Invacare ® Kite SERVICE MANUAL

Invacare ® Kite SERVICE MANUAL
Invacare ® Kite
SERVICE MANUAL
Edition: 11.09.2013
Invacare ® - Kite
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
(:
[email protected]
www.invacare.at
+32 (0)50 83 10 10
+32 (0)50 83 10 11
[email protected]
www.invacare.be
+41 (0)61487 70 80
Benkenstraße 260
Fax:
CH-4108 Witterswil
@:
+41 (0)61487 70 81
Switzerland
WWW:
Invacare Aquatec GmbH
(
Alemannenstraße 10
Fax
88316 Isny
@:
Deutschland
WWW:
Invacare A/S
( (Kundeservice):
Sdr. Ringvej 37
Fax (Kundeservice):
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:
[email protected]
www.invacare.ch
+49 (0)7562 70 00
+49 (0)7562 7 00 66
[email protected]
www.invacare-aquatec.de
+45 (0)36 90 00 00
+45 (0)36 90 00 01
[email protected]
www.invacare.dk
[email protected]
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:
[email protected]
www.invacare.fr
Invacare ® - Kite
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:
[email protected]
www.invacare.co.uk
United Kingdom
Invacare Mecc San s.r.l.
(:
+39 0445 38 00 59
Via dei Pini, 62
Fax:
+39 0445 38 00 34
I - 36016 Thiene (VI)
@:
Italia
WWW:
Invacare Ireland Ltd.
(:
+353 18 10 70 84
Unit 5 Seatown Business Campus
Fax:
+353 18 10 70 85
Seatown Rd, Swords
@:
County Dublin
WWW:
[email protected]
www.invacare.it
[email protected]
www.invacare.ie
Ireland
Invacare® AS
( (Kundeservice):
Grensesvingen 9
Fax (Kundeservice):
Postboks 6230
@:
[email protected]
Etterstad
@:
[email protected]
N-0603 Oslo
WWW:
+47 (0)22 57 95 00
+47 (0)22 57 95 01
www.invacare.no
Norge
Invacare® B.V.
(:
+31 (0)318 69 57 57
Celsiusstraat 46
Fax:
+31 (0)318 69 57 58
NL-6716 BZ Ede
@:
[email protected]
Nederland
@:
[email protected]
WWW:
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:
[email protected]
www.invacare.pt
3
Invacare ® - Kite
SERVICE MANUAL
Återförsäljare:
( (Kundtjänst):
+46 (0)8 761 70 90
Invacare® AB
Fax (Kundtjänst):
+46 (0)8 761 81 08
Fagerstagatan 9
@:
[email protected]
S-163 91 Spånga
@:
[email protected]
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
[email protected]
Deutschland
LANDSKRONA
(:
+46 (0)418 2 85 40
Fax:
+46 (0)418 1 80 89
@:
[email protected]
OSKARSHAMN
Eastern
european
countries
European Distributor
Organisation (EDO)
Kleiststraße 49
D-32457 Porta Westfalica
Deutschland
4
(:
+46 (0)491 1 01 40
Fax:
+46 (0)491 1 01 80
@:
[email protected]
(
+49 (0)5731 75 45 40
Fax
+49 (0)5731 75 45 41
@:
WWW:
[email protected]
www.invacare.de
Invacare ® - Kite
SERVICE MANUAL
Contents
Chapter
1
2
Page
Introduction
9
1.1
General information .................................................................................................................. 9
1.2
Notes on shipping ..................................................................................................................... 9
1.3
Definition and representation of information and safety information in this manual ...... 10
1.4
Hazard symbols and symbols used ....................................................................................... 11
1.5
Images in this manual ............................................................................................................. 12
Safety and fitting instructions
13
2.1
Before any inspection or repair work .................................................................................... 13
2.2
Personal safety equipment ..................................................................................................... 13
2.3
General safety information and information about fitting / removal .................................. 13
3
Tightening torques
15
4
Layout of components and componentry
16
4.1
Overview ................................................................................................................................... 16
4.2
Overview of the electronic modules (ACS 2 system)........................................................... 17
4.2.1
ACS 2 70 / ACS 2 70L / ACS 2 90L electronic module................................................. 19
4.2.2
ACS 2 90LG electronic module .................................................................................... 19
4.2.3
ACT actuator module .................................................................................................... 19
4.2.3.1
ACT 2 actuator module ............................................................................................ 19
4.2.3.2
ACT 4 actuator module ............................................................................................ 20
4.2.4
Lighting PCB ................................................................................................................. 20
5
Service plan (1x annually)
21
6
Operational faults
23
7
6.1
Drive fault diagnosis ............................................................................................................... 23
6.2
ACS2 remotes: Error codes and diagnostic codes .............................................................. 25
Test procedures
26
7.1
Testing the motor .................................................................................................................... 26
7.2
Testing the electro-mechanical parking brake ..................................................................... 27
7.3
Checking an actuator .............................................................................................................. 29
5
Invacare ® - Kite
SERVICE MANUAL
8
Repair work
8.1
8.2
Covers....................................................................................................................................... 30
8.1.1
Rear cover .................................................................................................................... 30
8.1.2
Middle cover.................................................................................................................. 31
8.1.3
Side cover ..................................................................................................................... 32
8.1.4
Front cover .................................................................................................................... 33
8.1.5
Replacing a front splash guard ..................................................................................... 34
8.1.6
Replacing the splash guard .......................................................................................... 35
Electronic modules.................................................................................................................. 36
8.2.1
Replacing the power module ........................................................................................ 36
8.2.2
Replacing the actuator module ..................................................................................... 38
8.2.3
Replacing the G-Trac sensor ........................................................................................ 39
8.2.4
Replacing the lighting circuit board ............................................................................... 40
8.2.5
Replace remote ............................................................................................................ 41
8.2.6
Drive program selection after component replacement ................................................ 42
8.2.6.1
Profile selection with remote REM A or REM B ....................................................... 42
8.2.6.2
Profile selection with remote REM 550 .................................................................... 43
8.3
Updating the driving program ................................................................................................ 44
8.4
Batteries ................................................................................................................................... 45
8.4.1
Removing the batteries ................................................................................................. 45
8.4.2
Correct handling of damaged batteries ......................................................................... 48
8.5
Checking and replacing the main fuse .................................................................................. 49
8.6
Checking the cables ................................................................................................................ 51
8.7
Lighting system ....................................................................................................................... 52
8.8
6
30
8.7.1
Replacing front headlight completely (LED lighting unit) .............................................. 52
8.7.2
Replacing the front bulb holder (LED lighting unit) ....................................................... 54
8.7.3
Replacing the rear light completely (LED lighting unit) ................................................. 55
8.7.4
Replacing light bulbs in the front (Conventional lighting system) .................................. 56
8.7.5
Replacing the head lamps completely (conventional lighting system) .......................... 57
8.7.6
Replacing the headlight bracket (conventional lighting system) ................................... 59
8.7.7
Replacing the rear bulb (conventional lighting unit) ...................................................... 61
8.7.8
Replacing the complete tail light assembly (conventional lighting system)................... 62
8.7.9
Replacing the tail light bracket (conventional lighting system)...................................... 63
Front wheels ............................................................................................................................ 64
8.8.1
Repairing a flat tire in the front ...................................................................................... 64
8.8.2
Replacing the steering head bearings on the steering wheels ..................................... 64
8.8.3
Changing a front wheel (normal front wheel) ................................................................ 67
8.8.4
Changing a front wheel (suspended front wheel) ......................................................... 69
Invacare ® - Kite
8.9
Drive wheels ............................................................................................................................. 70
8.9.1
Replacing the drive wheel ............................................................................................. 70
8.9.2
Replacing a tyre or inner tube ....................................................................................... 71
8.9.2.1
Replacing puncture-protected tyres ......................................................................... 71
8.9.2.2
Replacing puncture-proof tyres ................................................................................ 73
8.9.3
8.10
SERVICE MANUAL
Replacing the drive wheel hub ...................................................................................... 74
Drive unit .................................................................................................................................. 75
8.10.1 Replacing the motor/transmission unit.......................................................................... 75
8.10.2 Replacing or rotating the motor / gearbox unit sealing ring .......................................... 77
8.10.3 Replacing the motor / gearbox coupling ....................................................................... 78
8.10.4 Replacing the carbon brushes ...................................................................................... 80
8.11
Replacing the rubber shock absorbers ................................................................................. 82
8.12
Replacing the tube frame ........................................................................................................ 84
8.13
Replacing the double bearing of the Dual Swing Technology (D.S.T.) .............................. 86
8.14
Replacing the battery boxes ................................................................................................... 88
8.15
Seat system .............................................................................................................................. 89
8.15.1 Replacing the tilt actuator ............................................................................................. 89
8.15.2 Replacing the tilt module............................................................................................... 91
8.15.3 Replacing the lifter / tilt module ..................................................................................... 93
8.16
Backrest unit ............................................................................................................................ 97
8.16.1 Replacing the standard backrest .................................................................................. 97
8.16.2 Replacing a standard backrest with quick release........................................................ 99
8.16.3 Replacing a Flex2 backrest ........................................................................................ 100
8.16.4 Adjusting backrest former ........................................................................................... 101
8.17
Seat system Modulite ............................................................................................................ 102
8.17.1 Replacing the tilt actuator ........................................................................................... 102
8.17.2 Replacing the lifter actuator ........................................................................................ 103
8.17.3 Replacing the lifter / seat angle adjustment module ................................................... 104
8.17.4 Replacing the backrest actuator ................................................................................. 107
8.18
Backrest Modulite .................................................................................................................. 108
8.18.1 Replacing the standard backrest ................................................................................ 108
8.18.2 Replacing the backrest mounting bracket .................................................................. 109
8.18.3 Replacing the backrest mounting bracket for SB 53 .................................................. 110
8.19
Adjusting the seat width/ backrest width (Modulite) ......................................................... 111
8.19.1 Adjusting the seat width .............................................................................................. 111
8.19.2 Adjusting the backrest width ....................................................................................... 113
8.19.3 Adjusting the Flex3 backrest....................................................................................... 115
7
Invacare ® - Kite
SERVICE MANUAL
9
Installing accessories
116
9.1
Replacing the holding strap ................................................................................................. 116
9.2
Replacing seat belts (Modulite seat) ................................................................................... 117
9.3
9.2.1
Installation on the backrest mounting bracket (simple backrest) ................................ 117
9.2.2
Installation on the backrest mounting bracket (adjustable seat) ................................. 118
9.2.3
Installation on the seat frame profile (adjustable seat) ............................................... 119
Operating hours counter ...................................................................................................... 120
9.3.1
Replacing the operating hours counter ....................................................................... 120
9.3.2
Replacing the connecting cable of the operating hours counter ................................. 122
9.4
Luggage carrier...................................................................................................................... 124
9.5
Further accessories............................................................................................................... 125
10 Adjusting the seating position
10.1
126
Adjusting the lower leg length and seat depth ................................................................... 127
10.1.1 Adjusting the lower leg length ..................................................................................... 127
10.1.2 Adjusting the seat depth ............................................................................................. 127
10.2
Adjusting the seat angle ....................................................................................................... 128
10.2.1 12° Adjusting the seat angle with Standard seat or Flex2 seat .................................. 129
10.2.2 20° Adjusting the seat angle Flex2 seat or Modulite seat ........................................... 131
10.3
Adjusting the center of gravity of the seat .......................................................................... 133
10.3.1 Standard seat.............................................................................................................. 137
10.3.2 Flex2 seat ................................................................................................................... 138
10.3.3 Modulite seat............................................................................................................... 141
8
10.3.3.1
Adjustable seats .................................................................................................... 143
10.3.3.2
Simple seat ............................................................................................................ 144
Invacare ® - Kite
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 shipping
·
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.
9
SERVICE MANUAL
1.3
Invacare ® - Kite
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.
10
Invacare ® - Kite
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.
