Invacare ® Comet SERVICE MANUAL

Invacare ® Comet SERVICE MANUAL
Invacare ® Comet
SERVICE MANUAL
Edition: 28.03.12
Invacare ® - Comet
SERVICE MANUAL
These instructions contain information about:
Testing work
Repair Instructions
This manual is part of the instructions for use.
Service addresses
Invacare Austria GmbH
(:
+43 6232 5 53 50
Herzog Odilostrasse 101
Fax:
+43 6232 5 53 54
A-5310 Mondsee
@:
Austria
WWW:
Invacare n.v.
(:
Autobaan 22
Fax:
B-8210 Loppem (Brugge)
@:
Belgium
WWW:
Invacare AG
(:
Benkenstraße 260
Fax:
CH-4108 Witterswil
@:
Switzerland
WWW:
Invacare Aquatec GmbH
(
Alemannenstraße 10
Fax
88316 Isny
@:
Deutschland
WWW:
Invacare A/S
( (Kundeservice):
+45 (0)36 90 00 00
Sdr. Ringvej 37
Fax (Kundeservice):
+45 (0)36 90 00 01
DK-2605 Brøndby
@:
Danmark
WWW:
Invacare® SA
(:
+34 (0)972 49 32 00
c/ Areny s/n
Fax:
+34 (0)972 49 32 20
Polígon Industrial de Celrà
@:
E-17460 Celrà (Girona)
WWW:
info@invacare-austria.com
www.invacare.at
+32 (0)50 83 10 10
+32 (0)50 83 10 11
belgium@invacare.com
www.invacare.be
+41 (0)61487 70 80
+41 (0)61487 70 81
switzerland@invacare.com
www.invacare.ch
+49 (0)7562 70 00
+49 (0)7562 7 00 66
info@invacare-aquatec.com
www.invacare-aquatec.de
denmark@invacare.com
www.invacare.dk
contactsp@invacare.com
www.invacare.es
ESPAÑA
2
Invacare® Poirier SAS
(:
+33 (0)247 62 64 66
Route de St Roch
Fax:
+33 (0)247 42 12 24
F-37230 Fondettes
@:
France
WWW:
contactfr@invacare.com
www.invacare.fr
Invacare ® - Comet
SERVICE MANUAL
Invacare® Ltd
( (Customer services):
+44 (0)1656 77 62 22
Pencoed Technology Park
Fax (Customer services):
+44 (0)1656 77 62 20
Pencoed
@:
Bridgend CF35 5HZ
WWW:
uk@invacare.com
www.invacare.co.uk
United Kingdom
Invacare Mecc San s.r.l.
(:
Via dei Pini, 62
Fax:
I - 36016 Thiene (VI)
@:
Italia
WWW:
Invacare Ireland Ltd.
(:
Unit 5 Seatown Business Campus
Fax:
Seatown Rd, Swords
@:
County Dublin
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
ireland@invacare.com
www.invacare.ie
Ireland
Invacare® AS
( (Kundeservice):
+47 (0)22 57 95 00
Grensesvingen 9
Fax (Kundeservice):
+47 (0)22 57 95 01
Postboks 6230
@:
norway@invacare.com
Etterstad
@:
island@invacare.com
N-0603 Oslo
WWW:
www.invacare.no
Norge
Invacare® B.V.
(:
Celsiusstraat 46
Fax:
NL-6716 BZ Ede
@:
nederland@invacare.com
Nederland
@:
csede@invacare.com
WWW:
+31 (0)318 69 57 57
+31 (0)318 69 57 58
www.invacare.nl
Invacare Lda
(:
+351 225 10 59 46
Rua Estrada Velha, 949
(:
+351 225 10 59 47
P-4465-784 Leça do Balio
Fax:
+351 225 10 57 39
Portugal
@:
WWW:
portugal@invacare.com
www.invacare.pt
3
Invacare ® - Comet
SERVICE MANUAL
Återförsäljare:
( (Kundtjänst):
+46 (0)8 761 70 90
Invacare® AB
Fax (Kundtjänst):
+46 (0)8 761 81 08
Fagerstagatan 9
@:
sweden@invacare.com
S-163 91 Spånga
@:
finland@invacare.com
Sverige
WWW:
Tillverkare:
MÖLNDAL
Invacare® Deutschland GmbH
(┐
+46 (0)31 86 36 00
Kleiststraße 49
Fax:
+46 (0)31 86 36 06
D-32457 Porta Westfalica
@:
www.invacare.se
ginvacare@invacare.com
Deutschland
LANDSKRONA
(:
Fax:
@:
+46 (0)418 2 85 40
+46 (0)418 1 80 89
linvacare@invacare.com
OSKARSHAMN
(:
Fax:
Eastern
european
countries
European Distributor
Organisation (EDO)
Kleiststraße 49
D-32457 Porta Westfalica
Deutschland
4
+46 (0)491 1 01 40
+46 (0)491 1 01 80
@:
oinvacare@invacare.com
(
+49 (0)5731 75 45 40
Fax
+49 (0)5731 75 45 41
@:
WWW:
edo@invacare.com
www.invacare.de
Invacare ® - Comet
SERVICE MANUAL
Table of Contents
Chapter
1
INTRODUCTION
Page
7
1.1
General information
7
1.2
Notes on transport
7
1.3
Definition and representation of information and safety information in this manual
8
1.4
Hazard symbols and symbols used
9
1.5
Images in this manual
2
SAFETY AND FITTING INSTRUCTIONS
10
11
2.1
Before any inspection or repair work
11
2.2
Personal safety equipment
11
2.3
General safety information and information about fitting / removal
11
3
TIGHTENING TORQUES
13
4
OVERVIEW ELECTRONIC MODULES
14
5
SERVICE PLAN (1X ANNUALLY)
15
6
OPERATIONAL FAULTS
17
6.1
6.1.1
Operational faults
Drive fault diagnosis
17
17
6.2
Error Codes and Diagnostic Codes
18
7
REPAIR WORK
20
7.1
General warning information on installation work
20
7.2
Replacing the drive motor
20
7.3
Replacing wheel suspension
24
7.4
Replacing shock absorber
26
7.5
Replacing front axle
28
7.6
Replacing steering column/fork 3-wheel
30
7.7
Replacing brakes
34
5
SERVICE MANUAL
Invacare ® - Comet
7.8
Replacing brake cable
37
7.9
Replacing lifter/lifter electronic
38
7.10
Replacing steering linkage/steering rod
40
7.11
Replacing the seat suspension / spring
42
7.12
Replacing operating console
44
7.13
Replacing bend speed reducer
46
7.14
Replacing the potentiometer
48
7.15
Replacing front headlight (lamp)
51
7.16
Replacing the front direction indicators
53
7.17
Replacing centre brake light
54
7.18
Replacing rear lights/direction indicators
56
7.19
Replacing the electronic module
58
7.20
Updating software
62
8
8.1
6
ACCESSORIES
Installing the windshield
63
63
Invacare ® - Comet
1
Introduction
1.1
General information
1.2
SERVICE MANUAL
·
Service and maintenance work must be carried out taking this service manual into account.
