Invacare® Typhoon SERVICE MANUAL
Contents
1.2. PROBLEM OTHER POSSIBLE SOLUTION REFERENCE SYMPTOMS CAUSE Status display Various causes e Identify the See REM24 Error on remote is error code Codes and Diagnostic flashing Codes on page 18 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 42 display shows defective or U disconnected Wheelchai_ None Batteries may e Replace the See Replacing the r does not be defective batteries batteries on page 32 drive voltage not smoothly stable Drive motor s e Replacethe See Replacing a may be drive motor s conventional drive defective motor on page 20 and Replacing and calibrating a GB drive motor on page 24 Batteries None Batteries may e Replace the See Replacing the cannot be be defective batteries batteries on page 32 charged LEDs on the Charger may e Replace the See User Manual of the charger are be defective charger charger flashing Wheelchai Status display Seat lifter is not e Return seat See User Manual r drives on remote in driving lifter to driving too slowly flashes 2x position either position drive mode too high or too display shows low and has U activated the automatic speed reduction Speed e Adjust the See Adjusting and reduction micro switch replacing the speed micro switch on reduction switch on the seat lifter page 42
3. Page 46 As at 22 03 2004 Service Manual e Push the lower half of the walking beam down so that the tension on the spring 1 is released e Remove the upper end of the spring from the hole in walking beam e Use the Allen key 5mm to remove the bolt 1 that holds the retainer plate that secures the lower end of the spring e The spring can now be replaced Reassembly is done in reverse order As at 22 03 2004 Page 47 Typhoon Service Manual 6 12 Repairing a flat tyre conventional motor AN 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 AN 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 V Requirements e Alen 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 wi Note Pay attention to small pieces and the order in which the components are disassembled Arrange them in an orderly fashion so they
4. Replace motor if necessary Tighten screws nuts adjust or replace if necessary Tighten replace if necessary Replace cable if necessary See Replacing a drive wheel on page 52 See Replacing the steering head bearings on the front or rear castor wheels on page 43 See Repairing a flat tyre conventional motor on page 48 Lighting e Check cabling Y Replace bulbs or cables if i necessary e Check function As at 22 03 2004 Page 13 Typhoon Service Manual ze ome em rs e Batteries e Check batteries for Y Replace batteries if See Replacing the damage necessary batteries on page 32 WE e Check battery charge Y Charge batteries See User Manual WW e Check contacts and Y Clean contacts and See Replacing the terminals for corrosion terminals batteries on page 32 for Safety Information on working with batteries Remote Remote Y Evaluate flash code electronics status display blinking Fixing Tighten replace Replace Cable connecting plug Seef Joystick function y Replace cable connector Power supply plug or console Walking Beam Check spring for damage Y Replace if damaged See Replacing the Anti Dive Spring on page 46 Lifter Check correct function Y Repair if necessary Check function of the Stability Lock Page 14 As at 22 03 2004 Service Manual Typhoon 5 Troubleshooting the Typhoon Troubleshooting the Typhoon with ACS If a problem occurs with the wheelcha
5. 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 the electronics 2 e The motor connector for the left hand drive unit is to be found in the electronics on the far left side of 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 As at 22 03 2004 Page 21 Typhoon Service Manual wi 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 13m
6. wv 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 Page 24 As at 22 03 2004 Service Manual Typhoon 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 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 e Remove the three screws that hold the fender using the 4mm Allen key As at 22 03 2004 Page 25 Typhoon Service Manual 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 i
7. During dismantling reassembly 7 1 3 After completion of work before operating the wheelchair 8 2 TOOL LIST 9 2 1 Tightening torques and Loctite 10 3 LAYOUT OF COMPONENTS AND MODULES 11 4 SERVICE PLAN 1X ANNUALLY 13 5 TROUBLESHOOTING THE TYPHOON 15 5 1 Troubleshooting the Typhoon with ACS 15 5 1 1 Diagnosing driving faults 15 5 1 2 Diagnosing problems with electric actuators 17 5 1 3 REM24 Error Codes and Diagnostic Codes 18 6 REPAIR WORK 20 6 1 Replacing a conventional drive motor 20 6 2 Replacing and calibrating a GB drive motor 24 6 2 1 Replacing the motor 24 6 2 2 Calibrating GB motors 28 6 3 Replacing components of the electronics 30 6 4 Replacing the batteries 32 6 5 Replacing the main fuse 37 6 6 Checking the cables 39 6 7 Replacing the remote 40 6 8 Testing an actuator motor 41 6 9 Adjusting and replacing the speed reduction switch 42 6 10 Replacing the steering head bearings on the front or rear castor wheels 43 6 10 1 Front Castor Wheels 43 6 10 2 Rear Castor Wheels 44 As at 22 03 2004 Page 5 Typhoon Service Manual 6 11 Replacing the Anti Dive Spring 46 6 12 Repairing a flat tyre conventional motor 48 6 13 Repairing a flat tyre GB motor 50 6 14 Replacing a drive wheel 52 Page 6 As at 22 03 2004 Service Manual Typhoon 1 Safety and assembly instructions These safety instructions are intended to prevent accidents during work and it is imperative that they are observed 1 1 Before any inspection or repair