11
SERVICE MANUAL
1.5
Invacare ® - Kite
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.
12
Invacare ® - Kite
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 jacking up, secure the vehicle by using chocks to block the wheels.
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!
13
SERVICE MANUAL
Invacare ® - Kite
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 electronics.
· Always carry out a trial run at the end of your work.
CAUTION!
Danger of injury and damage to property, if the maximum speed reduction on a
wheelchair with a lifter does not function correctly!
The wheelchair’s control unit must reduce the maximum possible speed as soon as the
lifter is raised.
· Test the maximum speed reduction for correct function after any maintenance work or
modifications to the wheelchair.
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.
CAUTION!
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!
14
Invacare ® - Kite
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.
15
SERVICE MANUAL
4
Layout of components and componentry
4.1
Overview
Under the rear cover:
1)
2)
3)
4)
G-Trac sensor
Power module
Lighting PCB
Actuator module
The electronic modules used are
described in Chapter 4.2.
Electric seat tilting:
1) Actuator motor
16
Invacare ® - Kite
Invacare ® - Kite
4.2
SERVICE MANUAL
Overview of the electronic modules (ACS 2 system)
Different electronic modules can be fitted to the mobility aid.
1
2
3
4
5
6
7
8
9
Battery plug
Lighting cable
Contact bridge
Lighting circuit board
Lighting according to German
Road Traffic Act (StVZO).
LED lighting
Extension cable
Actuator cable lifter
Extension cable
10
11
12
13
14
15
16
End position switch "lower
position"
End position switch "upper
position"
Remotes
ACS attendant control,
switchable
Bus cables
Bus cables
ACT
17
18
19
A
B
C
D
E
F
G
G-Trac sensor
Bus cables
Power module
To the motor M1
To the motor M2
To the tilt actuator
To the lifter actuator
To the lifter actuator
Actuator left legrest
Actuator right legrest
17
Invacare ® - Kite
SERVICE MANUAL
Before you connect mobility aid components such as actuators or motors, please begin by
ascertaining which module is installed. Please refer to the following table for an overview of ACS 2
modules.
Electronicmodule
Name
Description
ACS 2 70
ACS 2 70L
ACS 2 90L
ACS 2 90L G
See chapter
See chapter
See chapter
See chapter
4.2.1
4.2.1
4.2.1
4.2.2
ACS 2 wiith ACT actuator module See chapter 4.2.3
The actuator module is
optional.
Actuator module
ACT 2
ACT 4
18
See chapter 4.2.3.1
See chapter 4.2.3.2
The actuator module is
optional.
Lighting PCB
See chapter 4.2.4
The lighting PCB is optional.
G-Trac sensor
The G-Trac sensor is
optional.
Operation hour counter
The operation hour counter
is optional.
Invacare ® - Kite
4.2.1
SERVICE MANUAL
ACS 2 70 / ACS 2 70L / ACS 2 90L electronic module
Connections
1)
2)
3)
4)
5)
6)
Battery 24V
Bus cable (to remote or ACT)
Bus cable (to remote or ACT)
Motor M1
Light (optional)
Motor M2
Rubber stoppers for free slots
2) & 3)
4.2.2
Order number: 1552876
ACS 2 90LG electronic module
Connections
7) Battery 24V
8) Cable to G-Trac sensor (GYRO)
9) Bus cable (to remote or ACT)
10) Motor M1
11) Light
12) Motor M2
4.2.3
ACT actuator module
Different adjusting motors, also known as actuators, can be fitted to the mobility aid. These
actuators are either connected directly to the power module or to a separate actuator module. The
actuator module is connected to the power module via a bus cable.
4.2.3.1
ACT 2 actuator module
Connections
1)
2)
3)
4)
5)
ACI*
Bus cable (ACT or power module)
Bus cable (ACT or power module)
Actuator - Channel 2
Actuator - Channel 1
Rubber stoppers for free slots
1)
Order number: 1555701
2) & 3) Order number: 1552876
4) & 5) Order number: 1555700
* The ACI connection is used for actuator limitation or speed reduction.
19
SERVICE MANUAL
4.2.3.2
ACT 4 actuator module
Connections
1)
2)
3)
4)
5)
6)
7)
ACI*
Bus cable (ACT or power module)
Bus cable (ACT or power module)
Actuator - Channel 4
Actuator - Channel 3
Actuator - Channel 2
Actuator - Channel 1
Rubber stoppers for free slots
1)
Order number: 1555701
2) & 3) Order number: 1552876
4) to 7) Order number: 1555700
* The ACI connection is used for actuator limitation or speed reduction.
4.2.4
Lighting PCB
Connections
1)
2)
3)
4)
5)
Driving light & l.h. indicator 1
Driving light & l.h. indicator 2
Power module
Driving light & r.h. indicator 1
Driving light & r.h. indicator 2
The lighting PCB connections are printed directly on the circuit board.
20
Invacare ® - Kite
Invacare ® - Kite
5
SERVICE MANUAL
Service plan (1x annually)
CAUTION!
Danger of injury and damage to property, if the maximum speed reduction on a
wheelchair with a lifter does not function correctly!
The wheelchair’s control unit must reduce the maximum possible speed as soon as the
lifter is raised.
· Test the maximum speed reduction for correct function after any maintenance work or
modifications to the wheelchair.
Component
Check
Remedy
Armrests
· Damage to armrests
· Replace covering
if damaged
· Armrest fixings
· Tighten screws
· Damage to side
panels
· Replace side
panels if damaged
· Side panel fixings
· Tighten screws
Seat lock
· Seat lock defective
· Replace seat lock
Seat angle
adjustment
· Tight seating of SL
fuses
· Replace SL fuses
if necessary
· Damage to backrest
· Replace parts if
damaged
Side panels
Power backrest
(if fitted)
· Seams
· Fixing
· Check cable
Notes
ü
· Tighten screws
· Replace cable
motor if necessary
· Check function
Frames
(chassis) /
battery
mounting
· Check fixings,
welded seams and
battery mounting
· Check drive wheels
Wheel
for tight fit and side
suspension and
play
wheels
Drive units,
coupling
mechanism
· Tighten screws
· Replace
components if
necessary
· Adjust, replace
wheel hubs
See chapter 8.9.3.
· Check steering
wheels for tight fit,
float and side play
· Replace wheels,
wheel fork or
wheel bearings
See chapter 8.8.2
· Pneumatic tyres (if
fitted)
· Repair or replace
if damaged
See chapter 8.9.2.
· Check functions in
drive and push
modes
· Replace motor if
necessary.
· Check coupling
mechanism
· Tighten
screws/nuts,
adjust or replace if
necessary
21
Invacare ® - Kite
SERVICE MANUAL
Component
Legrests
Power legrests
(if fitted)
Check
Remedy
· Check welded
seams, interlocking,
screws, footplates
· Tighten, replace if
necessary
· Check cable
· Replace cable if
necessary
· Check contacts
Notes
· check functions
Lighting (if
fitted)
Batteries
Remote /
electronic
module
· Check cable
· Check function
· Replace lamp or
cable if necessary
· Check batteries for
damage
· Replace batteries
if necessary
See chapter 8.4.
· Check battery
voltage
· Charge batteries
See operating
manual
· Check contacts and
terminals
· Clean contacts
and terminals
Please refer to the
safety information
in Chapter 8.4 for
handling batteries
· Remote, status
display blinking
· Evaluate
error/blink code
· Fixings
· Tighten fixings,
replace if
necessary
· Cables and
connecting plugs
· Tighten cables
and connecting
plugs, replace if
necessary
· Drive lever function
· Replace drive
lever if necessary
· Replace remote if
necessary
Drive program
22
· Power supply
· Tighten cables
and connecting
plugs, replace if
necessary
· Check drive
electronics program
version
· Update software if
newer version
available.
See chapter 8.3.
ü
Invacare ® - Kite
6
SERVICE MANUAL
Operational faults
Different power modules can be installed in the mobility aid in connection with different remotes.
The rectification of operational faults depends on the installed power module in each case.
The power modules used are described in 4.2.
Note
The tables for rectification of operational faults listed in the following chapters are only an excerpt
from the original manufacturer's manuals.
You can obtain the original manuals from Invacare®.
If you have problems with the mobility aid, please proceed as follows:
· First assess the possible cause of the problem using the following table.
· Check the remote status display. Evaluate the error code.
· Carry out the necessary checks and repairs as recommended in the following table.
6.1
Drive fault diagnosis
PROBLEM
OTHER
SYMPTOMS
POSSIBLE
CAUSE
SOLUTION
Documentation
Mobility
device will
not start
The remote
status display
illuminates
normally and
does not show
an error code.
Drive motors
disengaged
Engage drive
motors
See operating manual
Remote status
display does
not illuminate
Batteries
defective
Replace batteries
See chapter 8.4.
Completely
discharge
battery
Pre-charge
batteries
See operating manual
Power supply
to remote
interrupted
Check master
fuse
See chapter 8.5.
Check cables
between the
modules for loose
connections and
damage
See chapter 8.6.
Remote
defective
Replace remote
See chapter 8.2.5.
Various
causes
Assess error code
See chapter 6.2.
Remote status
display blinking
23
Invacare ® - Kite
SERVICE MANUAL
PROBLEM
OTHER
SYMPTOMS
POSSIBLE
CAUSE
SOLUTION
Documentation
Mobility
device
judders in
drive mode
None
Batteries
defective
(unstable
voltage)
Replace batteries
See chapter 8.4.
Drive motor(s)
defective
Replace motor(s)
See chapter 8.10.1.
Replace carbon
brushes
See chapter 8.10.4.
Batteries
not being
charged
Mobility
device runs
too slowly
Electrical
actuator
does not
respond
None
Batteries
defective
Replace batteries
See chapter 8.4.
LEDs blinking
on charging
unit
Charging unit
defective
Replace charging
unit
See charging unit
operating manual
None
Remote
defective
Replace remote
See chapter 8.2.5.
Batteries
defective
Replace batteries
See chapter 8.4.
Remote
displays
flashing "E",
status diode
on
light/actuator
module does
not extinguish
even if the
remote is shut
down or
disconnected
Lighting/actuat
or module
faulty
Replace
lighting/actuator
module
See chapter 8.1.5.
None
Cable
disconnected
or damaged
Ensure correct
cable
connection,
replace cable if
necessary
See chapter 8.6.
Electrical
actuator faulty
Check actuator
See chapter 7.3.
Remote faulty
24
Replacing the
remote
See chapter 8.2.5.
Invacare ® - Kite
6.2
SERVICE MANUAL
ACS2 remotes: Error codes and diagnostic codes
The drive electronics can automatically rectify some faults. In this case the status display will stop
blinking. Switch the remote on and off again several times. Wait around 5 seconds each time
before switching the remote on again. If this does not rectify the fault, determine the cause using
the blink codes from the following table.
BLINK CODE
POSSIBLE CAUSE
SOLUTION
DOCUMENTATION
1 x blink
Module defective
Replace defective module
See chapter 8.1.5.
2 x blink
Accessory error (for
Check accessory
example short circuit in the connections, check
actuator)
accessory
See chapter 7.3.
Lifter too high or too low
(seat not at driving height)
If the lifter is raised, lower it See operating manual
slowly until the status
display stops blinking. If the
lifter is too low, raise it
slowly until the status
display stops blinking. Only
drive when the seat is at
driving height.
3 x blink
Error in motor M1
Connection loose/faulty or
motor faulty
Check connection plug,
check motor
See chapters 8.6 and
7.1
4 x blink
Error in motor M2
Connection loose/faulty or
motor faulty
Check connection plug,
check motor
See chapters 8.6 and
7.1
5 x blink
Fault/brake fault in motor
M1. Connection loose or
faulty or motor faulty
Check connection plug,
check motor
See chapters 8.6 and
7.1
6 x blink
Fault/brake fault in motor
M2. Connection loose or
faulty or motor faulty
Check connection plug,
check motor
See chapters 8.6 and
7.1
7 x blink
Completely discharge
battery
Pre-charge battery
See operating manual
8 x blink
Battery voltage too high
Switch lighting to low
battery voltage
See charging unit
operating manual
Check battery charger
9 or 10 x blink
Faulty data transmission
between modules
Remove electronic modules See chapter 8.1.5.
except for the power
module and the remote.