·
It is imperative that you observe safety information.
·
Information about operation or about general maintenance and care work on the mobility aid
should be taken from the operating manual.
·
You can find information about ordering spare parts in the spare parts catalogue.
·
Only use original Invacare® spare parts. The guarantee will become invalid if other spare
parts are used!
·
We reserve the right to make any alterations on the grounds of technical improvements.
·
The mobility aid may only be maintained and overhauled by qualified personnel.
·
The minimum requirement for service technicians is suitable training, such as in the cycle or
orthopaedic mechanics fields, or sufficiently long-term job experience.
- Experience in the use of electrical measuring equipment (multimeters) is also a requirement.
- Special Invacare® training is recommended.
·
Alterations to the mobility aid 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.
·
If you have any problems or questions please contact Invacare® Service.
Notes on transport
·
If the mobility aid has to be shipped back to the manufacturer for major repairs, you should
always use the original packaging for transport.
·
Please attach a precise description of the fault.
7
SERVICE MANUAL
1.3
Invacare ® - Comet
Definition and representation of information and safety
information in this manual
Different types of information and signal words are used throughout this manual.
HAZARD!
The signal word "HAZARD!" refers to immediate hazards.
· The following lines in italics refer to actions which serve to avoid such hazards.
WARNING!
The signal word "WARNING!" refers to possibly-occurring hazards which can lead to
death or serious injuries if they are not avoided.
· The following lines in italics refer to actions which serve to avoid such hazards.
ATTENTION!
The signal word "ATTENTION!" refers to possibly-occurring hazards which can lead to
minor injuries and/or material damage if they are not avoided.
· The following lines in italics refer to actions which serve to avoid such hazards.
CAUTION!
The signal word "CAUTION!" refers to hazards which could lead to material damage if
they are not avoided.
· The following lines in italics refer to actions which serve to avoid such hazards.
Note
The signal word "Note" is used to denote general information which simplifies the handling of
your product and refers to special functions.
8
Invacare ® - Comet
1.4
SERVICE MANUAL
Hazard symbols and symbols used
Different types of hazard symbols and symbols are used throughout this manual.
General hazards
This symbol warns you of general hazards!
· Always follow the instructions to avoid injury to the user or damage to the product!
BURN HAZARD!
This symbol warns you of the danger of chemical burns, for example due to the discharge
of battery acids!
· Always follow the instructions to avoid injury to the user or damage to the product!
DANGER OF CRUSHING!
This symbol warns you of crushing hazards due to inattentive working with heavy
components.
· Always follow the instructions to avoid injury to the user or damage to the product!
EXPLOSION HAZARD!
This symbol warns you of an explosion hazard, which can be caused by excessive tyre
pressure in a pneumatic tyre.
· Always follow the instructions to avoid injury to the user or damage to the product!
Wear safety shoes
The symbol refers to the requirement for wearing safety shoes.
· Wear standardised safety shoes during all work.
Wear eye protection
This symbol refers to the requirement for wearing eye protection, for example when
working with batteries.
· Wear eye protection when this symbol is shown.
Wear safety gloves
This symbol refers to the requirement for wearing safety gloves, for example when
working with batteries.
· Wear safety gloves when this symbol is shown.
Note
This symbol identifies general information which is intended to simplify working with your product
and which refers to special functions.
Requirements:
· This symbol identifies a list of various tools, components and items which you will need in
order to carry out certain work. Please do not attempt to carry out the work if you do not
have the listed tools available.
Always dispose used or damaged batteries correctly
The symbol refers to information for the correct disposal of used or damaged batteries.
9
SERVICE MANUAL
1.5
Invacare ® - Comet
Images in this manual
The detailed images in this manual are given digits to identify various components. Component
numbers in text and operational instructions always relate to the image directly above.
10
Invacare ® - Comet
2
SERVICE MANUAL
Safety and fitting instructions
These safety instructions are intended to prevent accidents at work, and it is imperative that they
are observed.
2.1
2.2
Before any inspection or repair work
·
Read and observe this repair manual and the associated operating manual!
·
Observe the minimum requirements for carrying out the work (see chapter entitled „General
information)!
Personal safety equipment
Safety shoes
The mobility device, and some of its components, are very heavy. These parts can result
in injuries to the feet if they are allowed to drop.
· Wear standardised safety shoes during all work.
Eye protection
It is possible that battery acid can be discharged when working on defective batteries or
when handling batteries improperly.
· Always wear eye protection when working on any defective or possibly defective batteries.
Safety gloves
It is possible that battery acid can be discharged when working on defective batteries or
when handling batteries improperly.
· Always wear acid-proof safety gloves when working on any defective or possibly defective
batteries.
2.3
General safety information and information about fitting / removal
WARNING: Danger of crushing!
Various components such as the drive unit, batteries, seat etc are very heavy. This results
in injury hazards to your hands!
· Please note the high weight of some components! This applies especially to the removal of
drive units, batteries and the seat.
WARNING!
Injury hazard if the vehicle starts moving unintentionally during repair work!
· Switch the power supply off (ON/OFF key)!
· Engage the drive!
· Before raising the vehicle, secure the wheels by blocking them with wedges!
ATTENTION!
Fire and burn hazard due to electrical short-circuit!
