Invacare® Comet SERVICE MANUAL
Contents
1. The drive lever electronics could be faulty or incorrectly connected Check the cabling for open or short circuited circuitry Potentiometer is not correctly adjusted Put the potentiometer into the centre position 17 18 Blink Fault Consequence Comments code for the Scooter 8 Motor voltage error Stops driving e The motor or its cabling is defective Check the cabling for open or short circuited circuitry 9 Miscellaneous Stops driving e Contact your Invacare dealer internal fault 10 Push freewheel Stops driving e The Scooter has exceeded the mode error permissible maximum speed during pushing or freewheeling Switch the electronics system off and on again 6 1 gt amp Al Repair Work General warning information on installation 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 the drive motor CAUTION If the scooter is supported by the support wheels it will no longer be braked by the motor brake The scooter can roll away out of control e Place the scooter rear frame on a piece of suppor2. Remove motor cover Disconnect both battery plugs 1 From the operating manual Unscrew the rear wheel fixing bolts Remove rear wheels Remove the drive unit See chapter entitled Replacing drive motor Remove screws 1 on electronics module Replace electronics module 2 Reassembly of the drive and the electronics module takes place in reverse order Load drive program onto electronics module See electronics software description Check all functions trial run 55 6 19 Wi 56 Updating software Invacare is continuously carrying out further development and improvements to drive programs for electric vehicles For this reason you should always check whether the drive program version number is up to date when carrying out any repairs or regular maintenance If a newer version is available the drive program must be updated The procedure for updating the drive program is described in the wizard software operating manual NOTE The electronic system is supplied with a standard drive program If you have carried out customer specific modifications to the drive program you will have to make these changes again after installing the new electronics module CAUTION Any modifications made to the drive program can affect the drive behaviour and tipping stability e Changes to the drive program may only be carried out by trained Invacare specialist dealers e Invacare can only provide a g
3. When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence NOTE The drive motor needs to be removed before you can replace the left hand shock absorber If the right hand shock absorber is to be replaced you do not need to remove the drive motor Requirements e Open spanner 10 mm Open spanner 17 mm Phillips screwdriver 2 Allen keys 5m Supporting wooden block e Remove wheel see operating manual e Dismantle wheel cover see chapter Replacing drive motor e Replacing rear shock absorber e Remove top screw 1 on shock absorber 2 e Remove both screws 4 from motor bracket 5 e Remove shock absorber 2 with motor bracket 5 e Remove bottom screw 6 on shock absorber 2 e Replace shock absorber 2 Replacing front shock absorber Remove top screw 1 on shock absorber 2 Remove bottom screw 4 on shock absorber 2 Replace shock absorber 2 Reassembly of the shock absorber takes place in reverse order Use setting screw 3 to set the spring hardness Check function trial run 25 CC ue 26 Replacing front axle CAUTION Accident hazard e Secure the scooter against rolling away NOTE When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in
4. axle can only be replaced on the 3 wheel version The 4 wheel version does not have a replaceable axle Requirements e Open spanner 12 mm Open spanner 13 mm Philips screwdriver Allen key 5 mm Supporting wooden block e Remove the seat e Remove motor cover e Separate battery cable e Place a supporting wooden block under the front part of the frame so that the front wheel is no longer touching the floor e 3 wheel version e Slacken brake cable see chapter entitled Replacing brake cables e Disconnect the brake cable at the wheel 1 e Remove screws 3 on spacer 2 e Remove screws 6 on shock absorber 5 e Loosen axle bolts 4 simultaneously on both sides e Pull front axle slowly out 4 wheel version Slacken both brake cables Disconnect brake cable at affected wheel Loosen wheel bolt Pull wheel and brake off shaft Pull brake out of brake drum Replace brake lining or complete brake Reassemble wheel and brake Push wheel and brake onto shaft or push axle through Apply brake so that brake shoes can align Reassembly of the brake takes place in reverse order Adjust braking force on wheel using brake lever setting screw Check braking function while pushing 33 34 Replacing brake cable CAUTION Accident hazard e Secure the scooter against rolling away NOTE When disassembling note the position of small parts such as screws and