Replace the modules one
after another in order to
ensure which was the one
causing the fault.
11 x blink
Drive motors overloaded /
overheated
Switch remote on and off /
wait if necessary
-
12 x blink
Compatibility problems
between modules
Remove incorrect module
See chapter 8.1.5.
25
SERVICE MANUAL
7
Test procedures
7.1
Testing the motor
Invacare ® - Kite
Requirements:
· digital multimeter with resistance measurement
·
Use the remote to identify which motor is possibly defective, as described in chapter 6.2.
·
Switch the electronics OFF on the remote.
·
Remove the rear cover, as described in chapter 8.1.1.
·
Take exact note of the positions of all cables and the sockets that they are connected to. Mark
the connectors and sockets or take a photograph with a digital camera.
·
Disconnect the motor plug (1) of the motor to be tested from the power module.
·
Connect the digital multimeter to the motor plug contacts (3) and measure the resistance
between the contacts.
Note
A resistance of between 0.5 and 5 ohms indicates a motor ready for operation.
A resistance of between 15 ohms and infinity indicates a defective motor. High resistances are
normally caused by bad connections or worn carbon brushes.
26
Invacare ® - Kite
7.2
SERVICE MANUAL
Testing the electro-mechanical parking brake
Note
This test should only be carried out on mobility aids with conventional motor/transmission units.
CAUTION!
Material damage can be caused to the electronic module due to short-circuits in the
electro-mechanical brake.
· NEVER connect an electro-mechanical brake to an intact electronic module with a short-circuit!
· Always replace short-circuited brakes immediately.
Note
A defective motor can damage the power module, but a defective power module cannot camage
the motor.
Requirements:
· digital multimeter with resistance measurement
·
Use the remote to identify which motor is possibly defective, as described in chapter 6.2.
·
Switch the electronics OFF on the remote.
·
Remove the rear cover, as described in chapter 8.1.1.
·
Take exact note of the positions of all cables and the sockets that they are connected to. Mark
the connectors and sockets or take a photograph with a digital camera.
·
Disconnect the motor plug (1) of the motor to be tested from the power module.
27
SERVICE MANUAL
Invacare ® - Kite
·
Connect the digital multimeter to the adjacent central motor plug contacts (3) and measure the
resistance between the contacts.
·
If there is a defect, replace the motor and send it to Invacare® Service for inspection or repair.
Note
A resistance of between 40 and 80 ohms indicates an intact brake.
A resistance of 0 ohms or a very high resistance (mega-ohms or infinity) indicates a short-circuit,
a bad connection or a defective brake.
28
Invacare ® - Kite
7.3
SERVICE MANUAL
Checking an actuator
Requirements:
· digital multimeter with resistance measurement
·
Switch the electronics OFF on the remote.
·
Remove the rear cover, as described in chapter 8.1.1.
·
Take exact note of the positions of all cables and the sockets that they are connected to. Mark
the connectors and sockets or take a photograph with a digital camera.
Disconnect the motor plug (1) of the motor to be tested from the actuator module.
·
Check the electrical resistance at the
plug (1) of the actuator.
The plug can have a different shape than
show in the illustration.
·
If the resistance is close to infinity, the motor
is probably burnt out.
·
If the resistance is below 1 W, the motor has
a short-circuit.
·
The motor must be replaced in both cases.
29
SERVICE MANUAL
8
Invacare ® - Kite
Repair work
CAUTION!
Danger of injury and damage to property, if the maximum speed reduction on a
wheelchair with a lifter does not function correctly!
The wheelchair’s control unit must reduce the maximum possible speed as soon as the
lifter is raised.
· Test the maximum speed reduction for correct function after any maintenance work or
modifications to the wheelchair.
8.1
Covers
8.1.1
Rear cover
Removing the rear cover:
·
Loosen and remove the left and right thumbscrews (1) on the rear cover (2).
·
Carefully pull the rear cover backwards and off.
·
On models with LED lighting system (tail lights in the rear cover):
Pull both of the tail light plugs off of the lighting circuit board.
Assembling the rear cover:
30
·
On models with LED lighting system:
Plug both of the tail light plugs back into the lighting circuit board.
·
Push the rear cover over the battery box from the back. Pay attention to the electrical cables
while doing so.
·
Tighten both thumbscrews hand-tight.
Invacare ® - Kite
8.1.2
SERVICE MANUAL
Middle cover
Removing the middle cover:
·
Remove the rear cover, as described in chapter 8.1.1.
·
Loosen the two thumbscrews (1) on the left and right sides of the wheelchair.
·
Pull the cover towards the rear and out of the wheelchair.
Assembling the middle cover:
·
Push the cover into the wheelchair from the rear.
·
Make sure that the cables that run from the battery box to the seat are lying in the recesses
provided on the front edge of the cover.
·
Tighten both thumbscrews hand-tight.
31
SERVICE MANUAL
8.1.3
Side cover
Requirements:
· 4 mm Allen wrench
Removing the side cover:
·
Use a 4 mm Allen wrench to loosen the hexagon socket head screw (1).
·
Remove the cover (2).
Installing the side cover:
·
32
Assemble the parts in reverse order.
Invacare ® - Kite
Invacare ® - Kite
8.1.4
SERVICE MANUAL
Front cover
Requirements:
· 4 mm Allen wrench
· 5 mm Allen wrench
· 10 mm Allen wrench
· 11 mm socket wrench
· 13 mm socket wrench
· 13 mm open-ended wrench
· 19 mm open-ended wrench
· 36 mm open-ended wrench
· 24 mm box wrench
· torque wrench 20 – 200 Nm
· wooden blocks
Removing the front cover:
·
Disassemble the double bearing of the Dual Swing Technology (D.S.T.), as described in
chapter 8.13.
·
Use a 4 mm Allen wrench to loosen both hexagon socket head screws.
·
Remove both hexagon socket head screws, including the washers.
·
Remove the cover (2) towards the front.
·
Replace the cover.
Installing the front cover:
·
Assemble the parts in reverse order.
33
SERVICE MANUAL
8.1.5
Invacare ® - Kite
Replacing a front splash guard
ATTENTION: Danger of crushing to the hands and feet by the weight of the wheelchair!
· Pay attention to the hand and feet.
· Use proper lifting techniques.
Danger of injury due to uncontrolled movement of the wheelchair!
· Switch the vehicle's power system off (ON-/OFF key).
· Engage the drive motors.
· Secure the vehicle against rolling away by placing wedges under the wheels.
Requirements:
· 4 mm Allen wrench
· 24 mm socket wrench
· 24 mm open-ended wrench
· Flat screwdriver
· Oblong wooden blocks, at least 14 x 14 x 30 cm
· Medium strength thread locking adhesive, for example Loctite 243
· Heat gun
·
Lift the wheelchair on one side and place a 14 cm high wooden block underneath it so that the
front wheel is off the ground and can rotate freely. Use proper lifting techniques.
·
Remove the front wheel, as described in chapter 8.8.3.
Removing the splash guard:
·
Loosen and remove the four hexagon socket head screws (2) together with the washers.
·
Replace the splash guard (1).
Installing a splash guard:
·
34
Assemble the parts in reverse order.
Invacare ® - Kite
8.1.6
SERVICE MANUAL
Replacing the splash guard
Requirements:
· 6 mm Allen key
Note
Different splash guards have to be fitted depending on the depth of the seat, the width of the seat
and the seat support plates used.
Removing the splash guard:
·
Loosen and remove the two Allen screws (2) incl. the washers.
·
Remove the splash guard (1) from the transmission mounting. (3)
·
Replace the splash guard.
Refitting the splash guard:
·
Refit the parts in reverse order.
35
SERVICE MANUAL
8.2
Electronic modules
8.2.1
Replacing the power module
Invacare ® - Kite
Note
When replacing the power module in connection with a remote, please take the final selection of
the drive program into account as described in chapter 8.2.6.
Different power modules in connection with different remotes can be fitted to the mobility aid. The
possible power modules are described in chapter 4.2.
Replacement is described in the following section based on the example of a mobility aid with an
optional lighting PCB and an optional actuator module.
CAUTION!
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!
Note
All power modules are delivered with a standard drive program. If you have made any customerspecific modifications to the drive program, these must be adapted after the installation of the new
power module.
Requirements:
· 8 mm socket spanner
· To adapt the drive program:
programming software or hand programming device and system installation manual, available
from Invacare®.
Removing the power module:
36
·
Switch the electronics OFF on the remote.
·
Remove the rear cover, as described in chapter 8.1.1.
·
Take exact note of the positions of all cables and the sockets that they are connected to. Mark
the connectors and sockets or take a photograph with a digital camera.
Invacare ® - Kite
SERVICE MANUAL
·
Disconnect the plugs (1) from the power module (3) and from the actuator module (4).
·
Use the 8 mm socket wrench to loosen both nuts (2).
·
Pull the actuator module with the holder towards the rear and off of the guides.
·
Pull the power module towards the rear and off of the guides.
·
Replace the power module.
Installing the power module:
·
Assemble the parts in reverse order.
·
Reconnect all cable connectors to their former positions.
·
Plug all free slots with a suitable rubber stopper, see chapter 4.2.
·
Select the driving program, as described in chapter 8.2.6.
·
Update the driving program if a new software version is available, as described in chapter 8.3.
·
Modify the driving program using the programming software as needed.
·
The last step is to test all functions of the vehicle.
37
SERVICE MANUAL
8.2.2
Invacare ® - Kite
Replacing the actuator module
Requirements:
· 7 mm socket wrench
· Phillips screwdriver, size 2
Removing the actuator module:
·
Switch the electronics OFF on the remote.
·
Remove the rear cover, as described in chapter 8.1.1.
·
Take exact note of the positions of all cables and the sockets that they are connected to. Mark
the connectors and sockets or take a photograph with a digital camera.
·
Disconnect the plugs (3) from the actuator module (2).
·
Loosen both screws (1) with a Phillips screwdriver.
·
Replace the actuator module.
Installing the actuator module:
38
·
Assemble the parts in reverse order.
·
Reconnect all cable connectors to their former positions.
·
Plug all free slots with a suitable rubber stopper, see chapter 4.2.
·
The last step is to test all functions of the vehicle.
Invacare ® - Kite
8.2.3
SERVICE MANUAL
Replacing the G-Trac sensor
Requirements:
· 10 mm open-ended wrench
Uninstalling the G-Trac sensor:
·
Switch the electronics OFF on the remote.
·
Remove the rear cover, as described in chapter 8.1.1.
·
Take exact note of the positions of all cables and the sockets that they are connected to. Mark
the connectors and sockets or take a photograph with a digital camera.
·
Disconnect the plug (3) of the G-Trac sensor (1) from the power module. (2).
·
Loosen the M6 nut (4) and push the G-Trac sensor upwards.
·
Pull the G-Trac sensor backward and out.
·
Replace the G-Trac sensor.
Installing the G-Trac sensor:
·
Insert the square-end piece into the slot provided for this purpose.
·
When installing the G-Trac sensor, make sure it is positioned exactly vertical.
·
Reconnect all cable connectors to their former positions.
·
The last step is to test all functions of the vehicle.
39
SERVICE MANUAL
8.2.4
Invacare ® - Kite
Replacing the lighting circuit board
Requirements:
· 8 mm open-ended wrench
· Phillips screwdriver, size 2
Uninstalling the lighting circuit board:
·
Switch the electronics OFF on the remote.
·
Remove the rear cover, as described in chapter 8.1.1.