· The mobility device must be completely switched off before removal of voltage-carrying
components! To do this, remove the batteries.
· Avoid short-circuiting the contacts when carrying out measurements on voltage-carrying
components!
11
SERVICE MANUAL
Invacare ® - Comet
CAUTION!
Danger of burns from hot surfaces on the motor!
· Allow the motors to cool down before commencing work on them.
ATTENTION!
Injury hazard and danger of damage to vehicle due to improper or incomplete
maintenance work!
· Use only undamaged tools in good condition.
· Some moving parts are mounted in sockets with PTFE coating (Teflon™). Never grease
these sockets!
· Never use "normal" nuts instead of self-locking nuts.
· Always use correctly-dimensioned washers and spacers
· When reassembling, always replace any cable ties which were cut during dismantling.
· After completing your work / before renewed start-up of the mobility device, check all
connections for tight fitting.
· After completing your work / before renewed start-up of the mobility device, check all parts for
correct locking.
· Only operate the vehicle with the approved tyre pressures (see technical data).
· Check all electrical components for correct function. Please note that incorrect polarity can
result in damage to the electronic.
· Always carry out a trial run at the end of your work.
Note
Mark all current settings for the mobility aid (seat, armrests, backrest etc.), and the associated
cable connecting plugs, before dismantling. This makes reassembly easier.
All plugs are fitted with mechanical safety devices which prevent release of the connecting plugs
during operation. To release the connecting plugs the safety devices must be pressed in. When
reassembling ensure that these safety devices are correctly engaged.
WARNING!
Any changes to the drive program can affect the driving characteristics and the tipping
stability of the vehicle!
· Changes to the drive program may only be carried out by trained Invacare® specialist
dealers!
· Invacare® supplies all mobility aids with a standard drive program ex-works. Invacare® can
only give a warranty for safe vehicle driving behaviour - especially tipping stability - for this
standard drive program!
12
Invacare ® - Comet
3
SERVICE MANUAL
Tightening torques
The tightening torques stated in the following list are based on the thread diameter for the nuts and
bolts for which no specific values have been determined. All values assume dry and de-greased
threads.
Thread
M4
M5
M6
M8
M10
M12
Tightening torque
in Nm ±10%
3 Nm
6 Nm
10 Nm
25 Nm
49 Nm
80 Nm
M14
M16
120 Nm 180 Nm
CAUTION!
Damage can be caused to the mobility device due to improperly tightened screws, nuts or
plastic connections.
· Always tighten screws, nuts etc to the stated tightening torque.
· Only tighten screws or nuts which are not listed here fingertight.
13
Invacare ® - Comet
SERVICE MANUAL
4
Overview electronic modules
Different electronic modules can be installed in the scooter. These are listed below:
Electronic modules
14
Designation
Notes
Rhino1
max. current:
DS112KB02
DS162KD01
110 A
160 A
Rhino2
max. current:
DS120
120 A
Rhino2
max. current:
DS160
160 A
Invacare ® - Comet
5
SERVICE MANUAL
Service plan (1x annually)
Component
Seat:
Frames
(chassis) /
battery
mounting
Wheel
suspension and
wheels
Check
Remedy
· Welded seams,
fixings and
upholstery
· Seat suspension
· Tighten screws,
replace parts if
damaged
· Grease the spring
generously,
replace parts if
damaged
· Check fixings,
welded seams and
battery mounting
· Check battery fixing
straps
· Check drive wheels
for tight fit
· Tighten screws,
replace parts if
damaged
· Check steering
wheels for tight fit,
float and side play
· Pneumatic tyre
· Adjust / replace
· Check tracking and
steering linkage.
· Tighten screws
· Check tracking
and steering
· Adjust or replace
brake
· Adjust or replace
shock absorber
· Replace motor if
necessary
· Tighten screws /
nuts, adjust or
replace
· Replace lightbulbs
or cable
· Test brake function
in pushing mode
· Check shock
Shock absorber
absorber
· Check functions in
Drive units,
drive and push
coupling
modes
mechanism
· Check clutch
mechanism
· Check function
Lighting
· Check cable/plug
connections
· Check batteries for
Batteries
damage
Brake
Notes
ü
See "Replacing
the seat
suspension /
spring" on page
42
· Tighten hub nuts,
replace if
necessary
· Repair or replace
if damaged
· Replace batteries
· Check battery
voltage
· charge batteries
· Check contacts and
terminals
· Clean contacts
and terminals
See operating
manual
See operating
manual
See operating
manual
15
Invacare ® - Comet
SERVICE MANUAL
Component
Drive electronic
Drive program
Speed
reduction in
bends
16
Check
Remedy
· Status display
flashing
· Fixing
· Cable, connecting
plug
· Drive lever function
· Power supply
· Evaluate blinking
code
· Tighten or replace
fixing.
· Replace cable,
connecting plug.
· Replace drive
lever
· Replace cable,
connecting plug or
console
· Update software
· Check drive
electronic program
version Newer
version available?
· Check cable and
connecting plug
· Check function
· Adjust or replace
sensor on relay.
Notes
ü
Invacare ® - Comet
SERVICE MANUAL
6
Operational Faults
6.1
Operational faults
Please proceed as follows if you have any problems:
· First assess the possible cause of the problem using the following table.
· Check the drive console status display. Evaluate the blink error code.
· Carry out the necessary checks and repairs as recommended in the following table.
6.1.1
Drive fault diagnosis
PROBLEM
OTHER
SYMPTOMS
Scooter will Status display
not start
on operating
console does
not illuminate
POSSIBLE
CAUSE
batteries
defective
SOLUTION
Documentation
· Replace
batteries
See operating manual
· Pre-charge
completely
batteries
discharge battery
Power supply to · Check master
fuse
operating console
possibly
interrupted
· Check cable
between
modules for
loose
connections or
damage
· Replace
Operating
operating
console defective
console
Operating unit
status display
blinking
Various causes
· Assess error
code
See operating
instructions for main fuse
position
See "Replacing the
electronic module" on
page 58
See "Replacing
operating console" on
page 44
See "Error Codes and
Diagnostic Codes" on
page 18
17
Invacare ® - Comet
SERVICE MANUAL
Scooter
judders in
drive mode
None
· Replace
motor(s)
Drive motor
defective
· Replacing the
potentiometer
Drive lever
potentiometer
defective
Batteries
not being
charged
None
batteries
defective
LEDs blinking
Charging unit
on charging unit defective
Scooter
runs too
slowly
Scooter
does not
reduce
speed on
bends.