5. be wrongly connected because all plugs have a different size and only fit in one socket Requirements e Phillips screwdriver e Remove the seat e Remove motor cover e Disconnect battery cable 1 e Remove screws 1 below operating console e Remove operating console and fold upwards e Remove screws 3 on drive lever 2 and remove drive lever e Disconnect plug from operating console circuit board e Replace operating console e Reconnect plug with circuit board on new operating console 39 40 Reassembly of the operating console takes place in reverse order Check all functions trial run 6 12 Vd Replacing bend speed reducer CAUTION Accident hazard e Secure the scooter against rolling away NOTE When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence Requirements e Phillips screwdriver e Open spanner 32 mm e Remove the seat e Remove motor cover e Separate battery cable e Remove front and rear steering column cladding steering column and housing See chapter entitled Replacing steering column e Replacing sensors 5 without mounting e Loosen screws e Replace sensor e Replacing sensors 5 with mounting e Loosen fork bolt 1 e Replace sensors 5 with mounting e Replacing regulating unit 4 e Loosen screws e Rem
6. on Stops driving Drive lever is not in neutral when the keyswitch was turned Put the drive lever in neutral turn the power off and then turn on again It may be necessary to recalibrate the drive lever Contact your Invacare dealer Fault in speed potentiometer Stops driving The drive lever electronics could be faulty or incorrectly connected Check the cabling for open or short circuited circuitry Potentiometer is not correctly adjusted Put the potentiometer into the centre position Motor voltage error Miscellaneous internal fault Stops driving Stops driving The motor or its cabling is defective Check the cabling for open or short circuited circuitry Contact your Invacare dealer 10 Push freewheel mode error Stops driving The Scooter has exceeded the permissible maximum speed during pushing or freewheeling Switch the electronics system off and on again Blink code Fault Consequence for the Scooter Comments 1 Battery must be Continues to e The batteries are discharged Charge the charged drive battery as soon as possible Blink code Fault Battery voltage too low Consequence for the Scooter Stops driving Comments The batteries are depleted Charge batteries If you switch the Scooter off for a few minutes the battery can often recuperate to such a stage that a short journey is still possible Speed reduction f
7. panelling Lift the rear panelling upwards Remove screws 1 on brake light Replace brake light Reassembly of the brake light takes place in reverse order Check functions trial run 6 17 Replacing rear lights direction indicators CAUTION Danger of electric shock components Interrupt the power supply by removing the battery plugs before you start work on electric NOTE When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence Requirements e Phillips screwdriver e Remove the seat e Remove motor cover e Disconnect both battery plugs 1 e Remove the bolt 1 on the rear panelling e Lt the rear panelling upwards e Remove screws 1 on rear light 51 52 Remove rear light Remove screws 1 on rear light glass Remove rear light glass 1 Replace lightbulbs 2 Reassembly of the rear light direction indicator takes place in reverse order Check function Vd Replacing the electronics module CAUTION If the scooter is supported by the support wheels it will no longer be braked by the motor brake The scooter can roll away out of control e Place the scooter rear frame on a piece of supporting wood before removing the wheels CAUTION Burn and scald hazard if power cable is short circuited e Interrupt the power supply by removing th
8. the front part of the frame so that the front wheel is no longer touching the floor Replacing steering column Remove drive lever screws 3 Remove drive lever 2 Unscrew the bolts 1 on the drive console Remove drive console Remove screws 1 on rear steering column cladding Remove steering column cladding Loosen screws on front basket holder Remove basket holder Remove spacer bushes 29 30 Remove screws 3 on front steering column cladding Remove the front steering column cladding Loosen the brake cable see Chapter Replacing brakes Unscrew screw at clamp 1 Unscrew fixing bolt for steering column and remove Pull steering column out upwards Replacing fork 3 wheel Remove rubber mat in foot well Loosen screws in chassis below mat Remove chassis upwards Dismantle front wheel see chapter Replace front axle Pull off clamp 1 Loosen fork bolt 2 Loosen knurled screw 3 Replace fork Reassembly takes place in the reverse order Operate brake and hold tighten axle bolts at same time Check functions trial run 31 GP ven W e 32 Replacing brakes CAUTION Accident hazard e Secure the scooter against rolling away NOTE When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence NOTE The front