·
Take exact note of the positions of all cables and the sockets that they are connected to. Mark
the connectors and sockets or take a photograph with a digital camera.
·
Disconnect the plug (2) from the lighting circuit board (1).
·
Loosen and remove both screws on the lighting circuit board (3).
·
Replace the lighting circuit board.
Installing the lighting circuit board:
40
·
Assemble the parts in reverse order.
·
Reconnect all cable connectors to their former positions.
·
The last step is to test all functions of the vehicle.
Invacare ® - Kite
8.2.5
SERVICE MANUAL
Replace remote
Note
Replacing the remote is very easy and is not described in detail.
However, when replacing a remote in connection with the power module, please take the final
selection of the drive program into account as described in chapter 8.2.6.
Special instructions for replacing the REM24 remote
Requirements:
· To modify a drive programme you will need:
Programming software or a hand-held programming device and the installation manual,
available from Invacare®.
Note
All electronic modules are supplied with a standard drive programme. If you have performed
customer-specific modifications to the drive programme, then these will need to be recreated
manually after installing the new electronic module.
WARNING!
Every alteration to the drive programme can influence vehicle handling and the tipping
stability of the wheelchair!
· Alterations to the drive programme must only be carried out by authorised Invacare® dealers!
· Invacare® can only assume a warranty for the safe vehicle handling of the wheelchair – in
particular tipping stability - for this standard, unaltered drive programme!
41
SERVICE MANUAL
8.2.6
Invacare ® - Kite
Drive program selection after component replacement
The drive program is saved in the remote and in the power module. If one of these two components
is replaced, the system must be told which of the components has not been replaced so that it
knows which contains the current controller profile.
Note
The system allows normal usage of the mobility aid after component replacement only if the
profile is selected afterwards.
8.2.6.1
Profile selection with remote REM A or REM B
·
Insert the plug into the remote or into the power module respectively.
·
Switch the remote on.
·
LEDs (1) and (4) blink.
·
Use the bottom rocker switch (5) to select where the required controller profile is saved.
LED 1 = power module
LED 4 = remote
Only LED (1) or (4) blinks now depending on the selection.
·
Press the "Horn“ (2) and "+“ (3) buttons on the speed selection and hold them down for 3
seconds to confirm the selection.
The system will switch itself off and restart automatically. In the process, the selected profile is
saved in the remote and in the power module.
42
Invacare ® - Kite
8.2.6.2
SERVICE MANUAL
Profile selection with remote REM 550
·
Insert the plug into the remote or into the power module respectively.
·
Switch the remote on.
The display (2) shows that you need to select a profile.
·
Use the bottom rocker switch (3) to select where the required controller profile is saved.
I = remote
II = power module
The display shows which profile you have selected.
·
Press the "Horn“ (4) and "+“ (1) buttons on the speed selection and hold them down for 3
seconds to confirm the selection.
The system will switch itself off and restart automatically. In the process, the selected profile is
saved in the remote and in the power module.
43
SERVICE MANUAL
8.3
Invacare ® - Kite
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, after installing the new driving
program. This also applies to the customer-specific options of the seat setting for ACS 2 remotes,
which are activated ex works.
WARNING: Every alteration to the drive program can influence vehicle handling and the
tipping stability of the wheelchair!
· Alterations to the drive program must only be carried out by trained Invacare®-dealers!
· 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:
· Dynamic® Wizard software
· User manual for the 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/.
Note
When an electrical adjustment option is retrofitted, such as electrical legrests, then this option
needs to be activated in the driving program as well if you have an ACS 2 remote. For more
information, refer to the user manual of the Wizard software and the installation instructions for
the electronic modules
44
Invacare ® - Kite
8.4
Batteries
8.4.1
Removing the batteries
SERVICE MANUAL
ATTENTION:
Injury hazard and possible material damages if batteries are handled improperly!
· The installation of new batteries may only be carried out by authorised specialists.
· Observe the warning information on the batteries.
· Only use battery versions stated in the specifications.
ATTENTION:
Fire and burns hazard if battery terminal is bypassed!
· Please take great care to ensure that the battery terminals are never short-circuited with tools
or mechanical mobility device parts!
· Ensure that the battery terminal caps have been replaced if you are not working on the battery
terminals.
ATTENTION: Danger of crushing!
The batteries are extremely heavy. This results in injury hazards to your hands.
· Bear in mind that the batteries are sometimes very heavy!
· Please handle the batteries with care.
WARNING: BURN HAZARD!
Injury hazard due to discharged acid.
· Always wear acid-proof protective gloves when handling batteries.
· Always wear protective goggles when handling batteries.
What to do if acid is discharged:
· Always take clothing which has been soiled by or dipped in acid off immediately!
· Rinse any areas of your skin which has come into contact with battery acid off immediately
with plenty of water!
If contact with eyes is made:
· Rinse the affected eye under running water for several minutes! You should also consult an
eye specialist immediately afterwards!
Requirements:
· 11 mm socket wrench
Uninstalling the batteries:
·
Switch the electronics OFF on the remote.
·
Remove the rear cover, as described in chapter 8.1.1.
45
SERVICE MANUAL
46
·
Disconnect the battery cable from the electronic module.
·
Loosen and remove both of the knurled head screws (4).
·
Loosen and remove the knurled head screws (2).
·
Turn the rear cover (1) down along with the electronic modules.
·
Pull foam rubber block (3) backwards out of the battery box.
Invacare ® - Kite
Invacare ® - Kite
SERVICE MANUAL
·
Pull the rubber caps (2) off of both battery terminals (1).
·
Use the 11 mm socket wrench to loosen and remove the battery terminal screws.
·
Remove the battery cable.
·
Pull the battery (3) out onto the rear cover by its belt (4).
·
Remove the battery.
·
Pull the second battery towards you by its belt and repeat the previous steps.
Installing batteries:
·
Install the batteries in reverse order.
·
Make sure the battery box sockets and plugs are correctly installed. A diagram showing how to
connect the battery terminals correctly can be found in the rear cover.
47
SERVICE MANUAL
8.4.2
Invacare ® - Kite
Correct handling of damaged batteries
WARNING: BURN HAZARD!
Injury hazard due to discharged acid.
· Always wear acid-proof protective gloves when handling batteries.
· Always wear protective goggles when handling batteries.
What to do if acid is discharged:
· Always take clothing which has been soiled by or dipped in acid off immediately!
· Rinse any areas of your skin which has come into contact with battery acid off immediately
with plenty of water!
If contact with eyes is made:
· Rinse the affected eye under running water for several minutes! You should also consult an
eye specialist immediately afterwards!
Requirements:
· protective goggles
· acid-proof gloves
· acid-proof transport container
·
If handling damaged batteries, always wear suitable protective clothing.
·
Always deposit damaged batteries in suitable acid-proof containers immediately after removal.
·
Only transport damaged batteries in suitable acid-proof containers.
·
Always wash any objects which were contacted by acid in plenty of fresh water.
Always dispose of used or damaged batteries correctly
Used and damaged batteries will be taken back by your medical equipment supplier or
Invacare®.
48
Invacare ® - Kite
8.5
SERVICE MANUAL
Checking and replacing the main fuse
CAUTION: Fire hazard!
· Always use an original strip fuse with the approved amperage.
· If the main fuse has blown, first rectify the cause before fitting a new one.
CAUTION: Fire hazard!
Fitting the incorrect strip fuse causes a fire hazard!
· Only fix the strip fuses in the sequence shown in the image on the right!
· Tighten the nuts with 3.3 or 3.5 Nm!
· 1. Strip fuse
· 2. Spade
terminal
· 3. DIN 6923 nut
Requirements:
· 8 mm socket wrench
· 11 mm socket wrench
· 80 A strip fuse
Note
If the fuseholder is damaged, you can replace this complete with the battery cables.
Dismantling the main fuse:
·
Switch the electronics OFF on the remote.
·
Remove the rear battery, as described in chapter 8.4.
·
The fuse holder is located on top of the rear battery.
·
Open the fuseholder cover.
·
You see the strip fuses (2) once the fuse holder (1) is open.
·
If the strip fuse has blown, you must first ascertain and rectify the cause of the fault.
49
SERVICE MANUAL
·
The main fuse may only be replaced once the fault has been rectified.
·
Remove the strip fuse nuts (3) with an 8 mm socket spanner.
·
Replace the strip fuse.
Fitting the main fuse:
50
·
Refit all the parts again in reverse order.
·
To conclude, check all the mobility aid functions.
Invacare ® - Kite
Invacare ® - Kite
8.6
SERVICE MANUAL
Checking the cables
·
Switch the electronics OFF on the remote.
·
Remove the rear cover, as described in chapter 8.1.1.
·
Check all cables for visible damage, crushing points or abrasion points.
·
Replace damaged cables.
·
Pull on each plug carefully. The plug must not come out of its socket when pulled on lightly.
·
If a plug is loose, apply slight pressure to push the plug into the socket. The plug must snap in
place securely.
·
Check that the plug is firmly attached to its socket.
·
Remove the batteries, as described in chapter 8.4.
·
Check the battery cables for visible damage, crushing points or abrasion points.
·
Replace damaged cables.
·
Assemble all parts again in reverse order.
·
The last step is to test all functions of the vehicle.
51
SERVICE MANUAL
8.7
Lighting system
8.7.1
Replacing front headlight completely (LED lighting unit)
Invacare ® - Kite
Note
Replacing an individual LED is not possible. If there is a defect, replace the entire front headlight.
Requirements:
· Jaw spanner 7 mm
· Allen key 3 mm
· oblique pliers
· cable binder
Uninstalling head lamps:
52
·
Switch the electronics OFF on the remote.
·
Remove the rear and the middle covers, as described in chapter 8.1.1 und 8.1.2.
·
Take exact note of the positions of all cables and the sockets that they are connected to. Mark
the connectors and sockets or take a photograph with a digital camera.
·
Disconnect the plug (2) of the appropriate headlight from the lighting circuit board (1).
·
Pull the headlight cable out of the wheelchair. If necessary, also remove the cable ties.
Invacare ® - Kite
·
Remove the front headlight plug from the lighting PCB.
·
Free the cable or remove any cable ties.
·
Loosen the nut (2) with a 7 mm jaw spanner and a 3 mm Allen key.
·
Remove the front headlight (1) from the lamp holder (3).
·
Reassembly takes place in the reverse order.
·
To complete, check all vehicle functions.
SERVICE MANUAL
53
SERVICE MANUAL
8.7.2
Invacare ® - Kite
Replacing the front bulb holder (LED lighting unit)
Requirements:
· Jaw spanner 7 mm
· Allen key 3 mm
· TX25 torx screwdriver
· oblique pliers
· cable binder
54
·
Loosen the nut (2) with a 7 mm jaw spanner and a 3 mm Allen key and remove.
·
Remove the front headlight (1) from the lamp holder (3) and place it carefully to the side.
·
Undo and remove the two screws (4) with a TX25 torx screwdriver.
·
Replace the lamp holder (3).
·
Reassembly takes place in the reverse order.
·
To complete, check all vehicle functions.
Invacare ® - Kite
8.7.3
SERVICE MANUAL
Replacing the rear light completely (LED lighting unit)
Note
Replacing an individual LED is not possible. If there is a defect, replace the entire rear light.
Uninstalling the tail light:
·
Switch the electronics OFF on the remote.
·
Remove the rear cover, as described in chapter 8.1.1.
·
Press the clips of the tail light lens (1) together slightly
·
Pull the tail light lens carefully off of the rear cover (4).
·
Disconnect the plug of the tail light (2) and of the turn signal (3) from the tail light cable (5).
·
Press the clips of the tail light lens or the turn signal together slightly.
·
Pull the corresponding light towards the rear and out of the rear cover.
·
Replace the faulty part.
Installing the tail light:
·
Re-assembly is done in reverse order.
·
Pay attention to markings on the plugs of the tail light cable, of the tail light and of the turn
signal.