None
None
See operating manual
· Replace
charging unit
See charging unit
operating manual
See "Replacing
operating console" on
page 44
batteries
· Replace
defective
batteries
Speed reducer for · Adjust speed
bend travel not
reducer
adjusted.
See operating manual
· Replace speed See "Replacing bend
reducer
speed reducer" on page
46
Error Codes and Diagnostic Codes
Blink
code
Fault
Consequence
for the Scooter
Comments
1
Battery must be
charged
Continues to
drive
·
The batteries are discharged. Charge the
battery as soon as possible.
2
Battery voltage too Stops driving
low
·
The batteries are depleted. Charge
batteries.
·
If you switch the Scooter off for a few
minutes, the battery can often recuperate
to such a stage that a short journey is
still possible.
·
The battery voltage is too high. If the
battery charger is connected, disconnect
it from the Scooter.
·
The electronic system charges the
batteries when running downhill and
when braking. This fault is caused when
the battery voltage becomes too high
during this process. Switch the Scooter
off and on again.
3
18
See "Replacing the
potentiometer" on page
48
· Replace
batteries
· Replace
Operating
operating
console defective
console
Speed reducer
defective
6.2
See "Replacing the
drive motor" on page 20
Battery voltage too Stops driving
high
Invacare ® - Comet
Blink
code
4
SERVICE MANUAL
Fault
Power time
Consequence
for the Scooter
Stops driving
Comments
·
The maximum current was exceeded
over too long a period, probably because
the motor was overloaded or has been
working against an immovable
resistance. Switch the scooter off, wait a
few minutes and then switch on again.
·
The electronic system has determined a
motor short-circuit. Check the wiring
harness for short-circuit and check the
motor.
·
Contact your Invacare® dealer.
·
Ensure that the disconnection lever is
pressed in.
·
There is a defect in the braking coil or in
the cabling. Check the magnetic brake
and cabling for open or short-circuited
circuitry. Contact your Invacare® dealer.
·
Drive lever is not in neutral when the
keyswitch was turned. Put the drive lever
in neutral, turn the power off and then
turn on again.
·
It may be necessary to recalibrate the
drive lever. Contact your Invacare®
dealer.
·
The drive lever electronic could be faulty
or incorrectly connected. Check the
cabling for open or short-circuited
circuitry.
·
Potentiometer is not correctly adjusted.
Put the potentiometer into the centre
position.
exceeded
5
6
7
Brake failure
Stops driving
No neutral position Stops driving
when switching
Scooter on.
Fault in speed
potentiometer
Stops driving
8
Motor voltage error Stops driving
·
The motor or its cabling is defective
Check the cabling for open or shortcircuited circuitry.
9
Miscellaneous
internal fault
Stops driving
·
Contact your Invacare® dealer.
10
Push/freewheel
mode error
Stops driving
·
The Scooter has exceeded the
permissible maximum speed during
pushing or freewheeling. Switch the
electronic system off and on again.
19
SERVICE MANUAL
7
Repair Work
7.1
General warning information on installation work
Invacare ® - Comet
CAUTION!
Risk of damage to the vehicle! Collisions can be caused if shim rings are removed from
the drive wheels during installation work!
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!
· Install all shim rings in exactly the same positions they were in before dismantling.
7.2
Replacing the drive motor
ATTENTION! Risk of accident.
When parking the scooter on the scooters support wheels it is no longer slowed by the
engine brake. The scooter can roll away out of control.
· Place the scooter rear frame on a supporting wooden block before you remove the wheels.
ATTENTION! Risk of accident.
Accidental rolling can lead to accidents.
· Secure the scooter against rolling away.
NOTE:
When disassembling, note the position of small parts such as screws and washers. Put small
parts down so that they can be reassembled in the right sequence.
NOTE:
The plugs on the electronic module cannot be wrongly connected because all plugs have a
different size and only fit in one socket.
Requirements:
· Open spanner, 10 mm.
· Open spanner, 17 mm.
· oblique pliers
· Rubber hammer
· Phillips screwdriver
· Supporting wooden block
20
Invacare ® - Comet
·
Secure the scooter against rolling away.
·
Place supporting wooden block under the
frames at battery holder height.
·
Remove the seat.
·
Remove motor cover.
·
Disconnect both battery plugs (1).
SERVICE MANUAL
From the operating manual:
·
Unscrew the rear wheel fixing bolts.
·
Remove rear wheels.
21
Invacare ® - Comet
SERVICE MANUAL
·
Disconnect plugs from electronic module.
Rhino1:
DS112KB02
DS162KD01
Rhino 2:
DS120:
DS160
22
Invacare ® - Comet
·
Remove the bolt (2) on the wheel cover.
·
Remove wheel cover (1).
·
Place a supporting block of wood under the
motor link fork.
·
Remove screws (1) on shock absorber (2).
·
Remove screws (3) from the drive holder
(4).
·
Remove drive holder (4).
·
Remove screws (1) on disengaging lever
(2).
·
Remove disengaging lever (2).
·
Lifted drive out of its holder and take it out of
the frames to the side.
·
Replace drive unit.
·
Reassembly of the drive takes place in
reverse order
·
Check all functions (trial run).
SERVICE MANUAL
23
SERVICE MANUAL
7.3
Invacare ® - Comet
Replacing wheel suspension
ATTENTION! Risk of accident.
Accidental rolling can lead to accidents.
· Secure the scooter against rolling away.
NOTE:
When disassembling, note the position of small parts such as screws and washers. Put small
parts down so that they can be reassembled in the right sequence.
Requirements:
· Open spanner, 32 mm.
· Phillips screwdriver
· Supporting wooden block
24
·
Remove the seat.
·
Remove motor cover.
·
Disconnect battery cable (1).
·
Dismantle chassis and steering column (see
chapter entitled "Replacing steering
column/fork 3-wheel" on page 30).
