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Service Manual

1. Invecere Electra Service Manual How to get in touch with INVACARE If you have any questions or need help you can reach us using the following addresses and telephone numbers within Europe Invacare Deutschland GmbH Dehmer Str 66 D 32549 Bad Oeynhausen Deutschland Kundendienst 49 Technische Hotline 49 Fax Kundendienst 49 Fax Technische Hotline 49 0 5731 754 580 0 5731 754 570 0 5731 754 216 0 5731 754 208 annan Invacare SA c Areny s n Poligon Industrial de Celra 17460 Celra Girona ESPANA C 34 0 972 49 32 00 Fax 34 0 972 49 32 20 Invacare A S Sdr Ringvej 39 2605 Br ndby Danmark Kundeservice Fax Kundeservice 45 0 3690 0000 45 0 3690 0001 Invacare Ltd South Road Bridgend Mid Glamorgan CF31 3PY United Kingdom Customer Service 44 0 1656 647 372 Fax Customer Service 44 0 1656 649 016 Invacare POIRIER Les Roches F 37230 Fondettes France Service Apr s Vente 33 0 2 47 62 64 15 Fax Service Apr s Vente 33 0 2 47 62 64 64 Invacare AS Grensesvingen 9 0603 Oslo Norge Kundeservice 47 22 57 95 10 Fax Kundeservice 47 2257 9501 Mecc San S R L Invacare PORTUGAL Lda Rua Senhora de Campanha 105 4369 001 Porto PORTUGAL 352 225105946 Fax 352 225105739 Via Dei Pini 35 36016 Thiene VI
2. Chapter 0 page 27 Battery connector plug at controller Chapter Chapter 11 1 page 31 Chapter 10 1 5 page 27 Chapter 10 2 3 page 29 As at 15 04 02 Service Manual Invecere Electra 12 Appendix 12 1 Charging of fully discharged batteries If a voltage of less than 9 5 V is measured at a battery the battery is fully discharged Also observe the information on the charging of batteries contained e inthe vehicle Operating Manual e in the charger Operating Manual e onthe charger CAUTION Risk of accidents Batteries are not allowed to lie on their sides or stand on edge while being charged For charging a fully discharged battery proceed as follows e Remove the batteries from the vehicle e Pre charge each battery individually while simultaneously measuring the charging voltage e Pre charge battery up to 10 V by means of an unregulated charger Then stop charging procedure CAUTION Explosion hazard AN Do not fully charge batteries using an unregulated charger e Put batteries back into the vehicle e Fully charge battery using the Invacare charger via the Scooter charging socket The charging procedure should last for at least 48 hours 12 2 Connecting the programming device 12 2 1 Preparation e Secure the Scooter against rolling away by blocking the front wheel with wedges e Raise the rear of the Scooter until the drive wheels can turn freely and support by blocking up the anti tipper whee
3. ITALIA a 39 0 445 380059 Fax 39 0 445 380034 Invacare B V Celsiusstraat 46 NL 6716 BZ Ede The Netherlands Invacare S A Belgium Autobaan 14 8210 Loppem Brugge BELGIUM Kundeservice 32 50 831010 Fax Kundeservice 32 50 831011 ZF 31 0 318 69 57 57 Fax 31 0 318 69 57 58 Invacare AB Fagerstagatan 9 163 91 Sp nga Sverige Kundtjanst 46 0 8 761 70 90 Fax Kundtj nst 46 0 8 761 81 08 sweden invacare com Service INVACARE JARFALLA T 46 0 8 621 08 44 Fax 46 0 8 621 08 45 Invacare jarfalla swipnet se M LNDAL T 46 0 31 86 36 00 Fax 46 0 31 86 36 06 gborg scanmob swipnet se LANDSKRONA T 46 0 418 285 40 Fax 46 0 418 180 89 invacare la swipnet se OSKARSHAMN T 46 0 491 101 40 Fax 46 0 491 101 80 invacare O hamn swipnet se Page 2 As at 15 04 02 Service Manual Invecere Contents 1 GENERAL INFORMATION 2 TRANSPORT 3 IMPORTANT SYMBOLS USED IN THIS MANUAL 4 SAFETY INFORMATION 4 1 Before working 4 2 During work 4 3 After work 5 TOOL LIST 6 LAYOUT OF COMPONENTS AND DISPLAYS AND CONTROLS 7 MAINTENANCE PLAN 8 TROUBLESHOOTING 8 1 General 8 2 Fault causes 8 3 Fault and diagnosis codes 8 3 1 Status display error codes 9 MAINTENANCE AND REPAIR 9 1 Seat unit 9 1 1 Components Backrest and seat 9 1 2 Components Seat unit 9 1 3 Componen
4. e Please attach a precise description of the fault 3 Important symbols used in this manual CAUTION This symbol warns you of danger AN e Always follow the instructions in order to avoid injuries or damage to the Scooter Note This symbol identifies general information which is intended to simplify working with the Scooter and which refers to special functions Page 6 As at 15 04 02 Service Manual Invecere Electra 4 Safety information 4 1 Before working Note e Mark the current settings on the Scooter seat armrest backrest etc This makes rebuilding the Scooter much easier e Before disassembling electrical components mark the plug connections corresponding to the cables This makes reassembly easier CAUTION Injury hazard AN e Observe carefully all information in the repair and operating manual belonging to the Scooter e Please note the high weight of some components This applies especially to removal of drive units and batteries e The Scooter must be switched off before removal of voltage carrying components To do this remove the battery e When making measurements on voltage carrying components avoid short circuiting the contacts e Use only undamaged tools in good condition 4 2 During work NOTE e All plugs are fitted with mechanical snap in safety devices which prevent release of the connecting plugs during operation The snap lever on these devices must be pressed in before removing th