9. Invacare Comet SERVICE MANUAL These instructions contain information about testing work repair work Edition 11 04 08 43 6232 55 350 V Mobitec Mobilitatshilfen GmbH CT Herzog Odilostrasse 101 Fax 43 6232 55 354 A 5310 Mondsee office mobitec austria com Austria austria invacare com WWW www mobitec austria com e CR Invacare n v a 32 0 50 83 10 10 Autobaan 22 Fax 32 0 50 83 10 11 CL B 8210 Loppem Brugge belgium invacare com Belgium WWW www invacare be CH Mobitec Rehab AG a 41 0 61 48 77 080 _ BenkenstraBe 260 Fax 41 0 61 48 77 08 1 CH 4108 Witterswil office mobitec rehab ch Switzerland switzerland invacare com WWW www mobitec rehab ch D Invacare Aquatec a 0 75 62 7 00 251 7 Alemannenstrake 10 Fax 08 00 6 73 81 72 88316 Isny info invacare aquatec de Deutschland WWW www invacare aquatec de Invacare A S Sdr Ringvej 39 T Kundeservice Fax Kundeservice 45 0 36 90 00 00 45 0 36 90 00 01 DK 2605 Br ndby denmark invacare com Danmark WWW www invacare dk E Invacare SA T 34 0 972 49 32 00 el Areny s n Fax 34 0 972 49 32 20 Poligon Industrial de Celr contactsp invacare com 17460 Celr Girona WWW www invacare es ESPA A E Invacare Poirier SAS a 33 0 247 62 64 66 7 Route de St Roch Fax 33 0 247 42 12 24 F 37230 Fond
10. Replace fuse 1 Reassembly takes place in the reverse order Check function 6 10 Replacing steering linkage steering rod Loi CAUTION Accident hazard e Secure the scooter against rolling away i NOTE When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence A4 Requirements e Open spanner 10 mm Open spanner 12 mm Open spanner 13 mm Phillips screwdriver Circlip pliers Supporting wooden block e Remove the seat e Remove motor cover e Disconnect battery cable 1 e Dismantle the steering column and the chassis see chapter Replacing steering column forks 37 38 e Replacing steering link e Remove circlip 1 on steering link 2 e Replace steering link e Adjust length of steering link using setting screws 3 e Replacing steering rod e Remove circlip 4 on steering rod 5 e Replace steering rod e Adjust tracking by 1 inwards using setting screw 6 See sketch e Reassembly of the steering linkage and or steering rod takes place in reverse order e Check function trial run 6 11 Replacing operating console CAUTION Burn and scald hazard if power cable is short circuited e Interrupt the power supply by removing the battery plugs before you start work on the electronic system NOTE The plugs on the operating console cannot
11. d T Kundtj nst Fax Kundtj nst WWW M LNDAL a Fax LANDSKRONA a Fax OSKARSHAMN a Fax 46 0 8 761 70 90 46 0 8 761 81 08 sweden invacare com finland invacare com www invacare se 46 0 31 86 36 00 46 0 31 86 36 06 ginvacare invacare com 46 0 418 285 40 46 0 418 180 89 linvacare invacare com 46 0 491 101 40 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 SERVICE PLAN 1X ANNUALLY 5 OPERATIONAL FAULTS 5 1 Operational faults 5 1 1 Drive fault diagnosis 5 2 Error Codes and Diagnostic Codes 6 REPAIR WORK 6 1 General warning information on installation work 6 2 Replacing the drive motor 6 3 Replacing wheel suspension 6 4 Replacing shock absorber 6 5 Replacing front axle 6 6 Replacing steering column fork 3 wheel 6 7 Replacing brakes 6 8 Replacing brake cable 6 9 Replacing lifter lifter electronics 11 12 14 14 14 15 19 19 19 22 24 26 28 32 34 35 Page 6 10 6 11 6 12 6 13 6 14 6 15 6 16 6 17 6 18 6 19 Replacing steering linkage steering rod Replacing operat
12. dry and grease free threads Thread M4 M5 M6 M8 M10 M12 M14 M16 Tightening torque 3 NM 6Nm 10Nm 25Nm 49Nm 80 Nm 120 Nm 180 Nm in Nm 10 Caution All other nuts or plastic connectors not noted here must be tightened FINGERTIGHT 11 A 12 Service plan 1x annually Component Component Check Check Remedy Welded seams e Tighten screws fixings and replace parts if upholstery damaged e Check fixings e Tighten screws welded seams and replace parts if battery mounting damaged e Check battery fixing straps Wheel e Check drive wheels e Tighten hub nuts for tight fit replace if necessary Frames chassis battery mounting suspension and wheels e Check steering e Adjust replace wheels for tight fit float and side play Pneumatic Peres Repair or replace See operating if damaged manual Check E and Tighten screws steering linkage Check tracking and steering Brake Test brake function Adjust or replace in pushing mode brake Shock absorber Check shock Adjust or replace absorber shock absorber Drive units e Check functions in e Replace motor if coupling i drive and push necessary mech nism modes e Tighten screws e Check clutch nuts adjust or mechanism replace Check function Replace lightbulbs Lighting Check cable plug or cable connections Batteries Check batteries for e batteries See operating damage Kee Check battery charge batter