·
Dismantle steering linkage and steering rod
(see chapter entitled "Replacing steering
linkage/steering rod" on page 40 “).
·
Loosen wheel suspension screw (1).
·
Loosen knurled screw (2).
·
Replace wheel suspension
Invacare ® - Comet
·
Reassembly takes place in the reverse
order.
·
Apply brake and hold, tighten wheel bolts at
same time.
·
Adjust tracking (see chapter entitled
"Replacing steering linkage/steering rod"
on page 40 “).
·
Check function (trial run).
SERVICE MANUAL
25
SERVICE MANUAL
7.4
Invacare ® - Comet
Replacing shock absorber
ATTENTION! Risk of accident.
When parking the scooter on the scooters support wheels it is no longer slowed by the
engine brake. The scooter can roll away out of control.
· Place the scooter rear frame on a supporting wooden block before you remove the wheels.
ATTENTION! Risk of accident.
Accidental rolling can lead to accidents.
· Secure the scooter against rolling away.
NOTE:
When disassembling, note the position of small parts such as screws and washers. Put small
parts down so that they can be reassembled in the right sequence.
NOTE:
The drive motor needs to be removed before you can replace the left-hand shock absorber. If the
right-hand shock absorber is to be replaced, you do not need to remove the drive motor.
Requirements:
· Open spanner, 10 mm.
· Open spanner, 17 mm.
· Phillips screwdriver
· 2 Allen keys 5m
· Supporting wooden block
·
Remove wheel (see operating manual)
·
Dismantle wheel cover (see chapter entitled
"Replacing the drive motor" on page 20).
Replacing rear shock absorber:
26
·
Remove top screw (1) on shock absorber
(2).
·
Remove both screws (4) from motor bracket
(5).
·
Remove shock absorber (2) with motor
bracket (5).
·
Remove bottom screw (6) on shock
absorber (2).
·
Replace shock absorber (2).
Invacare ® - Comet
SERVICE MANUAL
Replacing front shock absorber:
·
Remove top screw (1) on shock absorber
(2).
·
Remove bottom screw (4) on shock
absorber (2).
·
Replace shock absorber (2).
·
Reassembly of the shock absorber takes
place in reverse order.
·
Use setting screw (3) to set the spring
hardness.
·
Check function (trial run).
27
SERVICE MANUAL
7.5
Invacare ® - Comet
Replacing front axle
ATTENTION! Risk of accident.
Accidental rolling can lead to accidents.
· Secure the scooter against rolling away.
NOTE:
When disassembling, note the position of small parts such as screws and washers. Put small
parts down so that they can be reassembled in the right sequence.
NOTE:
The front axle can only be replaced on the 3-wheel version. The 4-wheel version does not have a
replaceable axle.
Requirements:
· Open spanner, 17 mm.
· Open spanner, 19 mm.
· Supporting wooden block
28
·
Place a supporting wooden block under the
front part of the frame so that the front wheel
is no longer touching the floor.
·
Loosen axle bolts (1) simultaneously on both
sides.
·
Slacken brake cable (see chapter entitled
"Replacing brake cable" on page 37).
·
Disconnect the brake cable at the wheel (1).
·
Remove screws (3) on spacer (2).
·
Remove screws (6) on shock absorber (5).
·
Loosen axle bolts (4) simultaneously on both
sides.
·
Pull front axle slowly out.
Invacare ® - Comet
·
Reassembly of the axle takes place in
reverse order
·
Operate brake and hold, tighten axle bolts at
same time.
·
Check function (trial run).
SERVICE MANUAL
29
SERVICE MANUAL
7.6
Invacare ® - Comet
Replacing steering column/fork 3-wheel
ATTENTION! Risk of accident.
Accidental rolling can lead to accidents.
· Secure the scooter against rolling away.
NOTE:
When disassembling, note the position of small parts such as screws and washers. Put small
parts down so that they can be reassembled in the right sequence.
Requirements:
· Open spanner, 10 mm.
· Open spanner, 17 mm.
· Open spanner, 19 mm.
· Open spanner, 32 mm.
· Phillips screwdriver
· Supporting wooden block
30
·
Remove the seat.
·
Remove motor cover.
·
Separate battery cable.
·
Place a supporting wooden block under the
front part of the frame so that the front wheel
is no longer touching the floor.
Invacare ® - Comet
SERVICE MANUAL
Replacing steering column:
·
Remove drive lever screws (3).
·
Remove drive lever (2).
·
Unscrew the bolts (1) on the drive console.
·
Remove drive console.
·
Remove screws (1) on rear steering column
cladding.
·
Remove steering column cladding.
·
Loosen screws on front basket holder.
·
Remove basket holder.
·
Remove spacer bushes.
31
SERVICE MANUAL
·
Disconnect cable (1, 2) from wiring harness.
·
Remove screws (3) on front steering column
cladding.
·
Remove the front steering column cladding.
·
Loosen the brake cable. (see chapter
entitled "Replacing brakes" on page 34).
·
Unscrew screw at clamp (1).
·
Unscrew fixing bolt for steering column and
remove.
·
Pull steering column out upwards.
Replacing fork 3-wheel:
32
·
Remove rubber mat in foot well.
·
Loosen screws in chassis below mat.
·
Remove chassis upwards.
·
Dismantle front wheel (see chapter entitled
"Replacing front axle" on page 28).
Invacare ® - Comet
Invacare ® - Comet
·
Pull off clamp (1).
·
Loosen fork bolt (2).
·
Loosen knurled screw (3).
·
Replace fork.
·
Reassembly takes place in the reverse
order.
·
Operate brake and hold, tighten axle bolts at
same time.
·
Check functions (trial run).
SERVICE MANUAL
33
SERVICE MANUAL
7.7
Invacare ® - Comet
Replacing brakes
ATTENTION! Risk of accident.
Accidental rolling can lead to accidents.
· Secure the scooter against rolling away.
NOTE:
When disassembling, note the position of small parts such as screws and washers. Put small
parts down so that they can be reassembled in the right sequence.
NOTE:
The front axle can only be replaced on the 3-wheel version. The 4-wheel version does not have a
replaceable axle.
Requirements:
· Open spanner, 12 mm.
· Open spanner, 13 mm.