5. e PLEASE READ THROROUGHLY BEFORE CARRYING OUT REPAIRS e These repair instructions are only valid in connection with the operating manual for the appropriate Scooter e Information about operation or about general maintenance and care work should be taken from the Scooter Operating Manual e Service and maintenance work described in the operating manual will not be further dealt with in the repair instructions e Please observe all safety instructions e You can find information about ordering spare parts in the spare parts catalog e The Scooter 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 e Experience and knowledge of electrical measuring devices Multimeter is also a requirement e Alterations to the Scooter which occur as a result of incorrectly or improperly executed maintenance or overhaul work lead to the exclusion of all liability on the side of INVACARE e We reserve the right to make any alterations on the grounds of technical improvements 2 Transport If the Scooter or Scooter components need to be sent to INVACARE for major repairs please observe the following information e Pack the Scooter or its components so they cannot be damaged during transport If possible use the original packaging which the Scooter or its components were sent in
6. Cause maximum battery current supplier can be exceeded due to motor overload for example running against an immovable obstacle Motor short circuit e Check wiring harness for short circuit e Check motor 5 x blink Motors disengaged e Press disengaging lever in Braking coil defective e Replace drive unit 6 x blink Drive lever is not in neutral position e Ensure that the drive lever is in the central when switching on position turn the operating unit off and on again 7 x blink Speed controller defective e Replace speed controller 8 x blink Motor voltage error e Replace drive unit 9 x blink Internal error e Ascertain error message using programming device and evaluate As at 15 04 02 Page 13 Imacare Electra Service Manual 9 Maintenance and repair 9 1 Seat unit Detail Backrest Detail Seat 9 1 1 Components Backrest and seat Item Qty Description Item Qty Description 3 01 1 Seat S232 black 3 07 1 Bottom backrest tube S232 3 02 1 Seat plate 3 08 3 Knob black 3 03 1 Backrest S232 black 3 09 2 Plug black 3 04 1 Top backrest tube S232 3 10 1 End plug 30 X 30 black 3 05 6 Bolt M6 X 30 3 11 1 Knob M10 X 13 3 06 2 Washer 3 12 4 Washer Page 14 As at 15 04 02 Service Manual Invecere Electra d 3 o K ke 9 1 2 Components Seat unit Item Qty Description Item Qty Description 3 05 2 Bolt M6 X 30 3 20 2 Bolt M6 X 16 3 08 2 Knob black 3 21 2 Washer M6 X 1 3 13 1 Nut M8
7. Chapter Chapter 9 6 5 page 24 Carbon brushes Chapter Chapter 9 6 4 page 24 Chapter 9 6 5 page 24 Invecere Electra 11 3 Checking power supply to operati e Open operating unit see chapter 10 2 3 page 29 e Disconnect the wiring harness connector plugs 8 from the controller in the operating unit e Measure the voltage between the red and black cables in addition to the orange and violet cables in the plug The voltage must amount to a minimum of 19 V Test results Voltage lt 19 V e Battery fully No voltage discharged e Connecting cable defective e Controller defective Service Manual ng unit Connector plug in operating unit gt Check battery gt Replace connecting cable gt Replace controller 11 4 Checking power supply to operating unit e Remove drive unit panelling see chapter 9 3 page 19 e Disconnect the battery cable connecting plug at the controller 1 e Measure the voltage between the red and black cables on the battery feed You must measure all combinations between the red and black cables The voltage must amount to a minimum of 19 V Test results Voltage lt 19 V e Battery fully No voltage discharged e Main fuse defective e Cable defective gt Check battery gt Check replace main fuse gt Check replace cable Page 34 Chapter Chapter 11 1 page 31 Chapter 10 2 3 page 29