8. Service Manual Typhoon Flash code Meaning Solution Notes 5 x flashes Fault brake fault on right e Check connecting See Checking hand motor Connection plugs the cables on loose defective or motor page 39 defective a See Replacing a conventional drive motor on page 20 and Replacing and calibrating a GB drive motor on page 24 6 x flashes Fault brake fault on left e Check connecting See Checking hand motor Connection plugs the cables on loose defective or motor page 39 defective k See Replacing a conventional drive motor on page 20 and Replacing and calibrating a GB drive motor on page 24 7 x flashes Completely discharge e Pre charge battery See User Manual battery 8 x flashes Battery voltage too high e Switch lights on to See User Manual lower battery voltage e Check battery charger of battery charger 9 or 10 x flashes Faulty data transmission between modules Remove all electronic modules except the Power 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 30 11 x flashes Motors overloaded e Switch remote on overheated and off wait if necessary 12 x flashes Module used has e Remove incorrect See Replacing compatibility problems module components of the electronics on page 30 As at 22 03 2004 Page 19 Typhoon Service Man
9. They are thus easier to install wi 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 e Assemble in accordance with this installation sequence e Push the batteries 3 together with the Any carrying belt 5 and battery inserter 4 into 3 the chassis e 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 e Insert the connectors on the light circuit 4 board in the correct order Apply the front panelling 1 and secure using lateral Allen screws wi 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 As at 22 03 2004 Page 35 Typhoon Service Manual e Screw the battery cable onto the plus and minus pole Slide the pole caps over the poles e Plug all cables into the electronic components e Check that all connectors are fitted firmly e Check the cable routing No cable should be able to protrude into the lifter area AN CAUTION Danger of crushing e Please ensure that the regulating motor slides into the upper guiding device e Move the regulating motor to the uppermost position and ensure that it slides into the upper guiding device 1 e Raise the lifter slightl
10. can easily be assembled again in the right order e Prop up the wheelchair by lifting it up on the CH side that you want to work on and then K amp 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 Page 48 As at 22 03 2004 Service Manual Typhoon e Unscrew valve cap e Depressurise tyre by pressing in the pin in the valve 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 wv 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 wv 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 alittle air into the inner tube e Insert the cylinder head screws in the rim and tighten the wheel rims firmly 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 Heft the wheel As at 22 03 2004 Page 49 Typhoon Service Manu
11. 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 AN 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 AN 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 AN 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 Page 34 As at 22 03 2004 Service Manual Typhoon e Pull the battieres out to the front using the carrying belt e Remove the battery inserter and carrying belt from the battery AN 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 e Installation is carried out in the reverse order wi Please note The battery inserters can be inserted between the battery and the carrying belt
12. just on one side VI Requirements iiaii 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 VES View or edit GB Power Module NEXT YES GB Controller NEXT Torque XX EXIT NEXT DOWN UP Page 28 As at 22 03 2004 Service Manual Typhoon The programming device You should enter this shows the following GB Controller NEXT Tremor Damping XX d i 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 GB MOTOR CALIBRATION YES if drive wheels have been raised Wheels will move Drive wheels raised EXIT YES GB MOTOR CALIBRATION YES if drive wheels have been raised Chair will drive Are wheels raised EXIT YES GB MOTOR CALIBRATION BEGI