·
Test all functions of the vehicle.
55
SERVICE MANUAL
8.7.4
Invacare ® - Kite
Replacing light bulbs in the front (Conventional lighting system)
Requirements:
· Phillips screwdriver size 2
56
·
Loosen the concealed Phillips head screw (1) on the back of the head lamp / turn indicator
combination.
·
Remove the transparent plastic cover.
·
Replace the defective light bulb.
·
Reposition the cap and tighten the Phillips head screw hand-tight.
Invacare ® - Kite
8.7.5
SERVICE MANUAL
Replacing the head lamps completely (conventional lighting system)
Requirements:
· Phillips screwdriver size 2
· Side cutting pliers
· Cable ties
Uninstalling head lamps:
·
Switch the electronics OFF on the remote.
·
Remove the rear and the middle covers, as described in chapter 8.1.1 und 8.1.2.
·
Take exact note of the positions of all cables and the sockets that they are connected to. Mark
the connectors and sockets or take a photograph with a digital camera.
·
Disconnect the plug (2) of the appropriate headlight from the lighting circuit board (1).
·
Pull the headlight cable out of the wheelchair. If necessary, also remove the cable ties.
57
SERVICE MANUAL
·
Loosen both Phillips screws (1).
·
Detach the headlight from its holding bracket.
·
Replace the headlight.
Invacare ® - Kite
Installing headlights:
58
·
Assemble all parts again in reverse order.
·
Install the cables carefully and secure them with cable ties.
·
Tighten the screws hand-tight.
·
Check all vehicle functions.
·
Perform an approximate adjustment of the headlight using the ratchet plate as a guide. The
final adjustment can be performed by the user according to the instructions found in the User
Guide.
Invacare ® - Kite
8.7.6
SERVICE MANUAL
Replacing the headlight bracket (conventional lighting system)
Requirements:
· TX25 Torx wrench
· Phillips screwdriver size 2
If the headlight does not need to be replaced:
·
Loosen both Phillips screws (1).
·
Detach the headlight (2) from its holder.
·
Carefully put the headlight aside on its cable.
If the headlight does need to be replaced:
·
Remove the headlight, as described in chapter 8.7.5.
59
SERVICE MANUAL
Uninstalling the headlight bracket:
·
Loosen both Torx screws (2).
·
Remove the headlight bracket (1).
·
Replace the bracket.
Installing the headlight bracket:
60
·
Assemble all parts again in reverse order.
·
Tighten the screws hand-tight.
·
Check all vehicle functions.
Invacare ® - Kite
Invacare ® - Kite
8.7.7
SERVICE MANUAL
Replacing the rear bulb (conventional lighting unit)
Requirements:
· Phillips screwdriver size 2
·
Undo the Phillips screw in the transparent cover over the rear light/indicator combination.
·
Remove the transparent plastic cover.
·
Replace the defective bulb.
·
Close the cover and tighten the Phillips screw finger-tight.
61
SERVICE MANUAL
8.7.8
Invacare ® - Kite
Replacing the complete tail light assembly (conventional lighting system)
Requirements:
· 8 mm socket wrench
Uninstalling the tail light:
·
Switch the electronics OFF on the remote.
·
Remove the rear cover, as described in chapter 8.1.1.
·
Take exact note of the positions of all cables and the sockets that they are connected to. Mark
the connectors and sockets or take a photograph with a digital camera.
·
Disconnect the cable of the affected tail light from the lighting circuit board.
·
Remove both plastic covers (1).
·
Use the 8 mm socket wrench to loosen both nuts (2).
·
Remove the nut and the washers (3).
·
Pull the tail light (5) towards the rear and off and remove both bushings (4).
Installing the tail light:
62
·
Assemble all parts again in reverse order.
·
Tighten the screws hand-tight.
·
Check all vehicle functions.
Invacare ® - Kite
8.7.9
SERVICE MANUAL
Replacing the tail light bracket (conventional lighting system)
Requirements:
· Phillips screwdriver size 2
· 8 mm socket wrench
· 4 mm Allen wrench
· 5 mm Allen wrench
Uninstalling the tail light bracket:
·
Remove the complete tail light, as described in chapter 8.7.8.
·
Loosen the screw on the seat frame that goes through the drill hole of the light bracket, using a
5 mm Allen wrench.
·
Remove the hexagon socket head screw. Pay attention to the distance washer (1).
·
Use a 4 mm Allen wrench to loosen the hexagon socket head screw (6).
·
Remove the hexagon socket head screw. Pay attention to the distance washer (5) and the
distance tube (3).
·
Replace the lamp bracket (4).
Installing the headlight bracket:
·
Assemble all parts again in reverse order.
·
Check all vehicle functions.
63
SERVICE MANUAL
8.8
Front wheels
8.8.1
Repairing a flat tire in the front
·
8.8.2
Invacare ® - Kite
Repair the flat tire as described in the user manual supplied with the wheel chair.
Replacing the steering head bearings on the steering wheels
ATTENTION: Danger of crushing to the hands and feet by the weight of the wheelchair!
· Pay attention to the hand and feet.
· Use proper lifting techniques.
Danger of injury due to uncontrolled movement of the wheelchair!
· Switch the vehicle's power system off (ON-/OFF key).
· Engage the drive motors.
· Secure the vehicle against rolling away by placing wedges under the wheels.
CAUTION!
Incorrect reassembly can damage the bearings and cause the steering wheels to fall out!
The single-row angular ball bearing rings are not identical on both sides! There is only one correct
way to insert them!
· Follow the assembly instructions precisely!
Requirements:
· open-ended spanner, 19 mm
· Torque wrench
· large screwdriver, flat
· wooden block (approx.12 x 12x 30 cm for propping up vehicle)
Note
When disassembling, take care of small parts such as screws and washers. Put all small parts
down so that they can be reassembled in the right sequence.
64
·
Place the wooden block under the vehicle on the side on which the ball bearing is to be
replaced.
·
The wheel on the side where the bearing is to be replaced must have enough ground
clearance to enable it to be pulled out of the bearing.
·
Secure the vehicle against rolling away.
Invacare ® - Kite
·
Carefully remove the plastic cap (1) with the
large screwdriver.
·
Loosen the 19 mm nut (1) with the socket
spanner and remove it. Hold the wheel so
that it does not rotate when the nut is being
removed.
·
Pull the steering head shaft upwards out of
the steering head tube.
·
Take the washers out of the tube.
·
Take the ball bearing out of the tube.
·
The adjacent figure shows an overview of
the individual parts.
SERVICE MANUAL
1. Plastic cap
2. Ball bearing
3. 19 mm nut
·
Reassembly takes place in reverse order to
disassembly
·
Ensure that you insert the ball bearings
exactly as described below.
·
Also ensure that the washers are correctly
replaced.
65
SERVICE MANUAL
Invacare ® - Kite
CAUTION!
Incorrect reassembly can damage the bearings and cause the steering wheels to fall out!
The single-row angular ball bearing rings are not identical on both sides! There is only one correct
way to insert them!
· The bearings must always be assembled so that the narrow borders of the ball bearings are
facing each other (inside)!
· The steering head bolts and nuts must always be pressing against the wide (outside) border of
the ball bearings! Otherwise, the bearings will be pressed apart and damaged by the bolts!
The illustrations show the wide border of the ball bearing on the
outside of the ball race (A) and the narrow ball bearing edge on
the inside (B).
After assembly, the steering wheels should rotate freely but the
bearings should have no play.
66
·
First tighten the nuts to 20 Nm +/- 2 Nm.
·
Then loosen them slightly.
·
Then retighten to 15 Nm +/- 1.5 Nm.
Invacare ® - Kite
8.8.3
SERVICE MANUAL
Changing a front wheel (normal front wheel)
ATTENTION: Danger of crushing to the hands and feet by the weight of the wheelchair!
· Pay attention to the hand and feet.
· Use proper lifting techniques.
Danger of injury due to uncontrolled movement of the wheelchair!
· Switch the vehicle's power system off (ON-/OFF key).
· Engage the drive motors.
· Secure the vehicle against rolling away by placing wedges under the wheels.
Requirements:
· 24 mm socket wrench
· 24 mm open-ended wrench
· Flat screwdriver
· Oblong wooden blocks, at least 14 x 14 x 30 cm
· Medium strength thread locking adhesive, for example Loctite 243
· Heat gun
Removing the wheel:
·
Prop up the wheelchair on multiple wooden blocks. Use proper lifting techniques.
·
Use a Phillips screwdriver to remove the plastic cap (5).
·
Heat up the nut (4) using the heat gun to soften up the thread locking adhesive.
Alternatively, you can counter the axle (2) using a 24 mm wrench to prevent it from rotating.
·
Loosen and remove the nut with a 24 mm socket spanner.
67
SERVICE MANUAL
·
Remove the washer (3).
·
Take the wheel (1) off the axle (2).
Invacare ® - Kite
Refitting the wheel:
68
·
Refit the parts in reverse order.
·
When installing the wheel, pay attention to the correct direction of rotation.
·
Apply medium strength thread locking adhesive to the nut (4) when re-positioning it.
Invacare ® - Kite
8.8.4
SERVICE MANUAL
Changing a front wheel (suspended front wheel)
ATTENTION: Danger of crushing to the hands and feet by the weight of the wheelchair!
· Pay attention to the hand and feet.
· Use proper lifting techniques.
Danger of injury due to uncontrolled movement of the wheelchair!
· Switch the vehicle's power system off (ON-/OFF key).
· Engage the drive motors.
· Secure the vehicle against rolling away by placing wedges under the wheels.
Requirements:
· 5 mm Allen key
· 13 mm open-ended wrench
· Oblong wooden blocks, at least 14 x 14 x 30 cm
Removing the wheel
·
Prop up the wheelchair on multiple wooden blocks. Use proper lifting techniques.
·
Counter the axle (3) using an open-end wrench.
·
Loosen and remove the hexagon socket head screw (5). Pay attention to the washer (4).
·
Pull the axle out of the front fork (2).
·
Pull the wheel (1) out of the front fork.
Assembling the wheel:
·
Assemble the parts in reverse order.
·
When installing the wheel, pay attention to the correct direction of rotation.
69
SERVICE MANUAL
8.9
Drive wheels
8.9.1
Replacing the drive wheel
Invacare ® - Kite
ATTENTION: Danger of crushing to the hands and feet by the weight of the wheelchair!
· Pay attention to the hand and feet.
· Use proper lifting techniques.
Danger of injury due to uncontrolled movement of the wheelchair!
· Switch the vehicle's power system off (ON-/OFF key).
· Engage the drive motors.
· Secure the vehicle against rolling away by placing wedges under the wheels.
Requirements:
· 6 mm Allen key
· Long wooden blocks, min. 14 x 14 x 30 cm
Removing the drive wheel:
·
Lift the wheelchair on one side and place a 14 cm high wooden block underneath it so that the
drive wheel is off the ground and can rotate freely. Use proper lifting techniques.
·
Loosen the four or five 6 mm Allen screws (1).
·
Take the wheel (2) off the wheel hub.
Refitting the drive wheel:
NOTE
Please ensure that the wheel is re-fitted on the same side and in the same running direction as
removed.
·
70
Refit the wheel in reverse order.
Invacare ® - Kite
8.9.2
SERVICE MANUAL
Replacing a tyre or inner tube
Note
There are three different types of tyres or inner tubes, and specific points must be observed for
the replacement of each type.
It is easy to tell the difference between the tyre or inner tube types:
· Pneumatic tyres have black valve caps.
· Puncture-protected tyres have red valve caps
· puncture-proof tyres have no valves.
Please proceed in accordance with the appropriate chapter:
· Replacing pneumatic tyres – see user manual
· Replacing puncture-protected tyres – see chapter 8.9.2.1
· Replacing puncture-proof tyres – see chapter 8.9.2.2
8.9.2.1
Replacing puncture-protected tyres
Note
Pneumatic tyres have black valve caps. Puncture-protected tyres have red valve caps
Requirements:
· 6 mm Allen key
· Two long wooden blocks, min. 14 x 14 x 30 cm
· Tyre pump or compressor
· Talcum powder
Removing the tyres:
·
Remove the wheel as described in chapter 8.9.1.