8. Voltage under gt Battery fully gt Pre charge battery AY 9 5V discharged See chapter 12 1 A page 35 e Voltage under OV Check fuses gt Ah Batter The fuse is located Check master fuse 50 in the battery cable A of battery and cable bridges Chapter connections replace if 10 1 5 page 27 necessary replace battery if necessary e Different voltage gt batteries defective Replace batteries tolerance 0 2 V at each battery 11 2 Check drive motor 11 2 1 Motor coil continuity Drive unit connector e Remove drive unit panelling see chapter 9 3 page 19 plug e Remove the drive unit connecting plug at the controller 3 e Set the Multimeter to continuity check or resistance measuring e Measure the continuity or resistance Dn 0 Q of the motor circuit between the red and black cable on the motor plug Test results Chapter No continuity in motor e Broken cable in motor Replace drive unit Chapter 9 6 5 page 24 circuit R Q e Carbon brushes worn Check replace l out carbon brushes Chapter 9 6 4 page 24 Page 32 As at 15 04 02 Service Manual Invecere Electra 11 2 2 Magnet brake e Remove drive unit panelling see chapter 9 3 page 19 e Remove the drive unit connecting plug at the controller 3 e Engage motors e Set the Multimeter to resistance measuring e Measure the continuity or resistance Rreg 20 Q of the brake coil motor circuit between the grey and white cabl
9. e Always use a suitable striking tool for inserting the bearing shells 9 5 6 Reassembly sequence for replacing the wheel bearing e Remove the steering wheel Hex bolts size 13 mm nuts size 13 mm e Split the wheel rim Allen key bolt size 4 mm e Remove the wheel bearing with suitable tools e Always use a suitable striking tool for inserting the wheel bearings Note Replacing the steering head bearings Lager fetten Inserting the bearing shells Pal Einschlagwerkzeug benuizen w NV Replacing the wheel bearing e Only tap the wheel bearing into the wheel rim so far that it is flush with the rim edge Page 22 As at 15 04 02 Service Manual 9 6 Drive unit 9 6 1 Components Item Qty Description 5 23 1 Drive unit 5 24 1 Reduction gears 5 25 2 Rubber bumper 526 2 Spacer 5 27 1 Disengaging lever 5 28 1 Knob 9 6 2 Components involved A Chassis chapter 9 4 page 20 B Battery electronics chapter 10 1 page 26 As at 15 04 02 Item 5 29 5 30 5 31 5 32 5 33 N N HRP A Invecere Electra Description Bolt M8 X 55 Nut M8 self locking Washer M8 X 1 6 Bolt M5 Spring washer M5 C Drive wheels chapter 9 7 page 25 Page 23 Invacare Electra 9 6 3 Preparation for reassembly e Remove seat unit see chapter9 1 5 e Remove clamp and seat tube see chapter 9 1 6 e Carefully pull the chassis panelling upwards off the Velcro connectors e Interru
10. in the power supply by carrying out the following steps Schritt 1 Schritt 2 codes chapter 8 3 1 page 13 Schritt 3 8 2 Fault causes Limit fault causes as per table in chapter 8 2 page 12 Ascertain the blink code on the operating unit status display and evaluate using the Error Ascertain the error message using the programming device and evaluate it observe programming device operating manual and chapter 12 2 page 35 Fault Cause Measures Description in Scooter will not start gt drive motors engage motors Operating manual disengaged Operating unit status Operating unit Switch on operating i display has gone out Re switched off unit Operating manual L gt batteries defective Replace batteries Operating manual L completely Chapt 12 1 page discharge battery rhe Charge patery 35 L power supply Check main fuse at interrupted batteries Chapt 10 1 page Check all cable 27 connecting plugs L Controller defective Replace controller Fi 10 1 page Status display flashing Assess error code Chapt 8 3 page 13 Drive motor bucking gt Motor defective Replace motor Chapt 9 6 page 23 Batteries will not Batteries defective Replace battery Operating manual charge L Charging device Replace battery defective charger Page 12 As at 15 04 02 Service Manual Invecere Electra 8 3 Fault and diagnosis codes If there is an electrical fa
11. seams Replacing components chapt 9 1 page 14 1 5 Check backrest height adjustment for correct functioning 16 Check seat and seat frames for damage and tight fit pay special attention to welded seams 1 7 Check seat support tube for damage 18 Check seat unit rotation and unlocking lever for correct functioning 2 0 Steering Replacing components 2 1 Check all steering column components for damage chapt 9 2 page 17 20 Check steering column folding mechanism for correct i functioning Replacing components chapt 9 2 page 17 2 3 Check folding joint teeth for damage 3 0 Chassis 34 Check frames for damage and deformation pay special i attention to welded seams 3 2 Check panelling for damage Replacing components 3 3 Check reflectors for damage chapi 9 3 Page 19 Check steering had bearings for smooth running and zero 3 4 backlash 3 5 Check wheel rims for damage and side play Replacing components 3 6 Check tyres for wear and damage chapt 0 page 21 3 7 Anti tipper D Replacing components LA Z 3 7 1 Check all anti tipper components for damage chapt 9 3 page 19 3 7 2 L Check track rollers for smooth running Page 10 As at 15 04 02 Service Manual Invecere Electra Item Checks OK a Remedy 4 0 Drive unit 4 1 Check functioning and smooth running of motor and gearbox 4 2 Check motor clutch for push mode Replacing compo
