with pneumatic tyres EXPLOSION HAZARD On a vehicle with pneumatic tyres the wheel will explode if you do not let the air out of the tyre before removing the wheel e Always let the air out of the tyre before removing it press in the pin in the middle of the valve 23 e Unscrew valve cap e Depressurise tyre by pressing in the pin in the valve 1 e Unscrew 5 screws 2 using the 6mm Allen key e Remove the wheel rim half with the inner tube 7 2 1 2 Disassembling the rim and the tyre on a vehicle with puncture proof tyres A WARNING Danger of damage to the motor if the screws are not loosened and removed in the correct sequence e Make sure you loosen and remove the screws in the correct sequence Screws 1 to 5 must be loosened and removed in a particular sequence in relation to each other There is no pre defined numbering for the screws There is for example no screw with the pre defined number 1 For this reason you can start with any screw Th
19. he motor needs to be replaced 45 7 10 Adjusting and replacing the speed reduction switch Find out here how you can adjust and replace the switch that reduces the speed when in the upper lifter position yA Pre requisites dei e Small pliers e Move the lifter to the upper and lower position several times In doing so check whether the contact switches e If the contact does not switch bend the plate 1 slightly e If the contact is faulty replace the entire cable harness e Check all vehicle functions 46 7 11 Replacing the steering head bearings on the front or rear castor wheels A CAUTION Incorrect reassembly can damage the bearings or cause the steering wheels to fall out e The single row angular ball bearing races are not the same on both sides For this reason there is only one correct way to fit them It is imperative that you observe the reassembly information yA Requirements 7 e Small flat bladed screwdriver e Allen key 3mm e Socket wrench 19mm e Torque wrench 7 11 1 Front Castor Wheels e Prop up the wheelchair by lifting it up on the side that you want to work on and then placing the wooden block underneath the battery box on that side e Carefully remove the black plastic cap 1 that covers the end of the steering head tube using the small flat bladed screwdriver 47 e Loosen and remove the 19 mm nut using the socket wrench Hold the wheel so it does not ro
20. ights on to lower See User Manual of battery high battery voltage charger e Check battery charger 9 or 10 x Faulty data e Remove all electronic flashes transmission modules except the Power between modules Module and the Remote Re attach modules one by one to determine which one is causing the fault See Replacing components of the electronics on page 31 11 x flashes Motors overloaded e Switch remote on and off overheated wait if necessary 12 x flashes Module used has compatibility problems Remove incorrect module See Replacing components of the electronics on page 31 17 7 1 d 18 Repair Work CAUTION Risk of damage to the vehicle Collisions can be caused if shim rings are removed from the drive wheels during installation work e Shim rings are frequently placed between the drive shaft and the wheel hub to compensate tolerances Collisions can be caused if these shim rings are removed and not re installed Please install all shim rings in exactly the same positions they were in before dismantling Replacing a conventional drive motor Find out here how to replace the conventional Typhoon drive units CAUTION Danger of tipping over and crushing e Secure the vehicle with wedges and a jack up device to prevent it rolling and tilting as it tends to do this following removal of a drive wheel Pre requisites Small screwdriver 17 and 1
21. ing device 1 37 38 Raise the lifter slightly and unlock the retaining mechanism 1 The entire lifter load is now on the regulating motor again Test all vehicle functions Check the charge status of the new batteries and charge fully if necessary 7 5 A Replacing the main fuse CAUTION Fire hazard e Only ever use an original strip fuse and permissible strength of current e Inthe event that the main fuse has burnt out remedy the cause before fitting a new fuse Pre requisites e 8mm ring or open jawed wrench e Replacement fuse e Small flat screwdriver Please note In case the fuse holder is damaged this can be replaced completely together with the battery cables e Press in the retaining clips 1 and in doing so pull the electronic panelling upward and to the rear applying slight pressure to the handle 2 e Remove the fuse holder 1 from the electronics holder 2 For this purpose press in the plastic clips 3 lightly using a small flat screwdriver WARNING Danger of fire exists if the fuse is incorrectly assembled e Only ever assemble the fuse in the order shown in the illustration at right e Always tighten nuts to between 3 3 and 3 5 Nm Until 03 2004 After 03 2004 1 Fuse 1 Fuse 2 Fuse compartment 2 Fuse compartment 3 Washer 3 Nut DIN 6923 4 Nut M5 39 40 Open the cover on the fuse holder If the strip fuse 2 has burnt ou