13. e battery plugs before you start work on the electronic system CAUTION Any modifications made to the drive program can affect the drive behaviour and tipping stability e Changes to the drive program may only be carried out by trained Invacare specialist dealers e Invacare can only provide a guarantee for safe driving especially tipping stability for unmodified standard drive programs CAUTION Accident hazard e Secure the scooter against rolling away NOTE The electronic system is supplied with a standard drive program If you have carried out customer specific modifications to the drive program you will have to make these changes again after installing the new electronics module NOTE When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence NOTE The plugs on the electronic module cannot be wrongly connected because all plugs have a different size and only fit in one socket Requirements e Open spanner 10 mm Open spanner 17 mm Rubber hammer Phillips screwdriver Supporting wooden block To adapt the drive program programming software or hand programming device and electronics system installation manual available from Invacare 53 54 Secure the scooter against rolling away Place supporting wooden block under the frames at battery holder height Remove the seat
14. ecured 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 10 A WARNING Any alteration to the drive programme can influence vehicle handling and the tipping stability of the electric vehicle Alterations to the drive programme may only be carried out by trained Invacare dealers Invacare supplies all electric vehicles from the factory with a standard drive programme Invacare can only assume 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
15. electronics module on modules for page 53 loose connections or damage Operating e Replace See Replacing console defective operating operating console on console page 39 Operating unit status display blinking Various causes e Assess error code See Error Codes and Diagnostic Codes on page 15 5 2 PROBLEM OTHER POSSIBLE SOLUTION Documentation SYMPTOMS CAUSE Scooter None Drive motor e Replace See Replacing the judders in defective motor s drive motor on page 19 drive mode Drive lever e Replacing the See Replacing the potentiometer potentiometer potentiometer on page defective 43 Batteries None batteries e Replace See operating manual not being defective batteries charged LEDs blinking Charging unit e Replace See charging unit on charging unit defective charging unit operating manual Scooter None Operating e Replace See Replacing runs too console defective operating operating console on slowly console page 39 batteries e Replace See operating manual defective batteries Scooter None Speed reducer fon e Adjust speed does not bend travel not reducer reduce adjusted speed on bends Speed reducer e Replace speed See chapter Replacing defective reducer speed reducer Error Codes and Diagnostic Codes Blink Fault Consequence Comments code for the Scooter 1 Battery must be Continues to e The batteries are discharged Charge t
16. ettes contactfr invacare com France WWW www invacare fr Invacare Ltd South Road Bridgend Industrial Estate Mid Glamorgan CF31 3PY United Kingdom T Customer Service Fax Customer Service WWW 44 0 1656 664 321 44 0 1656 667 532 uk invacare com eire invacare com www invacare co uk Invacare Mecc San s r l Via Dei Pini 62 36016 Thiene VI ITALIA Invacare Ireland Ltd Unit 5 Seatown Business Campus Seatown Rd Swords County Dublin Ireland B Fax WWW B Fax 39 0445 38 00 59 39 0445 38 00 34 italia invacare com www invacare it 353 18 10 70 84 353 18 10 70 85 eire invacare com Invacare AS t i T Kundeservice 47 0 22 57 95 10 CT Grensesvingen 9 Fax Kundeservice 47 0 22 57 95 01 Postboks 6230 norway invacare com N 0603 Oslo WWW www invacare no Norge NLS Invacare B V a 31 0 318 69 57 57 Celsiusstraat 46 Fax 31 0 318 69 57 58 NL 6716 BZ Ede csede invacare com The Netherlands WWW www invacare nl r pa Invacare PORTUGAL Lda a 351 225105946 Rua Senhora de Campanha 105 Fax 351 225105739 P 4369 001 Porto portugal invacare com PORTUGAL WWW www invacare pt Ce terf rs ljare Invacare AB i EIN Fagerstagatan 9 5 163 91 Sp nga Sverige Tillverkare Invacare Deutschland GmbH KleiststraRe 49 D 32457 Porta Westfalica Deutschlan