12. CTRICS AND ELECTRONICS 26 10 1 Batteries main fuse controller 26 10 1 1 Components 26 10 1 2 Components involved 26 10 1 3 Preparations forreassembly 27 10 1 4 Reassembly information for removing the battery pack 27 10 1 5 Reassembly information for replacing the main fuse 27 10 1 6 Reassembly sequence for replacing the battery 27 10 1 7 Reassembly information for replacing the controller 27 10 2 Operating unit 28 10 2 1 Components 28 10 2 2 Preparations forreassembly 29 10 2 3 Reassembly sequence for replacing steering column wiring harness 29 10 2 4 Reassembly information for replacing the drive regulator potentiometer 30 11 TEST SEQUENCES ELECTRICS ELECTRONICS 31 11 1 Checking the battery voltage 31 11 1 1 Hints for Testing 31 11 1 2 Checking total voltage of the batteries in non operative state and under load 31 11 1 3 Testing the individual voltage of the batteries 31 11 1 3 32 11 2 Check drive motor 32 11 2 1 Motor coil continuity 32 11 2 2 Magnet brake 33 11 2 3 Freewheel switch 33 11 2 4 Carbon brushes 33 11 3 Checking power supply to operating unit 34 114 Checking power supply to operating unit 34 12 APPENDIX 35 Page 4 As at 15 04 02 Service Manual Invecere Electra 12 1 Charging of fully discharged batteries 35 12 2 Connecting the programming device 35 12 2 1 Preparation 35 12 2 2 Connecting the programming device 36 As at 15 04 02 Page 5 Invecere Electra Service Manual 1 General information
13. anual Invecere Electra 4 17 1 gt Battery charge display 4 20 1 Drive lever 448 1 ON OFF pilot light 421 2 Nut M3 self locking 4 33 1 Buzzer 4 22 2 Drive lever rubber 4 34 2 Nut M3 self locking 423 2 Pin 4 35 2 Spacer 6 4 X 4 X 19 47 4 24 1 Restoring spring 4 36 2 Bolt M6 X 30 4 25 1 Plate 4 37 1 Horn switch 4 26 1 Bolt M4 X 20 4 38 1 Keyswitch 4 27 1 Spacer 4 39 1 Steering cover bottom 4 28 1 Potentiometer support 4 40 2 Nut M2 429 2 Bolt M4 X 0 7 X 10 441 2 Spring washer M2 4 30 1 Nut M4 self locking 442 1 Battery charging cable 4 31 1 Potentiometer 5K 443 2 Bolt M6 X 12 4 32 1 Bolt M6 X 5 4 46 1 CHARGING SOCKET sticker 447 1 Spanner set 10 2 2 Preparations for reassembly Battery cable connector e Remove the seat unit see chapter 9 1 5 page 16 plug e Remove clamp and seat tube see chapter 9 1 6 page 16 e Carefully pull the chassis panelling upwards off the Velcro connectors e Interrupt power supply Battery cable 1 10 2 3 Reassembly sequence for replacing steering column wiring Plug at controller harness e Remove steering cover see chapter 9 2 page 17 e Remove all cable binders on the steering column wiring harness e Disconnect all wiring harness connecting plugs at the controller 4 and the power supply 5 As at 15 04 02 Page 29 Invecere Electra Service Manual e Open the operating unit Two Phillips screws 6 7 Open the operating unit e Disconnect the wiring harness conn
14. ce on a suitable support such as wooden block The drive wheels must not be under load CAUTION Danger of crushing AN Secure the raised Scooter against slipping and rolling away e Remove the drive wheel Self locking nut size 13 mm Note e Do not tap the drive wheels off the motor shaft with a hammer causes damage to aluminium wheel rim Use a pulling tool As at 15 04 02 Page 25 Imacare Electra Service Manual 10 Service and repair electrics and electronics 10 1 Batteries main fuse controller Detail Cable clamp position 1 12 Gi o d f ke Pi V T E GA tf dr ml A i f rt ASIA 9 1 09 10 1 1 Components Item Qty Description Item Qty Description 1 07 1 Electronics RHINO DS 72 K01 6 1 1 Battery complete 1 08 3 Bolt M4 X 25 6 01 2 Battery SP 53 1 09 3 Nut M4 self locking 6 02 1 Pocket black 1 10 1 Mains cable 6 03 1 Cable with connector plug 112 1 Cable holder PTS 0910 6 04 1 complete 1 13 Cable holder PTS 1214 Cable with fuse complete 1 14 40 A fuse 10 1 2 Components involved A Chassis chapter 9 4 page 20 B Drive unit chapter 9 6 page 23 Page 26 As at 15 04 02 Service Manual Invecere Electra 10 1 3 Preparations forreassembly e Remove seat unit see chapter9 1 5 e Remove clamp and seat tube see chapter 9 1 6 e Carefully pull the chassis panelling upwards off the Velcro connectors Battery plug 10 1 4 Reassembly information for removing the batter
15. e the installation of the anti tip mechanism is absolutely imperative Page 20 As at 15 04 02 Service Manual Invacare Electra 9 5 Steering fork front wheel 9 5 1 Components Item Qty Description 5 01 1 Front wheel fork 5 02 1 Wheel rim 200 X 50 5H black 5 03 1 Wheel rim 200 X 50 6H black 5 04 4 Bolt M6 X 30 5 05 4 Nut M6 self locking 5 06 1 Axle M8 X 82 5 07 1 Tyre 200 X 50 puncture proof 5 08 2 Bearings 608 ZZ 5 09 1 Spacer bush 11 X 42 X 1 2 5 10 2 Spacer bush 11 X 3 1 X 1 2 5 11 1 Nut M8 self locking 5 12 1 Washer M8 5 13 1 Front wheel cover 514 2 Bolt M6 X 10 5 15 1 Bearing set 8 pc for front wheel 5 16 1 fork 5 17 1 Stopper for steering stop Pin M6 X 25 9 5 2 Components involved A Chassis chapter 9 4 page 20 B Steering column chapter 9 2 page 17 9 5 3 Preparation for reassembly e Raise the Scooter and place on a suitable support such as wooden block The steering wheel must not be subjected to load CAUTION Danger of crushing Secure the raised Scooter against slipping and rolling away As at 15 04 02 Page 21 Invecere Electra Service Manual 9 5 4 Reassembly sequence for replacing steering head bearings steering fork e Remove the steering column chapter 9 2 3 page 18 e Remove the steering fork and replace the steering head bearings Locknut 1 size 32 mm adjusting nut 2 size 32 mm 9 5 5 Reassembly information for replacing steering head bearings