13. re adjust all parameters preferably save the current drive programme before replacing the remote e Switch off the remote F 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 e Installation of the remote is carried out in reverse order e Adapt the drive programme using the hand programming device or Wizard software or transcribe the copy onto the new remote e Check all vehicle functions Page 40 As at 22 03 2004 Service Manual Typhoon 6 8 Testing an actuator motor Wi Requirements We 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 the motor needs to be replaced As at 22 03 2004 Page 41 Typhoon Service Manual 6 9 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 V 4 Pre requisites e Small pliers e Move the lifter to the upper and lower position several times In doing so check whether the contact switches e Ifthe contact does not switch bend the plate 1 slightly e If the contact is faulty replace the entire cable harness
14. 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 A Caution e Please note the heavy weight of some components This applies especially to removal of drive units and batteries e The wheelchair must be switched off before removal of voltage carrying components To do this disconnect the batteries or remove them e When making measurements on voltage carrying components avoid short circuiting the contacts Danger of fire and combustion e Use only undamaged tools in good condition 1 2 During dismantling reassembly e Mark all current settings for the wheelchair seat armrests backrest etc and the cable connecting plugs associated before any removals This makes reassembly easier AN Caution e Prop up the lifted wheelchair with appropriate supports before starting the disassembly or assembly e Never use standard nuts instead of self locking nuts e Always use correctly dimensioned washers or spacers aw Note e All plugs are fitted with mechanical safety devices which prevent release of the connecting plugs during operation e To release the connecting plugs the safety devices must be pressed in e When reassembling ensure that these safety devices are correctly engaged e Cable binders which have been cut off during disassembly should be replaced by new ones during reass
15. 31011 B 31 0 318 69 57 57 Fax 31 0 318 69 57 58 Invacare AB Fagerstagatan 9 163 91 Spanga Sverige Kundtjanst 46 0 8 761 70 90 Fax Kundtjanst 46 0 8 761 81 08 sweden invacare com Service Invacare JARFALLA K 46 0 8 621 08 44 Fax 46 0 8 621 08 45 Invacare jarfalla swipnet se MOLNDAL K 46 0 31 86 36 00 Fax 46 0 31 86 36 06 invacare goteborg swipnet se LANDSKRONA T 46 0 418 285 40 Fax 46 0 418 180 89 invacare la swipnet se OSKARSHAMN EI 46 0 491 101 40 Fax 46 0 491 101 80 invacare O hamn swipnet se Page 2 As at 22 03 2004 Typhoon Service Manual Notes on transport e If the wheelchair 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 The following symbols are used in these repair instructions Note wv This symbol identifies general information which indicate special points or simplifications in dismantling reassembly CAUTION it is imperative that you observe any gt safety instructions lt identified with this symbol Y This symbol identifies required tools and materials bai Page 4 As at 22 03 2004 Service Manual Typhoon Contents 1 SAFETY AND ASSEMBLY INSTRUCTIONS 7 1 1 Before any inspection or repair work 7 1 2
16. Invacare Typhoon SERVICE MANUAL CE These instructions contain information about Troubleshooting Repair Edition 01 2002 Service Manual Typhoon General information These repair instructions contain all the information necessary for maintenance and overhaul of the wheelchair 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 wheelchair 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 wheelchair 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 wheelchair 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 lf you have any problems or questions p
17. N if drive wheels have been raised BEGIN to start Wheels will drive EXIT BEGIN GB MOTOR CALIBRATION No entry required Wait till end of calibration in progress Please wait GB MOTOR CALIBRATION EXIT Successful EXIT e Separate the programming device from the wheelchair Calibration is complete As at 22 03 2004 Page 29 Typhoon Service Manual 6 3 Replacing components of the electronics Find out here how to replace the Typhoon electronic components i Pre requisites ER 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 n order to remove the power module loosen both nuts 1 using an 8mm open jawed or ring wrench Page 30 As at 22 03 2004 Service Manual Typhoon e 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 e The drive unit is installed in reverse order e To allow the electronic carrier to lock into place correctly increase the distance between the chassis and the battery using a large crosstip screwdriver As at 22 03 2004 Page 31 Typhoon Service Manual 6 4 Replacing the batteries Find out here how to replace t
18. Please note It is easier to carry out a few work steps with the assistance 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 just a little more 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 Page 32 As at 22 03 2004 Service Manual Typhoon AN 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 As at 22 03 2004 Page 33 Typhoon Service Manual