17. he charged drive battery as soon as possible 2 Battery voltage too Stops driving e The batteries are depleted Charge low batteries e H you switch the Scooter off for a few minutes the battery can often recuperate to such a stage that a short journey is still possible 3 Battery voltage too Stops driving e The battery voltage is too high If the high battery charger is connected disconnect it from the Scooter The electronic system charges the batteries when running downhill and when braking This fault is caused when the battery voltage becomes too high during this process Switch the Scooter off and on again 15 16 Blink code Fault Power time exceeded Consequence for the Scooter Stops driving Comments The maximum current was exceeded over too long a period probably because the motor was overloaded or has been working against an immovable resistance Switch the scooter off wait a few minutes and then switch on again The electronic system has determined a motor short circuit Check the wiring harness for short circuit and check the motor Contact your Invacare dealer Brake failure Stops driving Ensure that the disconnection lever is pressed in There is a defect in the braking coil or in the cabling Check the magnetic brake and cabling for open or short circuited circuitry Contact your Invacare dealer No neutral position when switching Scooter
18. ies See operating voltage manual Check contacts and Clean contacts terminals and terminals Drive Status display Evaluate blinking electronics flashing code Fixing Tighten or replace Cable connecting fixing plug Replace cable Drive lever function connecting plug Power supply Replace drive lever Replace cable connecting plug or console Component Check Check drive electronics program version Newer version available Check cable and connecting plug Check function Drive program Speed reduction in bends Remedy Update software Adjust or replace sensor on relay Notes 13 5 1 1 14 Operational Faults Operational faults Please proceed as follows if you have any problems e First assess the possible cause of the problem using the following table e Check the drive console status display Evaluate the blink error code e Carry out the necessary checks and repairs as recommended in the following table Drive fault diagnosis PROBLEM OTHER SYMPTOMS Scooter will Status display not start on operating console does not illuminate POSSIBLE SOLUTION Documentation CAUSE batteries e Replace See operating manual defective batteries completely e Pre charge discharge battery batteries Power supply to operating console e Check master fuse See operating instructions for main fuse possibly position interrupted e Check cable See Replacing the between
19. ing console Replacing bend speed reducer Replacing the potentiometer Replacing front headlight lamp Replacing the front direction indicators Replacing centre brake light Replacing rear lights direction indicators Replacing the electronics module Updating software 37 39 41 43 46 48 49 51 53 56 1 1 1 2 gt Bs 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 Experience 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
20. ive takes place in reverse order Check all functions trial run 21 22 6 3 ya Replacing wheel suspension CAUTION Accident hazard e Secure the scooter against rolling away NOTE When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence Requirements e Open spanner 32 mm e Phillips screwdriver e Supporting wooden block e Replace wheel suspension e Remove the seat e Remove motor cover e Disconnect battery cable 1 e Dismantle chassis and steering column see chapter Replacing steering column forks e Dismantle steering linkage and steering rod see chapter Replacing steering link steering rod e Loosen wheel suspension screw 1 e Loosen knurled screw 2 os 1 Reassembly takes place in the reverse order Apply brake and hold tighten wheel bolts at same time Adjust tracking see chapter Replacing steering linkage steering rod Check function trial run 23 P 24 Replacing shock absorber CAUTION If the scooter is supported by the support wheels it will no longer be braked by the motor brake The scooter can roll away out of control e Place the scooter rear frame on a piece of supporting wood once you have removed the wheels CAUTION Accident hazard e Secure the scooter against rolling away NOTE
21. kes place in reverse order e Check function 47 6 15 Replacing the front direction indicators Wi Requirements z e Phillips screwdriver e Remove the seat e Remove motor cover e Separate battery cable e 3 wheel version e Remove direction indicator screw 1 e Disconnect direction indicator cable 2 from wiring harness e Replace direction indicator e Reassembly of the direction indicators takes place in reverse order e Check functions e 4 wheel version e Remove direction indicator screw 1 on housing e Disconnect direction indicator cable 2 from wiring harness e Remove screws 3 on indicator glass e Remove indicator glass e Loosen screws 4 on orange coloured cap 5 and remove cap e Replace lightbulb e Reassembly of the direction indicators takes place in reverse order e Check functions 48 6 16 Replacing centre brake light Loi CAUTION Danger of electric shock e Interrupt the power supply by removing the battery plugs before you start work on electric components i NOTE When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence V4 Requirements dei e Phillips screwdriver e Remove the seat e Remove motor cover e Disconnect both battery plugs 1 e Disconnect the plug 4 49 50 Remove the bolt 1 on the rear