16. e connecting plug e When reassembling the plugs ensure that these safety devices are correctly engaged e Always replace any cable binders removed during dissassembly with new ones CAUTION Injury hazard AN e Prop up the lifted Scooter with appropriate supports before starting the disassembly orassembly e Always use washers of the correct size CAUTION Risk of accidents AN e When reassembling always replace old self locking nuts with new ones As at 15 04 02 Page 7 Invecere Electra Service Manual 4 3 After work NOTE e Always ensure that the Scooter settings are returned to their previous values seat armrest backrest etc CAUTION Risk of accidents AN e Check all fixings for tight fit e Check all parts for correct interlocking e Check all displays and controls for correct working order e ALWAYS carry out a trial run after completing any repair or maintenance work 5 Tool list You will need a standard tool set with at least the following e Open end and ring spanner size 6 7 8 10 11 12 13 17 19 mm e Allen key 2 5 3 4 5 6 8 10 mm e torque wrench commercial e socket spanner set e slot headed screwdrivers various e Phillips screwdriver No 1 2 3 e oblique pliers e flat nosed pliers e pointed pliers e plumber s wrench e cable lug pliers e plastic hammer e wheel bearing puller e Multimeter with probes and various cable clips e drive wheel hub puller available f
17. e on the motor plug Test results R 0Q e Short circuit in gt Replace drive unit k e magnetic brake gt Replace drive unit R gt 200 Q but lt ev Fine short circuit in magnetic brake 11 2 3 Freewheel switch e Remove drive unit panelling see chapter 9 3 page 19 e Remove the drive unit connecting plug at the controller 3 e Disengage motors e Set the Multimeter to resistance measuring e Measure the braking coil resistance Req Q between the grey and white cable in the motor plug The measured value must be infinite Test results Rz co e Short circuit in gt Replace drive unit magnetic brake 11 2 4 Carbon brushes e Remove drive unit panelling see chapter 9 3 page 19 e Remove the drive unit connecting plug at the controller e Remove carbon brushes 2 see chapter 9 6 4 e Measure the length L Original length 18 mm Wear limit 15 mm Check the running surface Only very slight running traces must be noticeable If the running surface shows deep grooves the motor collector is damaged Overhaul of the motor collector can only be carried out by Invacare Test results L lt 15mm e Wear limit exceeded s Replace carbon brushes e Motor collector Running surface damaged shows deep scores gt Replace drive unit As at 15 04 02 Page 33 Drive unit connector plug Chapter Chapter 9 6 5 page 24 Chapter 9 6 5 page 24 Drive unit connector plug
18. ecting plug 8 in the operating unit e Replace the wiring harness 10 2 4 Reassembly information for replacing the drive regulator Replacing the potentiometer potentiometer e Disconnect the potentiometer wiring harness connecting plug 4 31 e Remove the drive lever mechanism from the operating unit e Loosen the Allen screw 4 32 and remove the drive lever 4 20 e Loosen the union nut on the potentiometer and replace the potentiometer e Bring the potentiometer shaft a into its central position by measuring the resistance The shaft is in its central position when the same resistance value approx 2 5 kOhm is shown at the right hand and left hand connecting cable b c e Fit the drive lever 4 20 and fix by tightening the Allen screw 4 32 CAUTION Risk of accidents e Bring the potentiometer into the central position before fixing the drive lever Page 30 As at 15 04 02 Service Manual Invecere Electra 11 Test sequences electrics electronics 11 1 Checking the battery voltage CAUTION AN e Risk of short circuit Take care with tools Do not bridge battery terminals e Only use the gel batteries indicated in the spare parts catalogue as replacement batteries 11 1 1 Hints for Testing e If the total voltage is below 24 V even though the batteries being charged the battery contacts and the guide pins and exterior connection sockets are to be checked for corrosion or damage e f the battery v
