Invacare® Lynx SERVICE MANUAL
Contents
1. D p lt Replacing front axle 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 Open spanner 9 mm Open spanner 10 mm Open spanner 12 mm Open spanner 13 mm From the operating manual Remove the seat Remove batteries Remove the drive unit Remove front wheels Further work Fold the steering column inwards and place the chassis on its side 25 26 Loosen the steering link nuts 1 and remove them note information below Remove steering link from deflector Loosen the axle suspension nut 2 and remove it In doing so secure the axle suspension bolts 3 against turning using an open ended spanner Pull the bolts 3 out and remove the axle casing When loosening the nuts 1 secure the steering link head against turning using an open ended spanner Reassembly of the axle takes place in reverse order Complete reassembly of vehicle2. T Kundtj nst Fax Kundtj nst WWW M LNDAL a Fax LANDSKRONA Fax OSKARSHAMN 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 4 General information 1 2 Notes on transport 1 3 Important symbols in this manual 2 SAFETY AND ASSEMBLY INSTRUCTIONS 24 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 the electronics 6 4 Updating the driving program 6 5 Replacing the potentiometer 6 6 Replacing operating console 6 7 Replacing front axle 10 11 12 12 12 13 15 15 15 18 20 21 23 25 Page 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
3. B 2 from the Socket strip Fold the drive forwards onto the locking mechanics Remove wheels 1 e Loosen motor fixing bolts 1 on both sides and remove e Remove the motor from the vehicle frame e Check rubber bearings 1 on both sides of the motor suspension Replace damaged rubber bearings e Reassembly of the motor takes place in reverse order e Complete reassembly of vehicle e Check all functions trial run 17 p 18 Replacing the electronics CAUTION Burn and scald hazard if power cable is short circuited e Interrupt the power supply by removing the batteries before you start work on the electronic system 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 guarantee for safe driving especially tipping stability for unmodified standard drive programs Requirements e Phillips screwdriver To adapt the drive program programming software or hand programming device and ACS electronics system installation manual available from Invacare
4. France WWW www invacare fr Invacare Ltd Pencoed Technology Park Pencoed Bridgend CF35 5HZ United Kingdom T Customer Service Fax Customer Service 9 WWW 44 0 1656 776 200 44 0 1656 776 201 uk invacare com eire invacare com www invacare co uk w Invacare Mecc San s r l Via Dei Pini 62 I 36016 Thiene VI ITALIA Invacare Ireland Ltd Unit 5 Seatown Business Campus Seatown Rd Swords County Dublin Ireland B Fax WWW B Fax WWW 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 www invacare ie Invacare AS f h Kundeservice 47 0 22 57 95 00 Grensesvingen 9 Fax Kundeservice 47 0 22 57 95 01 Postboks 6230 norway invacare com Etterstad WWW www invacare no N 0603 Oslo Norge NL Invacare B V a 31 0 318 69 57 57 Celsiusstraat 46 Fax 31 0 318 69 57 58 NL 6716 BZ Ede nederland invacare com Nederland WWW www invacare nl n m Invacare Portugal Lda a 351 225 1059 46 Rua Estrada Velha 949 a 351 225 1059 47 P 4465 784 Lega do Balio Fax 351 225 1057 39 Portugal portugal invacare com WWW www invacare pt Ce terf rs ljare nvacare AB C FIN Fagerstagatan 9 8 16391 Sp nga Sverige Tillverkare Invacare Deutschland GmbH KleiststraRe 49 D 32457 Porta Westfalica Deutschland
5. Remove screws 1 below operating console Pull the operating console upwards out of the front fixing 1 21 22 Remove drive lever 1 Separate the potentiometer connecting plug 2 Remove potentiometer 3 Set the potentiometer to the middle position see below Reassembly takes place in the reverse order Complete reassembly of vehicle Check all operating console displays Setting the potentiometer to the 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 6 6 Replacing operating console A CAUTION Burn and scald hazard if power cable is short circuited e Interrupt the power supply by removing the batteries before you start work on the electronic system AUT Requirements di e Phillips screwdriver e From the operating manual e Remove the seat e Remove the battery pack e Further work e Remove screws 1 below operating console e Pull the operating console upwards out of the front fixing 23 24 Remove plugs 3 from operating console Replace operating console Reassembly takes place in the reverse order Complete reassembly of vehicle Check all operating console displays
6. This symbol warns you of an explosion hazard which for example can be caused by excessive tyre pressure in a pneumatic tyre e Always follow the instructions to avoid injury to the user or damage to the product BURN HAZARD This symbol warns you of burns due for example to leaking battery acid e Always follow the instructions to avoid injury to the user or damage to the product NOTE This symbol identifies general information which is intended to simplify working with your product and which refers to special functions Requirements e This symbol identifies a list of various tools components and items which you will need in order to carry out certain work READ WELL BEFORE OPERATION This symbol advises you to read information carefully 2 1 Safety and assembly instructions These safety instructions are intended to prevent accidents during work and it is imperative that they are observed Before any inspection or repair work e Read and observe this repair manual and the associated operating manual e Observe the minimum requirements for carrying out the work see chapter entitled General information General safety information and notes on assembly disassembly Danger of injury by crushing e Please note the heavy weight of some components This applies especially to removal of drive units and batteries e Prop up the lifted electric vehicle with appropriate supports before sta