· Philips screwdriver
· Allen key 5 mm
· Supporting wooden block
34
·
Remove the seat.
·
Remove motor cover.
·
Separate battery cable.
·
Place a supporting wooden block under the
front part of the frame so that the front wheel
is no longer touching the floor.
Invacare ® - Comet
SERVICE MANUAL
3-wheel version:
·
Slacken brake cable (see chapter entitled
"Replacing brake cable" on page 37).
·
Disconnect the brake cable at the wheel (1).
·
Remove screws (3) on spacer (2).
·
Remove screws (6) on shock absorber (5).
·
Loosen axle bolts (4) simultaneously on both
sides.
·
Pull front axle slowly out.
4-wheel version:
·
Slacken both brake cables.
·
Disconnect brake cable at affected wheel.
·
Loosen wheel bolt.
·
Pull wheel and brake off shaft.
·
Pull brake out of brake drum.
·
Replace brake lining or complete brake.
35
SERVICE MANUAL
36
·
Reassemble wheel and brake.
·
Push wheel and brake onto shaft, or push
axle through.
·
Apply brake so that brake shoes can align.
·
Reassembly of the brake takes place in
reverse order
·
Adjust braking force on wheel using brake
lever setting screw.
·
Check braking function while pushing.
Invacare ® - Comet
Invacare ® - Comet
7.8
SERVICE MANUAL
Replacing brake cable
ATTENTION! Risk of accident.
Accidental rolling can lead to accidents.
· Secure the scooter against rolling away.
NOTE:
When disassembling, note the position of small parts such as screws and washers. Put small
parts down so that they can be reassembled in the right sequence.
Requirements:
· Open spanner, 10 mm.
· Phillips screwdriver
·
Decrease the brake tension on the wheel
using the setting screw (1).
·
Disconnect the brake cable at the wheel (2).
·
Disconnect brake cable at steering wheel
brake lever.
·
Route the brake cable through the cladding.
·
Loosen brake lever screw (3) at wheel.
·
Replace brake cable.
·
Reassembly of the brake cable takes place
in reverse order.
·
Check braking function while pushing.
37
SERVICE MANUAL
7.9
Invacare ® - Comet
Replacing lifter/lifter electronic
ATTENTION! Risk of accident.
Accidental rolling can lead to accidents.
· Secure the scooter against rolling away.
NOTE:
When disassembling, note the position of small parts such as screws and washers. Put small
parts down so that they can be reassembled in the right sequence.
Requirements:
· Open spanner, 14 mm.
· Phillips screwdriver
·
Secure the scooter against rolling away.
·
Remove the seat.
·
Remove motor cover.
·
Disconnect both battery plugs (1).
Replacing lifter:
·
Remove batteries.
·
Disconnect lifter cable at wiring harness
connecting plug in motor enclosure.
·
Remove screws (1) on lifter (2).
·
Replace lifter.
Replacing lifter electronic:
38
·
Remove both screws (1) from the lifter
electronic (2).
·
Replace lifter electronic (2).
Invacare ® - Comet
SERVICE MANUAL
Replacing fuses in lifter electronic:
·
Unscrew lifter electronic cover.
·
Replace fuse (1).
·
Reassembly takes place in the reverse
order.
·
Check function
39
SERVICE MANUAL
7.10
Invacare ® - Comet
Replacing steering linkage/steering rod
ATTENTION! Risk of accident.
Accidental rolling can lead to accidents.
· Secure the scooter against rolling away.
NOTE:
When disassembling, note the position of small parts such as screws and washers. Put small
parts down so that they can be reassembled in the right sequence.
Requirements:
· Open spanner, 10 mm.
· Open spanner, 12 mm.
· Open spanner, 13 mm.
· Phillips screwdriver
· Circlip pliers
· Supporting wooden block
40
·
Remove the seat.
·
Remove motor cover.
·
Disconnect battery cable (1).
·
Dismantle the steering column and the
chassis (see chapter entitled "Replacing
steering column/fork 3-wheel" on page
30).
Invacare ® - Comet
SERVICE MANUAL
Replacing steering link:
·
Remove circlip (1) on steering link (2).
·
Replace steering link.
·
Adjust length of steering link using setting
screws (3).
Replacing steering rod:
·
Remove circlip (4) on steering rod (5).
·
Replace steering rod.
·
Adjust tracking by 1° inwards using setting
screw (6). (See sketch).
·
Reassembly of the steering linkage and/or
steering rod takes place in reverse order.
·
Check function (trial run).
41
Invacare ® - Comet
SERVICE MANUAL
7.11
Replacing the seat suspension / spring
ATTENTION! Risk of accident.
Accidental rolling can lead to accidents.
· Secure the scooter against rolling away.
Note:
When disassembling, note the position of small parts such as screws and washers. Put small
parts down so that they can be reassembled in the right sequence.
Note
The following seat support tubes are available for the seat suspension:
User weight
Length of the seat support
tube
Part number
0 – 136 kg
508,5 mm
SP1528986
533,5 mm
SP1528987
558,5 mm
SP1528988
508,5 mm
SP1522459
533,5 mm
SP1522460
558,5 mm
SP1522461
136 – 160 kg
Requirements:
· 2 open spanners, 17 mm
42
·
Secure the scooter against rolling away.
·
Remove the seat.
·
Loosen the securing bolt of the seat support
tube.
Invacare ® - Comet
·
Remove the bolt (7), nut and washers.
·
Remove the seat support tube (2) from the
receptacle tube (1).
·
Remove the concertina type cover (3)
including the spring (5) and the plastic end
pieces (4 and 6).
·
Fit the plastic end pieces (4 and 6) to the
new spring.
·
Grease the spring generously. The spring
should be covered completely.
·
Assemble the concertina type cover (3).
·
Install the concertina type cover (3) including
the spring (5) and the plastic end pieces (4
and 6).
·
Insert the seat support tube (2) into the
receptacle tube (1) and press down gently.
·
Reposition the bolt (7), nut and washers.
·
Firmly tighten the seat support bolt.
·
Reposition the seat.
SERVICE MANUAL
43
SERVICE MANUAL
7.12
Invacare ® - Comet
Replacing operating console
ATTENTION!