22. is will then be number 1 Number 2 is then the screw next to it in a clockwise direction 3 is the next and so on e Loosen and remove screws 1 and 3 using the 6mm Allen key e Loosen screws 2 4 and 5 a single turn each one after the other going from screw to screw in a clockwise direction until they have all been completely loosened and removed e Remove the rim half and the puncture proof inlay from the wheel 7 2 1 3 Proceed with removing the motor e Remove the three screws that hold the fender using the 4mm Allen key 24 You will need to remove the entire upper half of the walking beam to replace the motor To do this you need to remove one of the pins 1 that hold the walking beam The pins are secured with snap rings from the inside e Use the circlip pliers or alternatively the small screwdriver to open and remove the snap ring that secures the pin e Use the two combination wrenches to loosen the bolts that hold the mounting plate for the headlight 1 e Remove the headlight with the mounting plate and tuck it up under the seat to get it out of the way The bolt that holds the upper arm of the walking beam at it s pivotal point 1 is secured with Loctite so you will not be able to remove it simply by inserting an Allen key and turning It will need some subtle persuasion with a hammer and chisel e Use the hammer and chisel to get the bolt started turning After it has turned one
23. ith grease Never use standard nuts instead of self locking nuts Always use correctly dimensioned washers or spacers Cable binders which have been cut off during disassembly should be replaced with new ones during reassembly e After completing maintenance work and before operating the electric vehicle make sure all fixations are correctly secured Check all parts for correct interlocking1 e Only operate the electric vehicle with correct tyre pressure see Technical Specifications e Check electrical components for correct functioning incorrect polarity of cables can result in damage to the electronics e Asa last check always carry out a test drive Notes Mark all current settings for the electric vehicle seat armrests backrest etc and the cable connecting plugs associated before any removals This makes reassembly easier All plugs are fitted with mechanical safety devices which prevent release of the connecting plugs during operation To release the connecting plugs the safety devices must be pressed in When reassembling ensure that these safety devices are correctly engaged WARNING Any alteration to the drive programme can influence vehicle handling and the tipping stability of the electric vehicle e Alterations to the drive programme may only be carried out by trained Invacare dealers e Invacare supplies all electric vehicles from the factory with a standard drive programme Invacare can only assu
24. ive wheels have been raised YES if drive wheels have been raised GB MOTOR CALIBRATION BEGIN to start Wheels will drive EXIT BEGIN BEGIN if drive wheels have been raised GB MOTOR CALIBRATION in progress Please wait No entry required Wait till end of calibration GB MOTOR CALIBRATION Successful EXIT EXIT e Separate the programming device from the wheelchair Calibration is complete 7 3 i Replacing components of the electronics Find out here how to replace the Typhoon electronic components Pre requisites e Large and small crosstip screwdrivers e 8mm open jawed or ring wrench e Press in the retaining clips 1 and in doing so pull the electronic panelling upward and to the rear applying slight pressure to the handle 2 e Remove all connectors from the module to be replaced e In order to remove the power module loosen both nuts 1 using an 8mm open jawed or ring wrench 31 32 Press in the retaining clip 1 using a small crosstip screwdriver and slide the Clam from the electronic carrier in the direction of the arrow The drive unit is installed in reverse order To allow the electronic carrier to lock into place correctly increase the distance between the chassis and the battery using a large crosstip screwdriver ZA amp Replacing the batteries Find out here how to replace the Typhoon batteries CAUTION Risk