7. Consequence for the Scooter Stops driving Comments The Scooter has used up too much power for a long period probably because the motor has been overloaded or the Scooter has attempted to work against insurmountable resistance Switch off the Scooter wait a few minutes and then switch it on again The electronic system has determined a motor short circuit Check the wiring harness for short circuits and check the motor Brake failure Stops driving Ensure that the disengaging lever is in the engaged position There is a defect in the braking coil or in the cabling Check the wheel lock and cabling for open or short circuited circuitry 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 Fault in speed potentiometer Stops driving The drive lever electronics could be faulty or incorrectly connected Motor voltage error Stops driving The motor or its cabling is defective Miscellaneous internal fault Stops driving The electronic system may have an internal error Check all cables and connections 10 Push freewheel mode error Movement braked The Scooter has exceeded the permissible maximum speed during pushing or freewheeling Switch the electronics syste
8. Invacare Lynx SERVICE MANUAL This manual contains information on Troubleshooting Maintenance Repair Edition 25 11 09 43 6232 55 350 Mobitec Mobilitatshilfen GmbH 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 T B 8210 Loppem Brugge belgium invacare com Belgium WWW www invacare be CH Mobitec Rehab AG a 41 0 61 48 77 08 0 Benkenstrafte 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 CD Invacare Aquatec a 49 0 75 62 7 000 Alemannenstrafe 10 Fax 49 0 75 62 7 00 66 88316 Isny info invacare aquatec com Deutschland WWW www invacare aquatec de Invacare amp A S Sdr Ringvej 37 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 a 34 0 972 49 32 00 cl Areny s n Fax 34 0 972 49 32 20 Pol gon Industrial de Celr contactsp invacare com E 17460 Celr Girona WWW www invacare es ESPA A F Invacare Poirier SAS a 33 0 247 62 64 66 77 7 Route de St Roch Fax 33 0 247 42 12 24 F 37230 Fondettes contactfr invacare com
9. after installing the new driving program WARNING Every alteration to the drive program can influence vehicle handling and the tipping stability of the wheelchair e Alterations to the drive program must only be carried out by trained Invacare dealers e Invacare can only assume a warranty for the safe vehicle handling of the wheelchair in particular tipping stability for unaltered standard drive programs Pre requisites e Dynamic amp Wizard software e User manual for the Wizard software e For further information on other requirements such as the minimum system configuration of the PC to be used for programming necessary programming cables see the user manual of the Wizard software You find the latest version of the user manual in the download area on http www dynamiccontrols com o d me lt P P Replacing the potentiometer CAUTIONI Burn and scald hazard if power cable is short circuited Interrupt the power supply by removing the batteries before you start work on the electronic system CAUTION Risk of accidents 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 Phillips screwdriver Allen key open ended spanner 2 mm e Digital multimeter From the operating manual Remove the seat Remove the battery pack Further work
10. al not being possibly batteries charged defective LEDs blinking Charging device Replace See charging unit on charging possibly charging unit operating manual unit defective Scooter None Operating Replace See Replacing runs too console possibly operating operating console on slowly defective console page 23 Batteries Replace See operating manual possibly batteries defective 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 the charged drive battery as soon as possible 2 Battery voltage too Stops driving e The batteries are depleted Charge low batteries e f 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 You should only do this in emergency however because this causes the batteries to become excessively discharged 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 Switch on the lights to use up some power 13 14 Blink code Fault Power time exceeded
11. blem 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 POSSIBLE CAUSE SOLUTION Documentation Scooter will not start Status display on operating console does not illuminate Batteries Replace See operating manual possibly batteries defective Batteries Pre charge See operating manual possibly over batteries discharged Power supply to Check master See operating operating fuse instructions for main console possibly fuse position interrupted e Checkcable See Replacing the between electronics on page 18 modules for loose connections or damage Operating Replace See Replacing console possibly operating operating console on defective console page 23 Operating unit status display blinking Various causes Assess error code See Error Codes and Diagnostic Codes on page 13 5 2 PROBLEM OTHER POSSIBLE SOLUTION Documentation SYMPTOMS CAUSE Scooter None Drive motor s Replace See Replacing the judders in possibly motor s drive motor on page drive mode defective 15 Drive lever Replacingthe See Replacing the potentiometer potentiometer potentiometer on page possibly 21 defective Batteries None Batteries Replace See operating manu