19. l You will now be able to check drive commands because the drive wheels can turn freely CAUTION Danger because Scooter can roll away e Secure the Scooter against rolling away by blocking the front wheel with wedges before raising As at 15 04 02 Page 35 Invecere Electra Service Manual 12 2 2 Connecting the programming device Switch off the Scooter Remove the cover cap Remove the chassis panelling see chapter 9 3 page 19 Remove the cover cap 1 next to the remote plug on the controller Plug the hand programming device connector plug into the socket Switch on the Scooter To program the Scooter see the programming device operating manual Note The connector plug also attached to the programming device for the charging socket cannot be used for programming the Scooter Removing the programming device Switch off the Scooter Remove the hand programming device connector plug from the socket Replace the cover cap Complete the Scooter Page 36 As at 15 04 02
20. nents 4 3 Check connection between drive unit and chassis for tight fit chapt 9 6 page 23 44 Check condition and tight fit of all cables and connecting i plugs 4 5 Check wheels for tight fit Replacing components 4 6 Check wheel rims for damage and side play chapt 9 6 page 23 4 7 Check tyres for wear and damage 5 0 Batteries 54 Check condition and tight fit of all cables and connecting plugs 5 2 Check batteries for damage Replacing components chapt 10 1 page 26 5 3 Check battery condition 5 4 Check battery contacts 5 5 Check battery voltage Chapt 11 1 page 31 6 0 Operating unit 6 1 Check operating unit for damage 6 2 Check operating unit pilot lights for correct functioning 6 3 Check drive lever for correct functioning Chapt 10 2 page 28 6 4 Check operating unit displays and controls for correct functioning 6 5 Check drive disabler and lock for correct functioning 7 0 Controller 71 Check condition and tight fit of all cables and connecting Replace defective i plugs cables Replacing defective 7 2 Check controller for damage components see chapt 10 1 page 26 8 0 General 8 1 Retighten all holders and screws 8 2 Trial run with examination of drive parameters acceleration As at 15 04 02 speed in bends braking behaviour Page 11 Invecere Electra 8 Troubleshooting 8 1 General Service Manual You can determine the reason for faults in the Scooter in drive mode on the server motors or
21. oltage falls below 23 V during operation the power supply to the motors will be interrupted and the status display on the operating unit will blink e Exact information on the condition of the batteries can be obtained by means of a capacity test This can only be performed by the manufacturer 11 1 2 Checking total voltage of the batteries in non operative state and under load Check total voltage U of the batteries at the Scooter charging socket between Checking total voltage poles 1 and 2 by means of a Multimeter measuring range 50 V 25 V DC charging socket Check Remedy ED e Voltage below 24V Charge batteries E See chapter 12 1 page 35 EL e Voltage below 19V Battery fully discharged See chapter 12 1 page 35 ra e Voltage is 0 V Check fuses H V The main fuse is located in the battery pack chapter 10 1 5 page 27 e Voltage U falls off rapidly in drive Charge batteries mode See chapter 12 1 page 35 Carry out measurement with blocked drive wheels and with lighting switched on As at 15 04 02 Page 31 Invecere Electra Service Manual 11 1 3 Testing the individual voltage of the batteries Test the individual voltage U on the batteries that have been taken out by means of a Multimeter measuring range 50 V 25 V DC see chapter 10 1 page 26 Test Fault Remedy e Voltage under Battery not gt Charge the battery with Check individual voltage 12V completely charged an Invacare charger K e
22. pt power supply Battery cable 1 9 6 4 Reassembly sequence for replacing carbon brushes e Carry out preparations for reassembly e Loosen the slotted screw 2 and remove the carbon brushes from the guide NOTE e Always replace both carbon brushes Service Manual Battery plug e The carbon brushes may not be tilted when fitting and they must be able to move smoothly within their guides 9 6 5 Reassembly sequence for replacing the drive unit e Carry out preparations for reassembly e Raise the Scooter and place on a suitable support such as wooden block The drive wheels must not be under load CAUTION Danger of crushing AN Secure the raised Scooter against slipping and rolling away e Remove the drive unit connecting plug at the controller 3 e Remove the drive wheels see chapter 9 6 page 23 e Remove the drive unit Allen key bolts size 4 mm nuts size 13 mm Page 24 Drive unit connecting plug As at 15 04 02 Service Manual Invecere Electra 9 7 Drive wheels 9 7 1 Components Item Qty Description Item Qty Description 5 2 1 Rear wheel unit 5 22 4 Nut M8 self locking 5 18 1 Wheel rim B 7 6 1 Nut M8 self locking 5 19 1 Wheel rim rear wheel 7 1 Washer M8 5 20 1 Tyre 200 X 50 puncture proof 5 21 4 Bolt M8 X 15 9 7 2 Components involved A Drive unit chapter 9 6 page 23 9 7 3 Reassembly information for replacing drive wheels Raise the Scooter and pla