22. middle position Loosen the bolts 1 on the drive lever mounting Twist the potentiometer shaft 2 until the same resistance approx 5kOhm is measured between the central connection cable 3 and both outputs 4 Retighten the bolts on the drive lever mounting Check settings and repeat the adjustment if necessary Reassembly of the operating console takes place in reverse order Check all functions trial run 45 6 14 46 Replacing front headlight lamp NOTE You can replace the headlight without removing the chassis If however the working space is too small you can remove the chassis as described in chapter Replacing steering column forks Requirements e Phillips screwdriver e Remove the seat e Remove motor cover e Disconnect battery cable 1 e Remove rear steering column cladding see chapter Replacing steering column forks e 3 wheel version e Remove screw 1 on front headlight under front cladding e Disconnect direction indicator cable 2 at wiring harness behind steering column cladding e 4 wheel version e Remove screws 1 on front headlight under front cladding e Disconnect direction indicator cable 2 at wiring harness behind steering column cladding e Remove headlight e Remove screws 1 on headlight glass e Remove headlight glass e Replace bulb 2 in headlight 2 ee d PAAT ariii E vil E e Reassembly of the headlight ta
23. or driving round bends activated Reduced driving speed Battery voltage too high Stops driving The battery voltage is too high If the battery charger is connected disconnect it from the Scooter The electronic system charges the batteries when running downhill and when braking This fault is caused when the battery voltage becomes too high during this process Switch the Scooter off and on again Power time exceeded Brake failure Stops driving Stops driving The maximum current was exceeded over too long a period probably because the motor was overloaded or has been working against an immovable resistance Switch the scooter off wait a few minutes and then switch on again The electronic system has determined a motor short circuit Check the wiring harness for short circuit and check the motor Contact your Invacare dealer Ensure that the disconnection lever is pressed in There is a defect in the braking coil or in the cabling Check the magnetic brake and cabling for open or short circuited circuitry Contact your Invacare dealer No neutral position when switching Scooter on Stops driving Drive lever is not in neutral when the keyswitch was turned Put the drive lever in neutral turn the power off and then turn on again It may be necessary to recalibrate the drive lever Contact your Invacare dealer Fault in speed potentiometer Stops driving
24. ore 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 e Only ever use tools which are undamaged in good condition e Some moving parts have Teflon bushings These parts must never be lubricated with grease e Never use standard nuts instead of self locking nuts e Always use correctly dimensioned washers or spacers e 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 s
25. ove sensor 5 e Loosen screws 3 e Replace regulating unit 4 41 42 Adjusting Set steering to straight ahead Align sensor straight using regulating unit Take hold of the sensor and tighten the fork screw Check Turn the steering completely to the right and then the left When the steering is turned to its limit the 3 regulating unit switches should be visible Reassembly takes place in the reverse order Check functions trial run 6 13 Replacing the potentiometer CAUTION Burn and scald hazard if power cable is short circuited e Interrupt the power supply by removing the battery plugs before you start work on the electronic system CAUTION Risk of accidents e The new potentiometer must be set to the middle position before inserting Potentiometers which are not in the middle position can result in dangerous driving situations Requirements e Phillips screwdriver e Digital multimeter e Allen key 2m e Remove the seat e Remove motor cover e Disconnect battery cable 1 e Remove screws 1 below operating console e Remove operating console and fold upwards e Remove screws 3 on drive lever 2 and remove drive lever 43 A4 Disconnect potentiometer plug 1 from the operating console Remove screws 1 on potentiometer Replace potentiometer Reconnect potentiometer plug 1 with operating console Setting the potentiometer to the