25. ly be assembled again in the right order e Prop up the wheelchair by lifting it up on the Yale side that you want to work on and then E e placing the wooden block underneath the battery box on that side e Unscrew the 4 bolts that hold the wheel 1 using the 5mm Allen key e Remove the wheel from the hub e Unscrew valve cap e Let the air out of the tyre completely by pressing the pin in the centre of the valve in e Remove the 5 cylinder head screws back of the wheel 2 e Remove the rim halves from the tyre e Remove the inner tube from the tyre e Repair inner tube and replace or insert a new one NOTE If the old inner tube is to be repaired and re used and has become wet during repair you can make replacement easier by sprinkling the inner tube with a little talcum powder NOTE Re assembly is done in reverse order Ensure that the tyre is replaced on the same side and in the same travel direction as it was previously mounted e Insert the wheel rim halves from outside into the tyre e Pump a little air into the inner tube e Insert the cylinder head screws in the rim and tighten the wheel rims firmly Make sure the inner tube does not get pinched between the rims halves e Ensure that the tyre outer is seated correctly e Pump the tyre up to the prescribed pressure e Check that the tyre is seated correctly once again e Screw the valve cap back on e Refit the wheel 53
26. me a warranty for the safe vehicle handling of the electric vehicle in particular tipping stability for this standard drive programme Tightening torques The tightening torques stated in the following table are dependent on the thread diameters for the nuts and bolts for which no special values are determined All values apply to dry and grease free threads Thread M4 M5 M6 M8 M10 M12 M14 M16 Tightening torque 3 Nm 6 Nm 10 Nm 25 Nm 49Nm 80 Nm 120 Nm 180 Nm in Nm 10 Caution All other nuts or plastic connectors not noted here must be tightened FINGERTIGHT 4 Layout of components and modules The following image shows the Typhoon from above rear with the seat lifter raised and the rear cowling removed Seat tilt actuator Seat frame rear cowling anti collision switch Speed reduction switch Power module CLAM Combined Light and Actuator Module aRWN 1 Lifter actuator 10 5 Service plan 1x annually EE Beaks Component Check e Armrest damage and fastening e Side panel damage and fixing Seat unit seat Cushion angle adjustment Check seat angle adjustment Damage and seams Fixings Check cabling Check function Armrests and side panels Backrest unit af mechanical af J e Backrest unit electrical e Check drive wheels for whee tight fit and side play suspension and wheels e Check steering wheels for tight fit fl
27. nce and knowledge of electrical measuring devices Multimeter is also a requirement Special Invacare training sessions are recommended e Alterations to the electric vehicle which occur as a result of incorrectly or improperly executed maintenance or overhaul work lead to the exclusion of all liability on the part of INVACARE e If you have any problems or questions please contact INVACARE SERVICE Notes on transport e If the electric vehicle has to be shipped back to the manufacturer for major repairs you should always use the original packaging for transport e You should also include as accurate a fault description as possible Important symbols in this manual WARNING This symbol warns you of danger e Always follow these instructions to avoid injury to the user or damage to the product EXPLOSION HAZARD This symbol warns you of an explosion hazard which for example can be caused by excessive tyre pressure in a pneumatic tyre e Always follow the instructions to avoid injury to the user or damage to the product BURN HAZARD This symbol warns you of burns due for example to leaking battery acid e Always follow the instructions to avoid injury to the user or damage to the product NOTE This symbol identifies general information which is intended to simplify working with your product and which refers to special functions Requirements e This symbol identifies a list of various tools c