71
SERVICE MANUAL
Invacare ® - Kite
ATTENTION: Explosion hazard!
If the wheelchair is fitted with pneumatic tyres, the wheel can explode if the air is not
released from the tyre before removing the wheel!
· Always release the air from the wheel before you remove it. Depress the small tappet in the
centre of the valve!
CAUTION!
Material damage hazard. The valve can become blocked by the puncture protection gel and
be unusable!
· During the following work you should always hold the valve up so that the puncture protection
gel cannot enter the valve.
·
Remove the valve cover (2).
·
Press the release pin in the valve inwards and evacuate all the air from the tyre.
·
Undo the five 6 mm Allen screws (4) on the inside of the wheel.
·
Remove the inner (3) and outer (6) ring of the rim from the tyre (1).
·
Replace any defective or worn parts.
Refitting the tyres:
·
Refit the inner tube in 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.
72
·
Refit rim rings (3) and (6) to the tyre. Please ensure that the boreholes and thread for the
screws are exactly above each other.
·
Fill some air into the inner tube.
·
Refit the five Allen screws on the inner side of the wheel and tighten them.
·
Check the exact fit of the tyre on the rim.
·
Inflate the tyre to the prescribed air pressure.
·
Re-check the exact fit of the tyre on the rim.
·
Screw the valve cap back on.
·
Refit the wheel.
Invacare ® - Kite
8.9.2.2
SERVICE MANUAL
Replacing puncture-proof tyres
Requirements:
· 6 mm Allen key
· Two long wooden blocks, min. 14 x 14 x 30 cm
· Three joiner's clamps with plastic caps
· Torque spanner 5 - 25 Nm (or similar)
· Talcum powder
Removing the tyres:
·
Remove the wheel as described in chapter 8.9.1.
ATTENTION: Explosion hazard!
There is considerable pressure in the tyre. Danger of injury! Parts can be thrown out and
injure you if you do not secure the rim rings.
· Secure the rim rings with joiner's clamps.
·
Secure the rim rings against unexpected discharge with three joiner's clamps. When doing so,
ensure that you do not scratch the rims.
·
Undo the five 6 mm Allen screws (2) on the inside of the wheel.
·
Now loosen the joiner's clamps carefully and alternately until you can remove the rim rings
without danger.
·
Remove the inner (3) and outer (1) ring of the rim from the tyre (4).
·
Replace any defective or worn parts.
Refitting the tyres:
·
Refit the tyres to the rim in the reverse sequence.
·
When fitting the rim rings together, ensure that the drillholes and threads for the bolts are
placed exactly above each other.
·
Place the joiner's clamps in position.
·
Tighten the joiner's clamps alternately in small stages until the rim rings are precisely aligned.
·
Tighten the Allen screws (2) to 18 Nm.
73
SERVICE MANUAL
8.9.3
Invacare ® - Kite
Replacing the drive wheel hub
CAUTION!
Possible material damage to mobility device! Collisions can be caused if the adjusting
washers are removed during fitting work to the drive wheels!
· Adjusting washers are often fitted between the drive shaft and the wheel hub to even out
tolerances. If these adjusting washers are removed and not replaced again, collisions can be
caused.
· Always replace the adjusting washers exactly as they were before you started dismantling.
Requirements:
· 19 mm socket spanner
Uninstalling a drive wheel hub:
·
Use the 19 mm socket wrench to loosen and remove the nuts (7).
·
Remove the washer (6).
·
Remove the distance ring (5).
·
Pull the wheel hub (4) off of the axle (2).
·
Remove the shim ring (3).
·
Remove the feather key (1) from the axle.
Installing a drive wheel hub:
74
·
Assemble the parts of the wheel hub in reverse order.
·
Use a thin film of lubricant to replace the wheel hub on the axle.
Invacare ® - Kite
8.10
SERVICE MANUAL
Drive unit
8.10.1 Replacing the motor/transmission unit
ATTENTION: Danger of crushing to the hands and feet by the weight of the wheelchair!
· Pay attention to the hand and feet.
· Use proper lifting techniques.
Danger of injury due to uncontrolled movement of the wheelchair!
· Switch the vehicle's power system off (ON-/OFF key).
· Engage the drive motors.
· Secure the vehicle against rolling away by placing wedges under the wheels.
ATTENTION: Danger of crushing!
The motor gearbox unit is extremely heavy. Injury hazards to hands!
· Please note the high weight
Requirements:
· 6 mm Allen key
· 19 mm socket spanner
· long wooden blocks, min. 14 x 14 x 30 cm
Removing the motor/transmission unit:
·
Switch the electronics OFF on the remote.
·
Remove the rear battery box cover, as described in chapter 8.1.1.
·
Pull the motor plug out of the power module.
·
Open the cable clamps and expose the motor cable.
·
Remove the drive wheel as described in chapter 8.9.1.
·
Remove the wheel hub as described in chapter 8.9.3.
·
Remove the splash guard as described in chapter 8.1.6.
75
SERVICE MANUAL
Invacare ® - Kite
·
Use a 6 mm Allen wrench and a 13 mm socket wrench to loosen and remove the four hexagon
socket head screws (1).
·
Remove the screws together with the washers.
·
Pull the motor/gear box unit (3) forwards out of its holder (2). Take into account the heavy
weight of the unit.
Refitting the motor/transmission unit:
·
Replace the defective components.
·
Before installing a new motor / gearbox unit, make sure the sealing ring is correctly mounted.
The sealing ring securely attaches the motor and the gearbox. The ring must be installed such
that the self-locking nut is located on the outside.
·
If the sealing ring is incorrectly installed, rotate it around as described in chapter 8.10.2.
·
Install the motor / gearbox unit in reverse order.
· Use the scale to align the motor to the centre axis (1):
2-pole motors:
- Left:
200°
- Right:
280°.
4-pole motors:
- Left:
280°
- Right:
280°.
· Make sure that the motor cable cannot be pinched or bent, and
that it is not exposed to chafing in any place.
· To conclude, you should always carry out a trial run to test the
vehicle functions.
76
Invacare ® - Kite
SERVICE MANUAL
8.10.2 Replacing or rotating the motor / gearbox unit sealing ring
CAUTION: Danger of crushing!
The motor / gearbox unit is very heavy. Danger of injury to the hands!
· Pay attention to the heavy weight.
Requirements:
· 10 mm socket wrench
Uninstalling the sealing ring:
·
Uninstall the motor / gearbox unit, as described in chapter 8.10.1.
·
Use the 10 mm socket wrench to loosen and remove the self-securing nuts (4) including the
washers.
·
Remove the carriage bolt, which secures the sealing ring (2).
·
Carefully bend the sealing ring apart and remove it.
Installing the sealing ring:
·
Install the sealing ring so that the square hole for the carriage bolt is on the inside of the
wheelchair.
·
Insert the carriage bolt through the sealing ring.
·
Install the washer and the self-locking nut.
·
Do not tighten the self-locking nut completely, as the motor orientation must be adjusted during
installation.
77
SERVICE MANUAL
Invacare ® - Kite
8.10.3 Replacing the motor / gearbox coupling
CAUTION: Danger of crushing!
The motor / gearbox unit is very heavy. Danger of injury to the hands!
· Pay attention to the heavy weight.
Requirements:
· 10 mm socket wrench
Uninstalling the motor / gearbox coupling:
·
Uninstall the motor / gearbox unit, as described in chapter 8.10.1.
·
Use the 10 mm socket wrench to loosen and remove the self-securing nut (4).
·
Remove the carriage bolt, which secures the sealing ring (2).
·
Carefully bend the sealing ring apart and remove it.
WARNING!
Danger of damage to the wheelchair if the coupling is not serviced correctly.
· Be careful not to damage the coupling mechanism during maintenance work.
78
·
Carefully pull the motor (3) and the gearbox (1) apart.
·
Remove the component parts of the coupling.
·
If necessary replace the coupling.
Invacare ® - Kite
SERVICE MANUAL
Installing the motor / gearbox coupling:
·
Place the new clutch (7) on the motor axle. Pay attention to the position of the groove.
·
Position the locking ring (5) on the motor (4) or the gearbox (1).
·
Carefully insert the motor into the gearbox. Pay attention to the position of the groove in the
axle of the gearbox. If necessary, rotate the motor and gearbox to the correct position.
·
Insert the carriage bolt through the locking ring. Do not forget the spacer sleeve (2)!
·
Install the washer and the self-locking nut.
·
Do not tighten the self-locking nut completely, as the motor orientation must be adjusted during
installation.
·
Install the motor / gearbox unit, as described in chapter 8.10.1.
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Invacare ® - Kite
8.10.4 Replacing the carbon brushes
Note
The wheelchair can be equipped with 2-pole or 4-pole motors.
Always replace all carbon brushes on both motors at the same time.
Always use carbon brushes of identical types.
ATTENTION: Danger of crushing to the hands and feet by the weight of the wheelchair!
· Pay attention to the hand and feet.
· Use proper lifting techniques.
Requirements:
· 6 mm Allen key
· 10 mm socket spanner
· blade screwdriver
· long wooden blocks, min. 14 x 14 x 30 cm
Removing the carbon brushes:
·
Switch off the mobility aid.
·
Remove the drive wheels as described in chapter 8.9.1.
·
Disengage the motor (1) by setting the engaging lever to “Push“.
Note
In the case of the SSD motor, you can unto the bolt (5) with a 10 mm socket spanner and then
turn the motor around so that you can access the rear carbon brushes more easily.
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Invacare ® - Kite
·
Loosen and remove all four plastic caps (3) using a blade screwdriver.
·
Note the fixing position and location of the carbon brushes.
SERVICE MANUAL
Note
Used carbon brushes need to the refitted exactly in the same position from which they were taken
in order to guarantee optimum contact to the collector.
·
Make a marking on the motor and the carbon brushes in order to guarantee correct refitting.
·
Remove the carbon brushes completely from the mounting (2).
·
Check the carbon brush and spring for the level of wear, broken components or discolouration.
Refitting the carbon brushes:
·
Depending on the condition of the brush and the spring:
- either replace the brushes in exactly the same position from which they were taken or
- fit new brushes.
·
Refit the plastic caps and tighten them firmly.
·
Turn the motor round in position so that the engaging lever can be set both to the "Push" and
the "Travel" position.
·
Now retighten the bolt ((5) fingertight.
·
Refit the drive wheels as described in chapter 8.9.1.
Note
The following procedure is necessary to run the carbon brushes in after replacement and thus
guarantee maximum performance.
WARNING: Risk of accidents!
Hazards to workers, surroundings and mobility device!
· Do not leave the mobility device unattended during the following procedure!
· Make sure that BOTH drive wheels are raised and CANNOT touch the ground.
· Secure the area.
·
Lift the wheelchair on one side and place a 14 cm high wooden block underneath it so that the
drive wheel is off the ground and can rotate freely. Use proper lifting techniques.
·
Also repeat this on the other side of the mobility aid.
·
Allow the motors to run for an hour in forward direction.
·
Allow the motors to cool down for 30 minutes.
·
Allow the motors to run for an hour in reverse direction.
·
Lift the mobility aid off the wooden blocks.
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8.11
Invacare ® - Kite
Replacing the rubber shock absorbers
Requirements:
· 13 mm socket wrench
· Several wooden blocks
Note
In the following procedure steps, the wheelchair is manually lifted up and secured in this position
using wooden blocks. Alternatively, you can achieve this by lifting the wheelchair using a crane or
a combination of pulley and belts, if your workshop has the corresponding equipment.
WARNING: Danger of accidents!
Danger to people, the surroundings and wheelchair!