12. ce 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 See Replacing wheels for tight fit front axle on page float and side play e Pneumatic tyre Repair or replace See operating if damaged manual e Check functions in Replace motor if See Replacing drive and push necessary the drive motor modes e Tighten screws on page 15 e Check clutch nuts adjust or mechanism replace if necessary Lightin Check function Replace bulbs or 9 g Check cable cable if necessary Batteries Check batteries for Replace batteries See operating damage if necessary manual Check battery charge batteries See operating voltage manual Check contacts and A contacts terminals A terminals Drive Status display e Evaluate blinking electronics flashing code Fixing Tighten replace Cable connecting Replace plug Replace drive Drive lever function lever Power supply Replace cable connecting plug or console Check drive Update software See Updating the electronics program on page 20 version Newer version available Drive units coupling mechanism Drive program 11 5 1 1 12 Operational Faults Operational faults Please proceed as follows if you have any problems e First assess the possible cause of the pro
13. e From the operating manual e Remove the seat e Remove the battery pack e Further work e Unlock the expanding rivet 1 on the rubber mat fixing by pressing the central clamping prong e Remove the expanding rivet and the rubber mat e Remove the electronics cover screws 1 e Fold up the electronics cover 2 and remove it e Remove all plugs 1 from electronic system e Remove screws 2 on both sides of the electronics system e Replace the electronics system e Fit the electronics cover panel e Press the expanding rivet clamping prong 1 back in 2 e Locate the rubber mat e Insert expanding rivet 1 and secure by pressing in clamping prong e Modify the drive program e Complete reassembly of vehicle e Check all vehicle functions trial run 19 6 4 Vd 20 Updating the driving program The driving programs for electric wheelchairs are continually updated and improved by Invacare For this reason you should check whether the version number is still up to date each time a wheelchair comes in for repairs and also during regular inspections If a newer version is available the driving program must be updated The procedure for updating the driving program is described in the user manual of the Wizard software NOTE The electronic system is supplied with a standard drive program If the driving program has been customised you have to perform this customisation again
14. m off and on again 6 1 6 2 d 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 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 When connecting the motor and magnetic brake cable ensure that the plug is in the right position The motor rotation direction will be reversed if the connection is wrong Requirements e Open spanner 13 mm e Phillips screwdriver e Rubber hammer e From the operating manual e Loosen rear wheel fixing bolts e Remove the seat e Remove the battery pack e Remove the drive unit e Further work e Support the drive unit with a wooden wedge 15 16 Loosen the fixing bolt 1 from the handle and remove it Remove handle Loosen the fixing bolt 2 on the rear panelling and remove it Remove the rear panelling Unplug the drive motor plug M M 1 and the magnetic brake plug B
15. 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 overhaul work lead to the exclusion of all liability on the part of INVACARE e f you have any problems or questions please contact INVACARE SERVICE Notes on transport e If the electric vehicle has to be shipped back to the manufacturer for major repairs you should always use the original packaging for transport e You should also include as accurate a fault description as possible Important symbols in this manual WARNING This symbol warns you of danger e Always follow these instructions to avoid injury to the user or damage to the product EXPLOSION HAZARD
16. r 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 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 10 Tightening torques The tightening torques stated in the following table are dependent on the thread diameters for the nuts and bolts for which no special values are determined All values apply to dry and grease free threads Thread M4 M5 M6 M8 M10 M12 M14 M16 Tightening torque 9 Nm 6Nm 10Nm 25 Nm 49Nm 80 Nm 120 Nm 180 Nm in Nm 10 Caution All other nuts or plastic connectors not noted here must be tightened FINGERTIGHT A Service plan 1x annually Component Component chek Check Remedy Welded seams e Tighten screws fixings and replace parts if upholstery damaged e Check fixings e Tighten screws welded seams and repla
17. rting 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 secured Check all parts for correct interlocking1 e Only operate the electric vehicle with correct tyre pressure see Technical Specifications e Check electrical components for correct functioning incorrect polarity of cables can result in damage to the electronics e Asa last check always carry out a test drive Notes Mark all current settings for the electric vehicle seat armrests backrest etc and the cable connecting plugs associated before any removals This makes reassembly easie
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