28. oat side play and correct torque 15 Nm 1 5 Nm e Check pneumatic tyres on the drive wheels e Check functions in drive and push modes e Check disengager fee Electrical footrests Drive units disengager Check welded seams interlocking screws footplates Check cabling Check contacts Check functions Ss e Check cabling Replace bulbs or cables if Replace batteries if See Replacing necessary the batteries on page 33 Batteries e Check batteries for damage Tighten screws replace padding if damaged Tighten screws replace side panels if damaged Replace covers upholstery if damaged Replace parts if damaged Replace parts if damaged Tighten screws Replace cable or motor if necessary See Replacing a drive wheel on Adjust replace wheel hubs See Replacing the steering head bearings on the front or rear castor wheels on page 47 See Repairing a flat tyre conventional motor on page Replace wheels wheel fork or wheel bearings Repair or replace if damaged Replace motor if necessary Tighten screws nuts adjust or replace if necessary Tighten replace if necessary Replace cable if necessary a e Check battery charge Charge batteries See User Manual EH 11 Component Remote electronics Walking Beam Driving Programme 12 Check e Check contacts and terminals for corrosion Remote status display blinkin
29. of chemical burns e Please look out for damaged batteries or ensure that you do not damage the batteries Leaking acid can cause chemical burns to the skin and eyes e If acid should come into contact with the skin rinse immediately using plenty of fresh water e f acid should get into the eyes rinse immediately using plenty of fresh water and consult a physician CAUTION Danger of crushing e Secure the lifter against unintentional folding by using the mechanism intended for this purpose The great weight of the lifter can cause serious injuries if it drops down e Check whether the battery belts are damaged and lift the batteries carefully CAUTION Risk of fire and burns if battery poles are short circuited e When replacing the batteries the battery poles MUST NOT come into contact with metal parts of the wheelchair causing bridging e Be sure to replace the battery pole caps after the batteries have been replaced CAUTION Environmental contamination e Used batteries should not be disposed of with domestic waste and outdoors Please dispose of the batteries professionally by giving them to your local harmful substance point of acceptance Pre requisites 11mm open jawed wrench 5mm and 6mm hexagon sockets Diagonal nosed cutting pliers Water resistant marker Cable binder Replacement battery ies Optional new battery belts Please note It is easier to carry out a few work steps with the assis
30. omponents and items which you will need in order to carry out certain work READ WELL BEFORE OPERATION k This symbol advises you to read information carefully 2 1 2 2 A Safety and assembly instructions These safety instructions are intended to prevent accidents during work and it is imperative that they are observed Before any inspection or repair work e Read and observe this repair manual and the associated operating manual e Observe the minimum requirements for carrying out the work see chapter entitled General information General safety information and notes on assembly disassembly Danger of injury by crushing e Please note the heavy weight of some components This applies especially to removal of drive units and batteries e Prop up the lifted electric vehicle with appropriate supports before starting the disassembly or assembly Danger of fire and burns due to electrical short circuit e The electric vehicle must be switched off before removal of voltage carrying components To do this disconnect the batteries e When making measurements on voltage carrying components avoid short circuiting the contacts Danger of fire and combustion Danger of injury and damage to the vehicle can result from incorrect or incomplete maintenance Only ever use tools which are undamaged in good condition Some moving parts have Teflon bushings These parts must never be lubricated w
31. onventional drive defective motor s motor on page 18 and Replacing and calibrating a GB drive motor on page 22 Batteries None Batteries may e Replace See Replacing the cannot be be defective the batteries batteries on page 33 charged LEDs on the Charger may e Replace See User Manual of the charger are be defective the charger charger flashing Wheelchai Status display Seat lifter is not e Return See User Manual r drives on remote in driving seat lifter to too slowly flashes 2x position either driving drive mode too high or too position display shows low and has U activated the automatic speed reduction Speed e Adjust See Adjusting and reduction the micro replacing the speed micro switch on switch reduction switch on the seat lifter page 46 may be badly adjusted None Remote may e Replace See Replacing the ACS be defective the remote Remote on page 42 Batteries may e Replace See Replacing the be defective the batteries batteries on page 33 6 1 2 Diagnosing problems with electric actuators In case an electric actuator will not function identify the source of the problem using the following table PROBLEM OTHER Electric Actuator does not function POSSIBLE SOLUTION REFERENCE SYMPTOMS CAUSE Remote CLAM is e Replace See Replacing displays a defective the CLAM components of the flashing E electronics on page 31 status diode on the CLAM does n