The specifications of the crane or pulley and belts must be sufficient for the weight
of the wheelchair.
· Pay attention to the maximum load capacity of the crane and the breaking
strength of the belts.
· Never position yourself under heavy objects suspended in the air by cranes or
pulleys.
Uninstalling rubber shock absorbers:
82
·
Remove the rear and the middle battery box covers, as described in chapter 8.1.1 und 8.1.2.
·
Use the 13 mm socket wrench to loosen and remove the self-securing nut (3).
·
Repeat this on the other side of the wheelchair.
·
Lift the frame tube of the wheelchair in the rear so that the threaded pin (2) is pulled out of the
guide.
·
Place one or more wooden blocks between the frame tube and the battery box.
·
Turn the rubber shock absorber clockwise (as seen from above) by hand and replace it.
·
Repeat this on the other side of the wheelchair.
Invacare ® - Kite
SERVICE MANUAL
Installing rubber shock absorbers:
·
Assemble the parts in reverse order.
·
Tighten the rubber shock absorbers and nuts hand-tight.
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8.12
Invacare ® - Kite
Replacing the tube frame
Requirements:
· 4 mm Allen wrench
· 5 mm Allen wrench
· 11 mm socket wrench
· 13 mm socket wrench
· 19 mm socket wrench
· 13 mm open-ended wrench
· 24 mm open-ended wrench
· 19 mm box wrench
· torque wrench 20 – 200 Nm
· wooden blocks
Disassembling the tube frame:
·
Remove both batteries, as described in chapter 8.4.
·
Remove both lateral covers, as described in chapter 8.1.3.
·
Remove the seat, together with the tilt module, as described in chapter 8.15.2.
·
Remove both tail light brackets, as described in chapter 8.7.9.
·
Remove both rubber shock absorbers, as described in chapter 8.11.
·
Remove both front forks, as described in chapter 8.8.2.
WARNING!
Risk of damage to the tube frame.
· You should counter the bearing bolt against slippage, but do not turn it.
84
·
Secure the bearing bolt (1) against slippage using a second 24 mm open-end wrench.
·
Use a 19 mm box wrench to loosen the nut (4).
·
Remove the bearing bolt. Pay attention to the self-locking nut (4), the washers as well as the
sliding bushing (5).
·
Repeat these work steps on the other side of the wheelchair.
·
Lift the tube frame (2) off of the double bearing of the Dual Swing Technology (D.S.T.).
Invacare ® - Kite
SERVICE MANUAL
Assembling the tube frame:
·
Assemble the parts in reverse order.
·
Tighten the self-locking nuts (4) to a torque of 120 Nm.
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SERVICE MANUAL
8.13
Invacare ® - Kite
Replacing the double bearing of the Dual Swing Technology
(D.S.T.)
Requirements:
· 4 mm Allen wrench
· 5 mm Allen wrench
· 10 mm Allen wrench
· 11 mm socket wrench
· 13 mm socket wrench
· 13 mm open-ended wrench
· 24 mm open-ended wrench
· 36 mm open-ended wrench
· 24 mm box wrench
· torque wrench 20 – 200 Nm
· wooden blocks
Disassembling the double bearing of the Dual Swing Technology (D.S.T.)
·
Remove both batteries, as described in chapter 8.4.
·
Remove the middle cover, as described in chapter 8.1.2.
·
Remove both lateral covers, as described in chapter 8.1.3.
·
Remove all cables that run from the electronic modules on the battery box to the seat (for
example to the remote or actuators) or to the tube frame (for example to the lighting system).
·
Place wooden blocks under the battery box, so that it is secured in its present position.
·
Loosen the lower screws on both rubber shock absorbers, as described in chapter 8.11.
WARNING!
Risk of damage to the tube frame.
· You should counter the bearing bolt against slippage, but do not turn it.
86
·
Secure the bearing bolt (1) against slippage using a second 24 mm open-end wrench.
·
Use a 19 mm box wrench to loosen the nut (4).
·
Remove the bearing bolt. Pay attention to the self-locking nut (4), the washers as well as the
sliding bushing (5).
Invacare ® - Kite
SERVICE MANUAL
·
Repeat these work steps on the other side of the wheelchair.
·
Push the seat and the tube frame to one side on the front wheels. Make sure the tube frame
does not get scratched during this procedure.
·
Use a 10 mm Allen wrench to loosen the hexagon socket head screw (1).
·
Remove the hexagon socket head screw together with the Nord-Lock washer (6) and the
spacer ring (2).
·
Pull the double bearing (3) off of the bearing bolt.
·
Remove and inspect the floating bearings (4) & (5). Replace the bearings if they are damaged
or worn.
·
Replace the double bearing.
Assembling the double bearing of the Dual Swing Technology (D.S.T.)
·
Assemble the parts in reverse order.
·
Tighten the hexagon socket head screw (1) to a torque of 80 Nm.
·
Tighten the self-locking nuts of the bearing bolts (4) to a torque of 120 Nm.
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8.14
Invacare ® - Kite
Replacing the battery boxes
Requirements:
· 4 mm Allen wrench
· 5 mm Allen wrench
· 6 mm Allen wrench
· 10 mm Allen wrench
· 8 mm socket wrench
· 11 mm socket wrench
· 13 mm socket wrench
· 13 mm open-ended wrench
· 24 mm open-ended wrench
· 24 mm box wrench
· Phillips screwdriver, size 2
· torque wrench 20 – 200 Nm
· Wooden blocks (approx. 12 x 12 x 30 cm) for jacking up the vehicle
Uninstalling the battery box:
·
Remove the rear and the middle covers, as described in chapter 8.1.1 and 8.1.2.
·
Remove the splash guards, as described in chapter 8.1.6.
·
Remove both lateral covers, as described in chapter 8.1.3.
·
Take exact note of the positions of all cables and the sockets that they are connected to. Mark
the connectors and sockets or take a photograph with a digital camera.
·
Remove all electronic modules, as described in chapter 8.1.58.4 and its subchapters.
·
Remove both batteries, as described in chapter 8.4.
·
Remove both drive wheels, as described in chapter 8.9.1.
·
Remove both motor/gear box units, as described in chapter 8.1.6.
·
Remove the seat, together with the tilt module, as described in chapter 8.15.2 or 8.17.3
(Modilite seat).
·
Remove both rubber shock absorbers, as described in chapter 8.11.
·
Remove the double bearing of the Dual Swing Technology (D.S.T.), as described in chapter
8.13.
·
Remove the front cover, as described in chapter 8.1.4.
·
Replace the battery box.
Installing the battery box:
·
88
Assemble the parts in reverse order.
Invacare ® - Kite
8.15
SERVICE MANUAL
Seat system
8.15.1 Replacing the tilt actuator
Requirements:
· flat screwdriver, blade width approx. 6 mm
· oblique pliers
· small hammer
· cable binder
·
Remove the legrests.
·
Switch the electronics OFF on the remote.
·
Remove the rear and the middle covers, as described in chapter 8.1.1 und 8.1.2.
·
Take exact note of the positions of all cables and the sockets that they are connected to. Mark
the connectors and sockets or take a photograph with a digital camera.
·
Disconnect the plug (1) of the actuator to be tested from the actuator module.
·
Pull the actuator cable out of the wheelchair. If necessary, also remove the cable ties.
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Invacare ® - Kite
·
Remove the SL fuse (2) on the bottom fixing
bolt (1) with the screwdriver.
·
Pull the fixing bolt (1) out.
·
Remove the SL fuse (2) on the top fixing bolt
(1) with the screwdriver.
·
Pull the fixing bolt (1) out.
·
Pull the adjustment spindle out together with the actuator.
·
Insert the new adjustment spindle with the actuator.
·
Reinsert the fixing bolts and SL fuses. Fix the SL fuses securely to the fixing bolt with the
hammer.
·
Connect the plug of the actuator to the electronic module.
·
Fasten the actuator cable to the frame with new cable ties. Position the cable such that it
does not get abraded or pinched.
·
To complete, check all seat tilting functions.
Invacare ® - Kite
SERVICE MANUAL
8.15.2 Replacing the tilt module
ATTENTION: Danger of crushing!
The seat/seat support is very heavy. Danger of injury to hands and feet!
· Use proper lifting techniques
Requirements:
· 10 mm Allen wrench
· 13 mm open-ended wrench
· 24 mm open-ended wrench
· 24 mm box wrench
· Side cutting pliers
· Cable ties
·
Remove the legrests.
·
If possible, tilt the seat back as far as it will go.
·
Switch the electronics OFF on the remote.
·
Remove the rear and the middle covers, as described in chapter 8.1.1 und 8.1.2.
·
Take exact note of the positions of all cables and the sockets that they are connected to. Mark
the connectors and sockets or take a photograph with a digital camera.
·
Disconnect the plug (1) of the actuator to be tested from the actuator module.
·
Pull the actuator cable out of the wheelchair. If necessary, also remove the cable ties.
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SERVICE MANUAL
92
·
Loosen and remove the four screws (2).
Depending on the tilt module, use a 13 mm
open-end wrench for all four screws
or
a 5 mm Allen key for the two in the front, and
a 13 mm open-end wrench for the two in the
back.
·
Remove the seat support (1) from the tilt
module (3).
·
Use the 10 mm Allen wrench to loosen and
remove both screws (1).
·
Use the 24 mm open-end wrench and the 24
mm box wrench to loosen and remove both
screws (2).
·
Remove the lifter from the vehicle frame and
replace it.
·
Re-assembly is done in reverse order.
·
Test all functions of the vehicle.
Invacare ® - Kite
Invacare ® - Kite
SERVICE MANUAL
8.15.3 Replacing the lifter / tilt module
ATTENTION: Danger of crushing!
The seat/seat support is very heavy. Danger of injury to hands and feet!
· Use proper lifting techniques
Requirements:
· 5 mm Allen key
· 6 mm Allen key
· 6 mm wrench
· Side cutting pliers
· Cable ties
Note
Take careful note of the exact position of the seat. Mark the position it is mounted in, the angle
and so on. If necessary, make photographs with a digital camera.
Any modification of the adjustment of the seat affects the centre of gravity of the wheelchair.
Uninstalling the lifter / tilt module:
·
If possible, raise the lifter to the highest position.
·
If possible, tip the wheelchair with the tilt module as far backwards as it will go.
·
Switch the electronic control system off.
·
Disconnect the plug at the height of the tilt actuator (1).
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Invacare ® - Kite
·
Open the power supply chain of the lifter:
- Flip the cover (1) up.
- Pull the flap (2) out of the cover.
- Repeat this procedure link by link.
·
Remove both cable ties that secure the cable at the ends of the power supply chain.
·
Pull the cable out of the power supply chain.
·
Use the Phillips screwdriver to loosen the screws (1).
·
Remove the power supply chain (2).
·
Use the Phillips screwdriver to loosen the screws (4).
·
Additionally the sensor (5) is secured with nuts.
Loosen the nuts while holding a 6 mm wrench against.
·
Remove the magnet (3).
·
Remove the sensor (5).
Invacare ® - Kite
SERVICE MANUAL
ATTENTION: Danger of crushing!
The seat/seat support is very heavy. Danger of injury to hands and feet!
· Use proper lifting techniques
·
Loosen the four screws (1) that attach the seat to the lifter / tilt module using a
5 mm Allen key.
·
Lift the seat up off of the lifter module / tilt module. Use proper lifting techniques.
·
Disconnect the plug (1) from the actuator module.
·
Free up all cables so that you can lift the seat off.
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·
Loosen the four screws (1).
·
Lift the lifter / tilt module out of the frame.
Invacare ® - Kite
Installing the tilt module:
·
Install the tilt module in reverse order. Make sure that seat tilt mounting brackets (2) are affixed
with screws to the top holes in the seat frame brackets (5).
·
Tighten the connecting screws of the seat tilt mounting brackets and the seat frame mounting
brackets to
18 Nm.
·
When installing the cables again, make sure that they are placed in such a way that they
cannot be crushed or damaged in any position of the tilt module.