19. a new strip fuse 2 and secure using both nuts 1 Close the cover on the fuse holder e Lock the fuse holder into place in the electronics holder until you hear a click e Close the electronic panelling e Check all vehicle functions Page 38 As at 22 03 2004 Service Manual Typhoon 6 6 Checking the cables Find out here how you can check the plug connections on the Typhoon electronics Wi Pre requisites ae 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 As at 22 03 2004 Page 39 Typhoon Service Manual 6 7 Replacing the remote y Pre requisites a e Crosstip screwdriver e Wizard software or hand programming device wi Please note All remotes are supplied with a standard drive programme This does not enable lighting and regulating motors to function If you do not wish to
20. al 6 13 Repairing a flat tyre GB motor AN 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 y 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 AN 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 Y Requirements es e Alen key 6 mm Torque wrench Repair kit for tyre repair or a new inner tube Talcum powder Screw blocker Loctite e g Loctite 243 wi 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 wheelc
21. e Check all vehicle functions Page 42 As at 22 03 2004 Service Manual Typhoon 6 10 Replacing the steering head bearings on the front or rear castor wheels AN 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 Yi Requirements We e Small flat bladed screwdriver e Alen key 3mm e Socket wrench 19mm e Torque wrench 6 10 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 As at 22 03 2004 Page 43 Typhoon Service Manual 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 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 PS The pictures show the wide rim on the outside of the bearing race L A and the narrow rim on the inside B The bearings must always be assembl
22. ed 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 6 10 2 Rear Castor Wheels e Use the Allen key 3mm remove the screws that hold the clear plastic cap of the rear light Page 44 As at 22 03 2004 Service Manual Typhoon 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 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 Q 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 pres
23. embly As at 22 03 2004 Page 7 Typhoon Service Manual 1 3 After completion of work before operating the wheelchair A Caution e Check all fixings for tight fit e Check all parts for correct interlocking e Only operate wheelchair with correct tyre pressure 2 5 bar e Check electrical components for correct functioning incorrect polarity of cables can result in damage to the electronics As a last check always carry out a test drive Page 8 As at 22 03 2004 Service Manual Typhoon 2 Tool list You will need a standard tool set with at least the following e set of open and ring spanners 6 24 mm e set of Allen keys 1 5 10 mm e torque wrench commercial e socket spanner set e set of screwdrivers 0 5 1 6 mm e oblique pliers e flat nosed pliers e circlip pliers e pointed pliers e cable lug pliers e wooden or plastic hammer e tyre repair kit commercial e tyre pressure indicator e valve removal tool e wheel bearing puller e multimeter with probes and various cable clips e soldering iron 30 W e front wheel hub puller available from INVACARE Service e Circlip pliers for star lock caps commercially available make Tigtemeyer e pop riveting tool e stepped mandrel As at 22 03 2004 Page 9 Typhoon Service Manual 2 1 Tightening torques and Loctite The tightening torques stated in the following table are dependent on the thread diameters for the nuts and bolts for which no
24. hair by lifting it up on the Wb side that you want to work on and then K TI placing the wooden block underneath the battery box on that side Page 50 As at 22 03 2004 Service Manual Typhoon 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 lt NOTE wv 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 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 alittle 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 As at 22 03 2004 Page 51 Typhoon Service Manual 6 14 Replacing a drive wheel Note vi 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 Page 52 As at 22 03 2004
25. he Typhoon batteries AN CAUTION Risk 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 Ifacid 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 AN 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 AN 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 AN 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 Y Pre requisites FS e 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 wi
26. ir 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 v 5 1 1 Diagnosing driving faults PROBLEM OTHER POSSIBLE SOLUTION REFERENCE SYMPTOMS CAUSE Wheelchai Status display Drive motors e Engagethe See User Manual r will not on remote may be drive motors drive lights up disengaged As at 22 03 2004 normally and does not show an error code Status display Batteries may e Replace the See Replacing the on remote be defective batteries batteries on page 32 does not light up Batteries may e Charge the See User Manual be completely batteries discharged Power supply e Check the See Replacing the main to the remote main fuse fuse on page 37 may be interrupted e Check cables See Checking the between cables on page 39 modules for loose connections or damage Remote may e Exchange See Replacing the be defective the remote on the wheelchair for a different one to eliminate the possibility that the remote may be the cause remote on page 40 Page 15 Typhoon Service Manual