32. or two revolutions then it can be removed the rest of the way using the 5mm Allen key 25 26 The illustration at the right shows how to position the chisel 1 on the head of the screw 2 to get it started turning Use the small screwdriver to carefully remove the clip that holds the emergency declutching latch 2 in place Remove the bolts that hold the motor on the mounting plate using the combination wrench 13mm The drive unit is re assembled in the reverse order The original bolt that held the walking beam at the pivot point will probably be severely damaged so use a new one Use some Loctite 243 on the new bolt Tighten the wheel screws to 25 Nm 7 2 1 4 7 2 1 5 Reassembling the rim and the tyre on a vehicle with pneumatic tyres e Re position the inner tube in the tyre e Re fit the rim half e Position the screws and tighten them a little e Fill the inner tube with a little air e Tighten the screws that hold the rim e Check to make sure the tyre is fitted snugly to the rim e Pump up the tyre to 3 Bar air pressure e Check again to make sure the tyre fits rim correctly e Screw on the valve cap Reassembling the rim and the tyre on a vehicle with puncture proof tyres e To reassemble a tyre with a puncture proof core you will need to coat the inner and outer edges of the tyre 1 and 3 and the inner surface of the puncture proof inlay 2 with tyre lubrication e Push the tyre
33. ot go out even if the remote is switched off or disconnected None Cable may e Check See Checking the be that the cable cables on page 41 disconnected is not or damaged disconnected or damaged If necessary replace the cable Electric e Test the See Testing an actuator actuator may actuator motor on page 45 be defective Remote may e Exchang See Replacing the ACS be defective e the remote Remote on page 42 on the wheelchair for a different one to eliminate the possibility that the remote may be the cause 15 REM24 Error Codes and Diagnostic Codes The drive electronics are capable of rectifying some errors automatically In this case the status display will cease to flash Please switch the remote on and off several times Wait approx 5 seconds each time before switching the remote on again If this does not rectify the error locate the error using the flash codes shown below Flash code Meaning Solution Notes 1x flash Module defective e Replace defective module See Replacing components of the electronics on page 31 2 x flashes Accessory error e Check accessory See Testing an actuator e g actuator connections check motor on page 45 short circuit accessories Lifter raised or e If lifter is raised lower in See User Manual lowered too far stages until the status seat not at driving display stops flashing If height lowered
34. starts to move in an uncontrolled manner if one or both of the drive wheels is touching the ground during calibration e Itis absolutely imperative to get BOTH drive wheels off the ground before calibrating not just on one side 4 Requirements an e Dynamic DX HHP handheld programming device e Prop up the wheelchair with wooden blocks The drive wheels must not be touching the floor or the work surface e Connect the programming device Programming device displays The programming device You should enter this shows the following DX HHp V1 20 GB Select a language GB D NL S TECH View or edit System YES DIAG TECH Technician mode Enter code 592 with keys D1 to D3 then select EXIT Enter Password 000 EXIT D1 D2 D3 Technician mode NEXT Master JS Module JOYSTICK CALIBRATION EXIT YES NEXT MAIN MENU YES View or edit GB Power Module NEXT YES GB Controller NEXT Torque XX EXIT NEXT DOWN UP GB Controller NEXT Tremor Damping XX EXIT NEXT DOWN UP GB Controller NEXT Speed Progression XX EXIT NEXT DOWN UP GB Controller NEXT Turn Progression XX EXIT NEXT DOWN UP GB Controller YES Calibrate Motors EXIT NEXT YES 29 30 The programming device You should enter this shows the following GB MOTOR CALIBRATION Wheels will move Drive wheels raised EXIT YES GB MOTOR CALIBRATION Chair will drive Are wheels raised EXIT YES YES if dr