Burn and scald hazard if power cable is short-circuited!
· Turn off the power completely before removing any power supply components of the electric
vehicle! Therefore take out the batteries.
· Avoid a bridging of the contacts during measurements on live electrical components!
NOTE:
The plugs on the operating console cannot be wrongly connected because all plugs have a
different size and only fit in one socket.
Requirements:
· Phillips screwdriver
44
·
Remove the seat.
·
Remove motor cover.
·
Disconnect battery cable (1).
·
Remove screws (1) below operating
console.
·
Remove operating console and fold
upwards.
·
Remove screws (3) on drive lever (2) and
remove drive lever.
·
Disconnect plug from operating console
circuit board.
·
Replace operating console.
·
Reconnect plug with circuit board on new
operating console.
Invacare ® - Comet
·
Reassembly of the operating console takes
place in reverse order
·
Check all functions (trial run).
SERVICE MANUAL
45
SERVICE MANUAL
7.13
Invacare ® - Comet
Replacing bend speed reducer
ATTENTION! Risk of accident.
Accidental rolling can lead to accidents.
· Secure the scooter against rolling away.
NOTE:
When disassembling, note the position of small parts such as screws and washers. Put small
parts down so that they can be reassembled in the right sequence.
Requirements:
· Phillips screwdriver
· Open spanner, 32 mm.
·
Remove the seat.
·
Remove motor cover.
·
Separate battery cable.
·
Remove front and rear steering column
cladding, steering column and housing (see
chapter entitled "Replacing steering
column/fork 3-wheel" on page 30).
Replacing sensors (5) without mounting:
·
Loosen screws.
·
Replace sensor.
Replacing sensors (5) with mounting:
·
Loosen fork bolt (1).
·
Replace sensors (5) with mounting.
Replacing regulating unit (4):
46
·
Loosen screws.
·
Remove sensor (5).
·
Loosen screws (3).
·
Replace regulating unit (4).
Invacare ® - Comet
SERVICE MANUAL
Adjusting:
·
Set steering to straight ahead.
·
Align sensor straight using regulating unit.
·
Take hold of the sensor and tighten the fork
screw.
Check:
·
Turn the steering completely to the right and
then the left.
·
When the steering is turned to its limit, the 3
regulating unit switches should be visible.
·
Reassembly takes place in the reverse
order.
·
Check functions (trial run).
47
SERVICE MANUAL
7.14
Invacare ® - Comet
Replacing the potentiometer
ATTENTION!
Burn and scald hazard if power cable is short-circuited!
· Turn off the power completely before removing any power supply components of the electric
vehicle! Therefore take out the batteries.
· Avoid a bridging of the contacts during measurements on live electrical components!
ATTENTION! Risk of accident.
Wrong potentiometer setting can result in dangerous driving situations!
· Set the new potentiometer to the middle position before inserting.
Requirements:
· Phillips screwdriver
· Digital multimeter
· Allen key 2m
48
·
Remove the seat.
·
Remove motor cover.
·
Disconnect battery cable (1).
·
Remove screws (1) below operating
console.
·
Remove operating console and fold
upwards.
·
Remove screws (3) on drive lever (2) and
remove drive lever.
Invacare ® - Comet
·
Disconnect potentiometer plug (1) from the
operating console.
·
Remove screws (1) on potentiometer.
·
Replace potentiometer
·
Reconnect potentiometer plug (1) with
operating console.
SERVICE MANUAL
49
SERVICE MANUAL
Setting the potentiometer to the middle
position:
50
·
Loosen the bolts (1) on the drive lever
mounting.
·
Twist the potentiometer shaft (2) until the
same resistance (approx. 5kOhm) is
measured between the central connection
cable (3) and both outputs (4).
·
Retighten the bolts on the drive lever
mounting.
·
Check settings and repeat the adjustment if
necessary.
·
Reassembly of the operating console takes
place in reverse order
·
Check all functions (trial run).
Invacare ® - Comet
Invacare ® - Comet
7.15
SERVICE MANUAL
Replacing front headlight (lamp)
NOTE:
You can replace the headlight without removing the chassis. If, however, the working space is too
small, you can remove the chassis as described in chapter entitled "Replacing steering
column/fork 3-wheel" on page 30.
Requirements:
· Phillips screwdriver
·
Remove the seat.
·
Remove motor cover.
·
Disconnect battery cable (1).
·
Remove rear steering column cladding (see
chapter entitled "Replacing steering
column/fork 3-wheel" on page 30).
3-wheel version
·
Remove screw (1) on front headlight under
front cladding.
·
Disconnect direction indicator cable (2) at
wiring harness behind steering column
cladding.
51
SERVICE MANUAL
4-wheel version
52
·
Remove screws (1) on front headlight under
front cladding.
·
Disconnect direction indicator cable (2) at
wiring harness behind steering column
cladding.
·
Remove headlight.
·
Remove screws (1) on headlight glass.
·
Remove headlight glass.
·
Replace bulb (2) in headlight.
·
Reassembly of the headlight takes place in
reverse order.
·
Check function
Invacare ® - Comet
Invacare ® - Comet
7.16
SERVICE MANUAL
Replacing the front direction indicators
Requirements:
· Phillips screwdriver.
·
Remove the seat.
·
Remove motor cover.
·
Separate battery cable.
3-wheel version
·
Remove direction indicator screw (1).
·
Disconnect direction indicator cable (2) from
wiring harness.
·
Replace direction indicator.
·
Reassembly of the direction indicators takes
place in reverse order
·
Check functions.
4-wheel version
·
Remove direction indicator screw (1) on
housing.
·
Disconnect direction indicator cable (2) from
wiring harness.
·
Remove screws (3) on indicator glass.
·
Remove indicator glass.
·
Loosen screws (4) on orange-coloured cap
(5) and remove cap.
·
Replace lightbulb.
·
Reassembly of the direction indicators takes
place in reverse order
·
Check functions.
53
SERVICE MANUAL
7.17
Invacare ® - Comet
Replacing centre brake light
ATTENTION!
Burn and scald hazard if power cable is short-circuited!
· Turn off the power completely before removing any power supply components of the electric
vehicle! Therefore take out the batteries.
· Avoid a bridging of the contacts during measurements on live electrical components!