27. itch As at 22 03 2004 Page 11 Typhoon Service Manual The following image shows the Typhoon from the front right with the lifter raised 1 Lifter actuator Page 12 As at 22 03 2004 Service Manual Typhoon 4 Service plan 1x annually compen own e meV Y Tighten screws replace padding if damaged Armrest damage and fastening Armrests and SZ side panels e Side panel damage and fixing Tighten screws replace side panels if damaged Cushion Replace covers upholstery if damaged Seat unit seat angle e Check seat angle adjustment adjustment Replace parts if damaged Damage and seams Replace parts if damaged Backrest unit s mechanical Fixings Tighten screws Check cabling Replace cable or motor if necessary Backrest unit electrical e Check function Check fixings welded seams and battery box Tighten screws replace components Frame chassis battery box Wheel suspension and wheels Drive units disengager Electrical footrests Check drive wheels for tight fit and side play Check steering wheels for tight fit float and side play Check pneumatic tyres on the drive wheels Check functions in drive and push modes Check disengager Check welded seams interlocking screws footplates Check cabling Check contacts Check functions Adjust replace wheel hubs Replace wheels wheel fork or wheel bearings Repair or replace if damaged
28. lease contact INVACARE SERVICE Invacare Deutschland GmbH KleiststraBe 49 32457 Porta Westfalica Deutschland Technische Hotline 01 80 5 26 22 64 Fax Technische Hotline 01 80 5 26 2275 Invacare SA c Areny s n Poligon Industrial de Celra 17460 Celra Girona ESPANA T 34 0 972 49 32 00 Fax 34 0 972 49 32 20 Invacare A S Sdr Ringvej 39 2605 Br ndby Danmark Kundeservice 45 0 3690 0000 Fax Kundeservice 45 0 3690 0001 As at 22 03 2004 Invacare POIRIER Les Roches F 37230 Fondettes France Service Apr s Vente 33 0 2 47 62 64 66 Fax Service Apr s Vente 33 0 2 47 42 12 24 Typhoon Service Manual Invacare Ltd South Road Bridgend Mid Glamorgan CF31 3PY United Kingdom Customer Service 44 0 1656 647 327 Fax Customer Service 44 0 1656 649 016 Invacare AS Grensesvingen 9 0603 Oslo Norge Kundeservice 47 22 57 95 10 Fax Kundeservice 47 22 57 95 01 Invacare Mecc San s r l Invacare PORTUGAL Lda Rua Senhora de Campanha 105 4369 001 Porto PORTUGAL T 351 225105946 Fax 351 225105739 Via Dei Pini 62 36016 Thiene VI ITALIA T 39 0 445 380059 Fax 39 0 445 380034 Invacare B V Celsiusstraat 46 NL 6716 BZ Ede The Netherlands Invacare n v Autobaan 14 8210 Loppem Brugge BELGIUM T 32 50 831010 Fax 32 50 8
29. m open jawed or ring wrench AN 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 AN CAUTION Risk of accident e Use anew self securing wheel nut and tighten it applying 60 Nm Page 22 As at 22 03 2004 Service Manual Typhoon vi Please note Only tighten the suspension nut using the noted number of turns This sets the wheel camber Incorrect wheel camber leads to one sided wheel wear and can reduce driving power e The drive unit is installed in the reverse order As at 22 03 2004 Page 23 Typhoon Service Manual 6 2 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 6 2 1 Replacing the motor AN 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 Gs 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 remo
30. may be badly adjusted None Remote may e Replace the See Replacing the be defective remote remote on page 40 Batteries may e Replace the See Replacing the be defective batteries batteries on page 32 Page 16 As at 22 03 2004 Service Manual Typhoon 5 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 POSSIBLE SOLUTION REFERENCE Electric Actuator does not function SYMPTOMS CAUSE Remote CLAM is e Replace the See Replacing displays a defective CLAM components of the flashing E electronics on page 30 status diode on the CLAM does not go out even if the remote is switched off or disconnected None Cable may e Check that See Checking the cables be the cable is on page 39 disconnected 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 41 be defective Remote may e Exchange See Replacing the be defective the remote on the wheelchair for a different one to eliminate the possibility that the remote may be the cause remote on page 40 As at 22 03 2004 Page 17 Typhoon Service Manual 5 1 3 REM24 Error Codes and Diagnostic Codes The drive electronics are capable of rectifying some errors automatically In thi
31. s 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 1 x flash Module defective Replace defective See Replacing module components of the electronics on page 30 2 x flashes Accessory error e g e Check accessory See Testing an actuator short circuit connections check actuator motor on accessories page 41 Lifter raised or lowered e If lifter is raised See User Manual too far seat not at driving lower in stages until height the status display stops flashing If lowered 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 Fault in right hand motor e Check connecting See Checking Connection plugs the ara on loose defective or motor e Check motor page defective See Replacing a conventional drive motor on page 20 and Replacing and calibrating a GB drive motor on page 24 4 x flashes Fault in left hand motor e Check connecting See Checking Connection plugs the cables on P or motor E Ba eit page 39 See Replacing a conventional drive motor on page 20 and Replacing and calibrating a GB drive motor on page 24 Page 18 As at 22 03 2004