35. t look for the cause and remedy The main fuse may only be replaced when the fault has been remedied Use an 8mm open jawed or ring wrench to unscrew the nuts 1 on the strip fuse 2 Insert a new strip fuse 2 and secure using both nuts 1 Close the cover on the fuse holder Lock the fuse holder into place in the electronics holder until you hear a click Close the electronic panelling Check all vehicle functions 7 6 i Checking the cables Find out here how you can check the plug connections on the Typhoon electronics Pre requisites e None e Move the lifter to the uppermost position e Press in the retaining clips 1 and in doing so pull the electronic panelling upward and to the rear applying slight pressure to the handle 2 e Check all cables for signs of damage and crushing e Pull each connector lightly It may not come away from the bush e lf aconnector is loose use slight pressure to press the connector into the bush It must lock into place e Check whether the connector is fitted firmly If not please repeat the work step e Press in the retaining clips 1 and in doing so close the electronic panelling applying slight pressure from the top e Check all vehicle functions 41 42 7 7 d Replacing the ACS Remote Pre requisites e Phillips screwdriver e To modify a drive programme you will need Programming software or a Handheld Programmer and the
36. tance of another person in particular when lifting the lifter and unlocking the retaining mechanism e Move the lifter to the uppermost position e Raise the lifter further by pulling the piston rod of the actuator towards the front to unfasten the piston rod head from its socket and simultaneously pulling the seat upwards so that the retaining mechanism 1 locks into place e Check whether the retaining mechanism 1 is fully locked into place e Move the regulating motor to the lowest position The regulating motor slides out of the upper guiding device 33 34 CAUTION Cables can pull off e Remove the front panelling carefully on vehicles with a lighting system as the light circuit board is attached to it Hold on to the panelling until you have marked and released all connectors e Unscrew the screws 1 and 2 on both sides of the vehicle using a 5 or 6mm hexagon socket e Remove the front panelling to the front and hold with one hand or lay aside carefully e Mark the connectors on the light circuit board using a water resistant marker so that they can be re fitted in the right position e Remove the five connectors e Lay the front panelling aside e Open the plug in connection on the regulating motor cable e Pull the nest together with the regulating motor slightly to the front 1 and then lift 2 Now remove the regulating motor and the nest completely e Press in the ret
37. tate while removing the nut e Pull the steering head shaft down and out of the steering head tube e Remove the washer and the bearing race from the top of the tube The other bearing race should be on the shaft IMPORTANT REASSEMBLY INFORMATION The pictures show the wide rim on the outside of the bearing race A and the narrow rim on the inside B The bearings must always be assembled so that the narrow rims are facing each other inwards The steering head bolt and the nut must always press against the wide rims from the outside Otherwise the bearings will be forced out apart by the pressure of the bolt The steering wheels should swivel freely after assembly but there should be no play in the bearings e First tighten the nut to 20 Nm 2 Nm e Loosen the nut a little e Retighten to 15 Nm 1 5 Nm 7 11 2 Rear Castor Wheels e Use the Allen key 3mm remove the screws that hold the clear plastic cap of the rear light 48 e Carefully remove the black plastic cap 1 that covers the end of the steering head tube using the small flat bladed screwdriver e Loosen and remove the 19 mm nut using the socket wrench Hold the wheel so it does not rotate while removing the nut e Paull the steering head shaft down and out of the steering head tube e Remove the washer and the bearing race from the top of the tube The other bearing race should be on the shaft IMPORTANT REASSEMBLY INFORMATION A and
38. the narrow rim on the inside B The bearings must always be assembled so that the narrow rims are facing each other inwards The steering head bolt and the nut must always press against the wide rims from the outside Otherwise the bearings will be forced out apart by the pressure of the bolt The steering wheels should swivel freely after assembly but there should be no play in the bearings e First tighten the nut to 20 Nm 2 Nm e Loosen the nut a little e Retighten to 15 Nm 1 5 Nm 49 7 12 50 Replacing the Anti Dive Spring CAUTION Danger of the wheelchair tipping over or rolling away e Secure the wheelchair from tipping over by propping it up with a wooden block under the battery box that is long and wide enough Using a wooden block that is too short or too high could cause the wheelchair to tip over e Switch the wheelchair off at the remote Requirements e 5 mm Allen key e Circlip pliers Note Pay attention to small pieces and the order in which the components are disassembled Arrange them in an orderly fashion so they can easily be assembled again in the right order e Prop up the wheelchair by lifting it up on the side that you want to work on and then placing the wooden block underneath the battery box on that side 1 e To access the spring you will need to remove the lower pin 2 that holds the walking beam e The pin is secured with a circlip from the insid