23. rom INVACARE Service Page 8 As at 15 04 02 Service Manual Invecere Electra 6 Layout of components and displays and controls The following illustrations show the general arrangement of the Electra Scooter s subassemblies components and control elements Seat element with armrest and backrest Electra Scooter standard Steering column configuration Rear wheel drive with standard seat Chassis with panelling Lever for turning and removing seat Disengaging lever for drive unit Antitipper Footplates Disengager for steering column adjustment O ON Oa FW N Operating unit 10 Battery charge display 11 Power pilot light status display 12 Drive lever 13 Keyswitch 14 Horn button 15 Speed controller 16 Charging socket As at 15 04 02 Page 9 Invecere Electra 7 Maintenance plan Service Manual Carry out an inspection on the Scooter using the maintenance plan You can make this inspection easier by copying the maintenance plan and noting any defects found in the plan Item Checks OK Sc Remedy 1 0 Seat 14 Check armrest for damage and tight fit pay special attention i to welded seams 12 Check folding mechanism for armrests ease of movement no play in joints 1 3 Check armrest width adjustment correct functioning 14 Check backrest and backrest frames for damage and tight fit i pay special attention to welded
24. self locking 3 22 2 Nut M6 with plastic cap 3 14 2 Spring washer M8 3 23 4 Bolt M6 X 30 3 15 2 Washer M8 X 1 5 3 24 2 Plug black 3 16 1 Pin M8 X 110 3 25 1 Armrest tube LH 3 17 1 Armrest tube RH 3 18 2 Armrest tube 3 4 Seat tube complete 3 19 2 Armrest upholstery black As at 15 04 02 Page 15 Invecere Electra Service Manual 9 1 3 Components involved A Panelling chapter 9 3 page 19 9 1 4 Reassembly information Before disassembling the seat unit mark the height of the seat attachment 3 4 the backrest and the armrest width settings 9 1 5 Reassembly information for removing seat unit Removing seat unit top e Pull release lever 1 view e Turn the seat unit by about 14 revolution to the right or left 2 and remove the seat unit upwards out of the seat attachment 9 1 6 Reassembly information for removing seat tube e Loosen the clamp lever and remove seat tube 9 1 7 Reassembly information for replacing seat unit Making the clamp fast e Place the clamp 1 on the seat tube 2 The clamp opening a must be in alignment with the slot in the seat tube b e Push the seat tube 3 into the attachment tube and turn until the guide groove c noticeably locates into the seat tube anti turn device e Tighten clamp 4 Page 16 As at 15 04 02 Service Manual Invecere Electra 9 2 Steering column Detail connection to steering fork 1 04 1 03 is 1 e By d i des D Ze P
25. ts involved 9 1 4 Reassembly information 9 1 5 Reassembly information for removing seat unit 9 1 6 Reassembly information for removing seat tube 9 1 7 Reassembly information for replacing seat unit 9 2 Steering column 9 2 1 Components 9 2 2 Components involved 9 2 3 Reassembly information for removing steering column 9 2 4 Reassembly information for replacing joint 0 3 Panelling 9 3 1 Components 9 3 2 Components involved 9 4 Chassis 9 4 1 Components As at 15 04 02 Page 3 Electra 13 13 14 14 14 15 16 16 16 16 16 17 17 17 18 18 19 19 19 20 20 Invecere Electra Service Manual 9 4 2 Components involved 20 9 4 3 Reassembly information for replacing anti tipper wheels 20 9 5 Steering fork front wheel 21 9 5 1 Components 21 9 5 2 Components involved 21 9 5 3 Preparation forreassembly 21 9 5 4 Reassembly sequence for replacing steering head bearings steering fork 22 9 5 5 Reassembly information for replacing steering head bearings 22 9 5 6 Reassembly sequence for replacing the wheel bearing 22 9 6 Drive unit 23 9 6 1 Components 23 9 6 2 Components involved 23 9 6 3 Preparation forreassembly 24 9 6 4 Reassembly sequence for replacing carbon brushes 24 9 6 5 Reassembly sequence for replacing the drive unit 24 9 7 Drive wheels 25 9 7 1 Components 25 9 7 2 Components involved 25 9 7 3 Reassembly information for replacing drive wheels 25 10 SERVICE AND REPAIR ELE