32. special values are determined All values apply to dry and grease free threads Thread diameter Unit M5 M6 M8 M10 M12 M16 Torque Nm 3 4 4 9 5 9 7 8 14 19 25 34 44 61 115 155 mkp 0 35 0 80 0 60 0 80 1 4 1 9 2 6 3 5 4 5 6 2 11 5 16 Spanner width mm 8 10 13 17 19 24 For comparison Lever arm on ring mm 180 190 215 240 265 285 spanner DIN 838 Therefore achievable Nm 56 63 70 84 101 125 torque Caution All other nuts or plastic connectors not noted here must be tightened FINGERTIGHT Caution Tighten the front wheel on the castor fork fingertight and without play Apply micro encapsulated adhesive to the thread INVACARE uses VIBRATITE VC3 for this purpose Caution When reassembling the front wheel fork in the head tube ensure that the fork is free moving The union should be tightened fingertight and should not result in stiff movement of the head tube bearing Page 10 As at 22 03 2004 Service Manual Typhoon 3 Layout of components and modules The following image shows the Typhoon from above rear with the seat lifter raised and the rear cowling removed 1 Seat tilt actuator 2 Seat frame rear cowling anti collision switch Speed reduction switch Power module CLAM Combined Light and Actuator Module 1 Cable loom connectors 2 Seat lifter and tilt actuator end position switch Speed reduction switch Seat frame rear cowling anti collision sw
33. sure 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 As at 22 03 2004 Page 45 Typhoon Service Manual 6 11 Replacing the Anti Dive Spring AN 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 W e 5mm Allen key e Circlip pliers or a small flat bladed screwdriver if you don t have these special pliers wi 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 snap ring from the inside 1 e You will need to use the circlip pliers or alternatively the small screwdriver to open and remove the snap ring that secures the pin
34. t 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 or two revolutions then it can be removed the rest of the way using the 5mm Allen key Page 26 As at 22 03 2004 S e rvice Manual Typhoon e The illustration at the right shows how to position the Zem chisel 1 on the head of the screw 2 to get it started turning 4 e Use the small screwdriver to carefully remove the clip that holds the emergency declutching latch 2 in place e Remove the bolts that hold the motor on the mounting plate using the combination wrench 13mm e The drive unit is re assembled in the reverse order e 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 e Tighten the wheel screws to 25 Nm As at 22 03 2004 Page 27 Typhoon Service Manual 6 2 2 Calibrating GB motors The following sections explain the calibration process with the handheld programming device AN Injury hazard The wheelchair 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
35. ual 6 Repair Work 6 1 Replacing a conventional drive motor Find out here how to replace the conventional Typhoon drive units AN 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 Wi Pre requisites SS e Small screwdriver 17 and 19mm 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 wi 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 Use a19mm ring wrench to loosen the wheel nut 1 e Pull the complete wheel from the wheel hub AN 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 wi 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 Page 20 As at 22 03 2004 Service Manual e Cut off the end cap on the Bowden cable
36. ving 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 replacing them gt AN 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 wi 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 Requirements e 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 Note
37. y and unlock the retaining mechanism 1 The entire lifter load is now on the regulating motor again H er ait 1 ee e Test all vehicle functions e Check the charge status of the new batteries and charge fully if necessary Page 36 As at 22 03 2004 Service Manual Typhoon 6 5 Replacing the main fuse Find out here how to check and replace the main Typhoon fuse AN 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 Wi Pre requisites IN e 8mmring or open jawed wrench e Replacement fuse e Small flat screwdriver wi 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 8 lightly using a small flat screwdriver As at 22 03 2004 Page 37 Typhoon Service Manual e Open the cover on the fuse holder e Ifthe strip fuse 2 has burnt out look for the cause and remedy The main fuse may only be replaced when the fault has been remedied e Use an 8mm open jawed or ring wrench to unscrew the nuts 1 on the strip fuse 2 e Insert
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