39. ts up disengaged motors normally and does not show an error code Status display Batteries may e Replace See Replacing the on remote does not light up be defective the batteries batteries on page 33 Batteries may be completely discharged Charge the batteries See User Manual Power supply to the remote may be interrupted Check the main fuse See Replacing the main fuse on page 39 Check cables between modules for loose connections or damage See Checking the cables on page 41 Remote may be defective Exchang e the remote on the wheelchair for a different one to eliminate the possibility that the remote may be the cause See Replacing the ACS Remote on page 42 Status display on remote is flashing Various causes Identify the error code See REM24 Error Codes and Diagnostic Codes on page 16 13 14 PROBLEM OTHER POSSIBLE SOLUTION REFERENCE SYMPTOMS CAUSE Status display Speed e Replace See Adjusting and on remote reduction cable or replacing the speed flashes 2x switch on the switch reduction switch on drive mode lifter may be page 46 display shows defective or U disconnected Wheelchai None Batteries may e Replace See Replacing the r does not be defective the batteries batteries on page 33 drive voltage not smoothly stable Drive motor s e Replace See Replacing a may be the drive c
40. with the puncture proof inlay onto the motor rotor casing 27 28 Position the rim half in the tyre The holes for ae the screws in the rim half and the ones in i the rotor casing need to be aligned with each other It can be helpful to align the notch in the rim half and the one in the rotor casing where the valve would usually be using them as a positioning guide Insert the three M8 x 30mm screws at positions 1 3 and 5 and tighten them by hand Tighten screws 1 3 and 5 one turn one after the other going from screw to screw in a clockwise direction until 8 Nm are attained if necessary check this value with a torque wrench This is necessary to pull the rim up flush with the rotor casing in a straight manner not crooked Position two of the original M8 x 25 screws mm at positions 2 and 4 and tighten them by hand max 8 Nm Remove the temporary M8 x 30 mm screw at Position 5 Re position the original M8 x 25 mm screw and tighten by hand max 8 Nm Remove the temporary M8 x 30 mm screw at Position 1 Re position the original M8 x 25 mm screw and tighten by hand max 8 Nm Remove the temporary M8 x 30 mm screw at Position 3 Re position the original M8 x 25 mm screw and tighten by hand max 8 Nm Tighten all screws to 25 Nm 7 2 2 Calibrating GB motors The following sections explain the calibration process with the handheld programming device A Injury hazard The wheelchair
41. y lifting it up on the d side that you want to work on and then placing the wooden block underneath the battery box on that side e Unscrew valve cap e Depressurise tyre by pressing in the pin in the valve 1 e Unscrew 5 screws 2 e Remove the wheel rim halves e Remove the inner tube from the tyre NOTE If the old inner tube is to be repaired and re used and has become wet during repair you can make replacement easier by sprinkling the inner tube with a little talcum powder NOTE Re assembly is done in reverse order Ensure that the tyre is replaced on the same side and in the same travel direction as it was previously mounted 2 e Repair inner tube and replace or insert new e Replace the inner tube in the tyre e Insert the wheel rim halves once again e Insert the screws and tighten slightly e Pump a little air into the inner tube e Tighten the wheel screws to 25 Nm e Ensure that the tyre outer is seated correctly e Pump the wheel up to its prescribed pressure e Check that the tyre is seated correctly once again e Screw the valve cap back on 7 15 Replacing a drive wheel Note CH For information on how to remove a drive wheel on a Typhoon with either standard or GB motors please see the sections on repairing flat tyres 7 16 Replacing the safety belt A Requirements SES e 10mm socket spanner e 4mm Allen key 55 56 Dismantling the safety belt
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