26. overhaul work lead to the exclusion of all liability on the part of INVACARE e Ifyou 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 an example of which 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 V d 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 components and items which you will need in order to carry out certain work 2 1 Safety and assembly instructions These safety instructions are intended to prevent accidents during work and it is imperative that they are observed Bef
27. the right sequence NOTE The front axle can only be replaced on the 3 wheel version The 4 wheel version does not have a replaceable axle Requirements e Open spanner 17 mm e Open spanner 19 mm e Supporting wooden block e Place a supporting wooden block under the front part of the frame so that the front wheel is no longer touching the floor e Loosen axle bolts 1 simultaneously on both sides e Slacken brake cable see chapter entitled Replacing brake cables e Disconnect the brake cable at the wheel 1 e Remove screws 3 on spacer 2 e Remove screws 6 on shock absorber 5 e Loosen axle bolts 4 simultaneously on both sides e Pull front axle slowly out Reassembly of the axle takes place in reverse order Operate brake and hold tighten axle bolts at same time Check function trial run 27 D ror P oa T Replacing steering column fork 3 wheel CAUTION Accident hazard e Secure the scooter against rolling away NOTE When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence Requirements e Open spanner 10 mm Open spanner 17 mm Open spanner 19 mm Open spanner 32 mm Phillips screwdriver Supporting wooden block e Remove the seat e Remove motor cover e Separate battery cable e Place a supporting wooden block under
28. ting wood before removing the wheels CAUTION Accident hazard e Secure the scooter against rolling away NOTE When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence NOTE The plugs on the electronic module cannot be wrongly connected because all plugs have a different size and only fit in one socket Requirements e Open spanner 10 mm Open spanner 17 mm oblique pliers Rubber hammer Phillips screwdriver Supporting wooden block e Secure the scooter against rolling away e Place supporting wooden block under the frames at battery holder height e Remove the seat e Remove motor cover e Disconnect both battery plugs 1 19 20 From the operating manual Unscrew the rear wheel fixing bolts Remove rear wheels Disconnect plugs 1 2 3 from electronic module Disconnect brake light plug 4 Disconnect motor brake plug 5 Remove the bolt 2 on the wheel cover Remove wheel cover 1 Place a supporting block of wood under the motor link fork Remove screws 1 on shock absorber 2 Remove screws 3 from the drive holder 4 Remove drive holder 4 Remove screws 1 on disengaging lever 2 Remove disengaging lever 2 Lifted drive out of its holder and take it out of the frames to the side Replace drive unit Reassembly of the dr
29. uarantee for safe driving especially tipping stability for unmodified standard drive programs Requirements e Dynamic Wizard software e Operating manual for Wizard software e Further requirements such as a minimum system configuration for the PC used for programming required programming cables etc can be taken from the Wizard software operating manual
30. washers Put small parts down so that they can be reassembled in the right sequence Requirements e Open spanner 10 mm e Phillips screwdriver e Decrease the brake tension on the wheel using the setting screw 1 e Disconnect the brake cable at the wheel 2 e Disconnect brake cable at steering wheel brake lever e Route the brake cable through the cladding e Loosen brake lever screw 3 at wheel e Replace brake cable e Reassembly of the brake cable takes place in reverse order e Check braking function while pushing 6 9 Vd Replacing lifter lifter electronics CAUTION Accident hazard e Secure the scooter against rolling away NOTE When disassembling note the position of small parts such as screws and washers Put small parts down so that they can be reassembled in the right sequence Requirements e Open spanner 14 mm e Phillips screwdriver e Secure the scooter against rolling away e Remove the seat e Remove motor cover e Disconnect both battery plugs 1 e Replacing lifter e Remove batteries e Disconnect lifter cable at wiring harness connecting plug in motor enclosure e Remove screws 1 on lifter 2 e Replace lifter e Replacing lifter electronics e Remove both screws 1 from the lifter electronics 2 e Replace lifter electronics 2 35 36 Replacing fuses in lifter electronics Unscrew lifter electronics cover
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