26. ult this is displayed by the fact that the power pilot Status display light 11 status display in the operating unit blinks This displays an error code which allows an approximate fault diagnosis The diode 11 then flashes in a particular blink sequence The electronics system is able to correct some errors automatically e Switch the Scooter off wait five seconds and then switch it on again The test checks whether the error can be automatically rectified by the electronics and if necessary deactivates the blinking status display at the operating unit If the error cannot be rectified limit the source of error using the Status display error codes table see chapter 8 3 1 page 13 8 3 1 Status display error codes Localise the error using the brink codes as follows e turn the operating unit off and on again e check which blink code is showing by counting e wait for the blink code pause approx 2 3 seconds e re count the code Error code Error Immediate measure 1 x blink Batteries are discharged e Charge battery 2 x blink Battery voltage too low e charge batteries 3 x blink Battery voltage too high babag battery charger from charging socket e Turn the Scooter off and then on again Cause the batteries can be charged during downhill runs and during braking by the motor return current 4 x blink Current delay exceeded e Switch the Scooter off and then on again after a few minutes
27. ver bolt 1 04 4 04 1 05 a Page 18 As at 15 04 02 Service Manual 9 3 Panelling 9 3 1 Components Item Qty Description 1 11 4 Velcro loop strip 50 X 25 1 18 1 Snap buckle 2 01 1 Panelling 2 02 1 INVACARE sticker 9 3 2 Components involved A Seat unit chapter 9 1 page 14 As at 15 04 02 Item 2 03 2 04 2 05 2 06 2 07 Page 19 Invacare Electra Description Reflector Reflector red ELECTRA sticker Velcro strap 50 X 25 Battery wiring circuit sticker Invacere Electra Service Manual 9 4 Chassis Detail antitipper 1 2 1 3 9 4 1 Components Item Qty Description Item Qty Description 1 01 1 Chassis unit complete 1 19 1 Fixing for anti tipper wheel 1 02 1 Fixing for rear panelling 1 20 1 Anti tipper wheel 40 mm 1 15 2 Bolt M6 X 30 1 21 1 Bolt M6 X 36 5 1 16 4 Washer M5 1 22 2 Washer M6 1 17 2 Nut M5 1 23 1 Nut M6 self locking 1 24 1 Bolt M8 X 40 1 2 1 Anti tipper unit LH 1 25 1 Nut M8 self locking 1 3 1 Anti tipper unit RH 1 26 Washer M8 9 4 2 Components involved A Steering fork front wheel chapter 0 page 21 C Battery electronics chapter 10 1 page 26 B Drive unit chapter 9 6 page 23 9 4 3 Reassembly information for replacing anti tipper wheels e Only tighten the fixing bolts 1 on the anti tipper wheel enough to make sure that the anti tipper wheels turn freely CAUTION Risk of accidents e In vehicles with rear wheel driv
28. we d IN e ei A A KL 4 A 1 vi L D 1 F e A AN PA J I f 9 2 1 Components Item Qty Description Item Qty Description 4 01 1 Handlebar 8533 4 13 1 Steering cover top 4 03 1 Handle LH 4 20 1 Drive lever 4 04 1 Handle RH 4 39 1 Steering cover bottom 4 05 1 Basket holder 4 44 2 Washer M4 4 06 2 Bolt M6 X 10 4 45 2 Bolt M4 X 95 4 07 2 Bush 6 x 20 x 1 4 08 1 Spacer 1 03 1 Steering column attachment 4 09 1 Steering cover front 1 04 1 Clamping lever 4 10 4 Bolt M4 X 30 1 05 1 Pressure spring 411 2 Bolt M6 X 35 1 06 1 Nut M10 X 1 5 self locking 412 1 Basket 9 2 2 Components involved A Chassis chapter 9 3 page 19 B Operating unit chapter 10 2 page 28 As at 15 04 02 Page 17 Invecere Electra Service Manual 9 2 3 Reassembly information for removing steering column Connecting plugs e Remove seat unit see chapter9 1 5 e Carefully pull the chassis panelling upwards off the Velcro connectors e Interrupt power supply Battery cable 1 e Disconnect the power supply connecting plug at the operating unit 2 and the connecting plug at the controller 3 e Loosen self locking nut 1 size 13 mm e Remove connecting bolts 2 Allen key size 4 mm e Pull the steering column 3 out of the steering head 9 2 4 Reassembly information for replacing joint Screwing down the e Tum the self locking nut 1 06 size 13 mm just far enough so that it locks Steering column joint off flush with the clamping le
29. y pack e Separate the battery cable connecting plug 1 e Remove the battery pack from the chassis 10 1 5 Reassembly information for replacing the main fuse The fuse holder 2 is inserted in the battery cable bridge It is fitted with a turn lock fastener 10 1 6 Reassembly sequence for replacing the battery Removing the battery e Loosen the battery cable in the following sequence cable 1 Remove the cable bridge negative terminal with main fuse 2 Remove the cable bridge positive terminal with main fuse 3 Loosen the battery cable negative terminal 4 Loosen the battery cable positive terminal CAUTION e Risk of short circuit Take care with tools Do not bridge battery terminals Plug allocation 10 1 7 Reassembly information for replacing the controller e Disconnect all connecting plugs on the controller Plug allocation 1 Power feed battery cable 2 Drive unit 3 Operating unit e Replace controller Phillips screws a nuts size 8 mm As at 15 04 02 Page 27 Invecere Electra Service Manual 10 2 Operating unit 4 22 10 2 1 Components Item Qty Description Item Qty Description 4 02 1 Main wiring harness 4 48 1 INVACARE sticker 4 13 1 Steering cover top 4 49 1 Wiring harness steering PCB top 4 14 1 Sticker 5532 4 50 1 Wiring harness steering PCB 4 15 1 Potentiometer VR 30 K bottom 1 4 16 Potentiometer knob Detail Drive lever Page 28 As at 15 04 02 Service M

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