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:
· Phillips screwdriver
54
·
Remove the seat.
·
Remove motor cover.
·
Disconnect both battery plugs (1).
·
Disconnect the plug (4).
Invacare ® - Comet
·
Remove the bolt (1) on the rear panelling.
·
Lift the rear panelling upwards.
·
Remove screws (1) on brake light.
·
Replace brake light.
·
Reassembly of the brake light takes place in
reverse order.
·
Check functions (trial run).
SERVICE MANUAL
55
SERVICE MANUAL
7.18
Invacare ® - Comet
Replacing rear lights/direction indicators
ATTENTION!
Burn and scald hazard if power cable is short-circuited!
· Turn off the power completely before removing any power supply components of the electric
vehicle! Therefore take out the batteries.
· Avoid a bridging of the contacts during measurements on live electrical components!
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:
· Phillips screwdriver
56
·
Remove the seat.
·
Remove motor cover.
·
Disconnect both battery plugs (1).
·
Remove the bolt (1) on the rear panelling.
·
Lift the rear panelling upwards.
·
Remove screws (1) on rear light.
Invacare ® - Comet
·
Remove rear light.
·
Remove screws (1) on rear light glass.
·
Remove rear light glass (1).
·
Replace lightbulbs (2).
·
Reassembly of the rear light/direction
indicator takes place in reverse order.
·
Check function
SERVICE MANUAL
57
SERVICE MANUAL
7.19
Invacare ® - Comet
Replacing the electronic module
ATTENTION! Risk of accident.
When parking the scooter on the scooters support wheels it is no longer slowed by the
engine brake. The scooter can roll away out of control.
· Place the scooter rear frame on a supporting wooden block before you remove the wheels.
ATTENTION!
Burn and scald hazard if power cable is short-circuited!
· Turn off the power completely before removing any power supply components of the electric
vehicle! Therefore take out the batteries.
· Avoid a bridging of the contacts during measurements on live electrical components!
WARNING!
Any changes to the drive program can affect the driving characteristics and the tipping
stability of the mobility aid!
· Changes to the drive program may only be carried out by trained Invacare® specialist
dealers!
· Invacare® can only give a warranty for safe mobility aid driving behaviour - especially tipping
stability - for unaltered standard drive programs!
ATTENTION! Risk of accident.
Accidental rolling can lead to accidents.
· Secure the scooter against rolling away.
Note:
The electronic system is supplied with a standard drive program. If you have carried out
customer-specific modifications to the drive program, you will have to make these changes again
after installing the new electronic module.
Note:
When disassembling, note the position of small parts such as screws and washers. Put small
parts down so that they can be reassembled in the right sequence.
Note:
The plugs on the electronic module cannot be wrongly connected because all plugs have a
different size and only fit in one socket.
Requirements:
· Open spanner, 10 mm.
· Open spanner, 17 mm.
· Rubber hammer
· Phillips screwdriver
· Supporting wooden block
· To adapt the drive program: programming software or hand programming device and
electronic system installation manual, available from Invacare®.
58
Invacare ® - Comet
·
Secure the scooter against rolling away.
·
Place supporting wooden block under the
frames at battery holder height.
·
Remove the seat.
·
Remove motor cover.
·
Disconnect both battery plugs (1).
SERVICE MANUAL
From the operating manual:
·
Unscrew the rear wheel fixing bolts.
·
Remove rear wheels.
·
Remove the drive unit (see chapter entitled
"Replacing the drive motor" on page 20).
59
Invacare ® - Comet
SERVICE MANUAL
·
Remove screws (1) on electronic module.
Rhino1:
DS112KB02
DS162KD01
Rhino 2:
DS120:
DS160:
60
Invacare ® - Comet
·
Replace electronic module (2).
·
Reassembly of the drive and the electronic
module takes place in reverse order.
·
Load drive program onto electronic module.
See electronic software description.
·
Check all functions (trial run).
SERVICE MANUAL
61
SERVICE MANUAL
7.20
Invacare ® - Comet
Updating software
Invacare is continuously carrying out further development and improvements to drive programs for
electric vehicles. For this reason, you should always check whether the drive program version
number is up-to-date when carrying out any repairs or regular maintenance. If a newer version is
available, the drive program must be updated. The procedure for updating the drive program is
described in the wizard software operating manual.
NOTE:
The electronic system is supplied with a standard drive program. If you have carried out
customer-specific modifications to the drive program, you will have to make these changes again
after installing the new electronic module.
WARNING!
Any changes to the drive program can affect the driving characteristics and the tipping
stability of the mobility aid!
· Changes to the drive program may only be carried out by trained Invacare® specialist
dealers!
· Invacare® can only give a warranty for safe mobility aid driving behaviour - especially tipping
stability - for unaltered standard drive programs!
Requirements:
· Dynamic® Wizard software
· Operating manual for Wizard software
· 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/.
62
Invacare ® - Comet
8
Accessories
8.1
Installing the windshield
SERVICE MANUAL
Requirements:
· 13 mm open-ended wrench
· 14 mm open-ended wrench
·
Remove the rear view mirror and the
stoppers of the plastic cover on the
handlebars.
·
Remove the threaded bolts of the rear view
mirror holder.
·
Insert the threaded bolts (1) into the holes in
the brackets (2).
·
Place the spacer sleeves (3) on the
threaded bolts.
·
Screw the threaded bolts instead of the
mirror brackets into the holes provided for
this purpose, but don't tighten the bolts
completely yet. Make sure the brackets are
turned so they point upwards and outwards
towards the ends of the handlebars.
·
Loosen the wing nuts (1).
·
Insert the non-threaded ends of the
windshield brackets (2) into the fixtures from
below.
63
SERVICE MANUAL
64
·
Insert the threads of the windshield
mounting brackets (3) through the bracket
holders (1).
·
Secure the windshield mounting brackets
with the self-locking nuts (2).
·
Adjust the windshield using the nuts (2) and
(4) on both sides so that it is perpendicular
to the direction of travel .
·
Adjust the windshield so that it is horizontal.
·
Tighten the wing nuts.
·
Now tighten the threaded bolts.
·
Install the rear view mirrors again.
Invacare ® - Comet
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