ATTENTION: Danger of crushing!
The seat is very heavy. Danger of injury to hands and feet!
· Use proper lifting techniques.
96
·
Install the seat.
·
Install all covers again.
·
Check all functions of the vehicle and go for a test drive.
Invacare ® - Kite
8.16
SERVICE MANUAL
Backrest unit
8.16.1 Replacing the standard backrest
Requirements:
· 5 mm Allen key
· open-ended spanner, 10 mm
· open-ended spanner, 13 mm
Dismantling the backrest unit:
·
Remove the backrest cushion.
·
Undo and remove the handwheels (3).
·
Use two 13 mm socket spanners to undo the bolts (4) including the nuts and washers on the
left-hand and right-hand side of the chair.
·
Remove the backrest tube (1) from the backrest holders (2).
·
If the backrest holders also need to be replaced: Undo and remove the Allen screws (5)
including the nuts and washers on the left-hand and right-hand side of the chair. To do this,
use a 5 mm Allen key and a 10 mm socket spanner.
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Refitting the backrest unit:
98
·
Replace the parts in the reverse order.
·
To conclude, you should always carry out a trial run to test the vehicle functions.
Invacare ® - Kite
SERVICE MANUAL
8.16.2 Replacing a standard backrest with quick release
Requirements:
· 5 mm Allen key
· open-ended spanner, 10 mm
· open-ended spanner, 13 mm
Dismantling the backrest unit:
·
Remove the backrest cushion.
·
Use two 13 mm socket spanners to undo the bolts (4) including the nuts and washers on the
left-hand and right-hand side of the chair.
·
Pull the quick release cord (5) to unlock the backrest tube.
·
Remove the backrest tube (1) from the backrest holders (2).
·
If the backrest fixations are to be replaced also:
Loosen and remove the hexagon socket head screws (3) including the nuts and washers on
the left and right side of the chair. Use a 5 mm Allen key and a 10 mm socket wrench for this
purpose.
Refitting the backrest unit:
·
Replace the parts in the reverse order.
·
To conclude, you should always carry out a trial run to test the vehicle functions.
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8.16.3 Replacing a Flex2 backrest
Requirements:
· Torx Bit TX40 wrench
Dismantling the backrest unit:
·
Remove the backrest cushion.
·
Loosen the hand wheels (4).
·
Remove the backrest tube (1) from the backrest mounting bracket (2).
·
Loosen and remove the screws (3), including the sleeve and washers, with a Torx Bit TX40
wrench on the left and right side of the chair.
·
Remove the backrest mounting bracket (2).
Refitting the backrest unit:
100
·
Replace the parts in the reverse order.
·
To conclude, you should always carry out a trial run to test the vehicle functions.
Invacare ® - Kite
SERVICE MANUAL
8.16.4 Adjusting backrest former
The backrest former can be individually adapted to the user's back shape.
·
Pull the front and rear faces of the backrest upholstery (1) apart and remove. The backrest
upholstery front and rear faces are held together using Velcro fastenings.
·
Open the backrest belt (2) Velcro fastenings and adjust to the required length.
·
Reattach the backrest upholstery and fix with Velcro fastenings.
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8.17
Invacare ® - Kite
Seat system Modulite
8.17.1 Replacing the tilt actuator
Note
Replacing the actuator for the seat angle adjustment in the lifter / seat tilt adjustment module is
also described.
Requirements:
· Screwdriver, flat, width 6 mm
· 13 mm jaw spanner (2x)
· Slotted screwdriver
·
Remove legrests.
·
Switch the electronics OFF on the remote.
·
Disconnect the actuator cable from the cable
harness
Variant actuator - tilt:
· Bottom fixing bolt (3) with nut (4) –
Loose the nut with the open-ended wrenches.
Remove the nut and bolt.
·
Top fixing bolt (2) secured with snap rings (1) –
Remove a snap ring using a screwdriver and
remove the bolt.
·
Pull the actuator out.
·
Insert a new actuator.
·
Reassembly takes place in the reverse order.
·
Connect the actuator cable to the cable harness.
·
To complete, check all seat tilting function
Variant seat angle adjustment actuator in the
lifter/seat angle adjustment module:
· Bottom fixing bolt (3) with slot –
Loosen the fixing bolt with a screwdriver.
Remove the bolt.
102
·
Top fixing bolt (2) secured with snap rings (1) –
Remove a snap ring using a screwdriver and
remove the bolt.
·
Pull the actuator out.
·
Insert a new actuator.
·
Reassembly takes place in the reverse order.
·
Connect the actuator cable to the cable harness.
·
To complete, check all seat tilting function.
Invacare ® - Kite
SERVICE MANUAL
8.17.2 Replacing the lifter actuator
Requirements:
· Screwdriver flat, width 6 mm
· Large screwdriver
· Flat screwdriver
·
Remove legrests.
·
Run the lifter up to if possible.
·
Switch the electronics OFF on the remote.
·
Secure the seat.
·
Pull the plug from the actuator.
·
Bottom fixing bolt (2) secured with snap rings
– Remove a snap ring using a screwdriver
and remove the bolt.
·
Top fixing bolt (3) with slot –
Loosen the fixing bolt with a screwdriver.
Remove the bolt.
·
Replace actuator.
·
Reassembly of the actuator takes place in
the reverse order.
·
Connect the plug of the actuator cable to the
actuator.
·
To complete, check all seat tilting function.
If the lifter cannot be raised, a cover can be removed from the upper rear side of the module. This
way it is possible to reach the lower fixation bolt of the actuator.
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8.17.3 Replacing the lifter / seat angle adjustment module
Note
Replacement of the seat angle adjustment module is performed in the same manner.
ATTENTION: Danger of crushing!
The seat is very heavy. Danger of injury to hands and feet!
· Use proper lifting techniques
Requirements:
· 3 mm Allen key
· 5 mm Allen key
· T25 Torx wrench
· T40 Torx wrench
· Side cutting pliers
· Cable ties
· Remove legrests.
· Tilt the seat tilting completely to the rear if
possible.
· Switch the electronics OFF on the remote.
· Remove the backrest cushion.
· Loosen and remove the screws, which secure
the middle seat plate (A) with a 3 mm Allen key.
· Remove the middle seat plate (B).
· Loosen and remove the screws on both sides,
which secure the lateral seat plates (C) with a
3 mm Allen key.
· Remove the lateral seat plates (D).
or
· Remove the seat cushion.
· Loosen and remove the screws on both sides,
which secure the sling seat (A) with a
T25 Torx wrench.
· Remove the sling seat (B).
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·
Remove the seat frame by removing the screws (1) with a T40 Torx wrench.
·
Disconnect the actuator cable and microswitch cable from the cable harness.
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Invacare ® - Kite
·
Loosen and remove the screws (2) incl. the washers with a 5 mm Allen key.
·
Lift the module of the seat angle adjustment (1) from the adapter and replace it.
·
Reassembly takes place in the reverse order.
·
To complete, check all seat tilting function.
Invacare ® - Kite
SERVICE MANUAL
8.17.4 Replacing the backrest actuator
Dismantling the backrest actuator:
·
Pull the cable off directly where it is connected to the actuator (1)
·
Detach the bracket of the actuator at the top and bottom; to do this, slide the bolts (3) to the
side using the lever (4) and tilt the actuator (1) out of the backrest clamp (2).
·
Replace actuator.
Refitting the backrest actuator:
·
Assemble the parts in the reverse order.
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SERVICE MANUAL
8.18
Invacare ® - Kite
Backrest Modulite
8.18.1 Replacing the standard backrest
Requirements:
· 5 mm Allen key
Dismantling the backrest unit:
·
Remove the backrest cushion.
·
Loosen the fixation lever (2) of the backrest tube.
·
Remove the backrest tube.
·
Use the Allen key to loosen and remove the hexagon socket head screws (3) including the nuts
and washers on the left and right side of the chair.
Refitting the backrest unit:
108
·
Replace the parts in the reverse order.
·
To conclude, you should always carry out a trial run to test the vehicle functions.
Invacare ® - Kite
SERVICE MANUAL
8.18.2 Replacing the backrest mounting bracket
Requirements:
· 5 mm Allen key
Dismantling the backrest unit:
·
Remove the backrest cushion.
·
Loosen the fixation levers (2) of the corresponding backrest tube (1), depending on the version.
There are two versions:
(2) - for the manual backrest
(3) - for the electrically adjustable backrest
·
Remove the backrest tube.
·
Loosen and remove the two hexagon socket head screws (4) to the sliding block (5) on the left
and right side of the chair.
Refitting the backrest unit:
·
Replace the parts in the reverse order.
·
To conclude, you should always carry out a trial run to test the vehicle functions.
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8.18.3 Replacing the backrest mounting bracket for SB 53
Requirements:
· 5 mm Allen key
Dismantling the backrest unit:
·
Remove the backrest cushion.
·
Loosen the fixation levers (2) of the corresponding backrest tube (1), depending on the version.
There are two versions:
(2) - for the manual backrest
(3) - for the electrically adjustable backrest
·
Remove the backrest tube.
·
Loosen and remove the two hexagon socket head screws (4) to the sliding block (5) on the left
and right side of the chair.
Refitting the backrest unit:
110
·
Replace the parts in the reverse order.
·
To conclude, you should always carry out a trial run to test the vehicle functions.
Invacare ® - Kite
8.19
SERVICE MANUAL
Adjusting the seat width/ backrest width (Modulite)
8.19.1 Adjusting the seat width
You can only adjust the seat width for the adjustable seat plate or for the adjustable sling seat.
The sling seat is available in two widths:
- for a seat width of 38-43 cm and
- for a seat width of 48-53 cm.
When modifying the seat width, the backrest width must also be correspondingly adapted. See
chapter 8.19.2.
Requirements:
· 3 mm Allen key
· 5 mm Allen key
· 13 mm open-ended spanner
· T25 Torx wrench
· T40 Torx wrench
· Remove the backrest cushion.
· Remove the backrest from the backrest
mounting bracket.
See chapter 8.18.
· Loosen and remove the screws, which secure
the middle seat plate (A) with a 3 mm Allen key.
· Remove the middle seat plate (B).
· Loosen and remove the screws on both sides,
which secure the lateral seat plates (C) with a
3 mm Allen key.
· Remove the lateral seat plates (D).
or
· Remove the seat cushion.
· Loosen and remove the screws on both sides,
which secure the sling seat (A) with a
T25 Torx wrench.
· Remove the sling seat (B).
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Invacare ® - Kite
SERVICE MANUAL
· Loosen and remove the screws of the seat
frame adjustment (A) with a T40 Torx
wrench.
· Loosen and remove the screws of the
fixation of the legrest mounting brackets
(B).
· Adjust the seat frame and the legrest fixation to the desired width according to the following
illustrations and tables:
Seat frame:
Screw position
A
B
C
D
Seat width
530 mm
480 mm
430 mm
380 mm
Leg supports connection:
Screw position
A
B
C
D
Seat width
380 mm
430 mm
480 mm
530 mm
Note
When switching from 430 mm to
480 mm and the other way around,
the fixation of the legrests must be
replaced.
· Reposition the screws and tighten them again.
· Install the seat plate or the sling seat.
· Reposition the seat cushion.
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SERVICE MANUAL
8.19.2 Adjusting the backrest width
The backrest width is adjusted by performing the following tasks:
·
Adjust the backrest tube.
·
Adjust the backrest:
- Sling backrest, as described in chapter 8.16.4.
- Flex3 backrest, as described in chapter 8.19.3.
·
Replace the backrest cushion (these are available in various widths).
When modifying the backrest width, the seat width must also be correspondingly adapted. Please
see chapter 8.19.1.
Requirements:
· 3 mm Allen key
· 5 mm Allen key
· 13 mm Open-ended spanner
The screw position for the backrest width, refer to the table:
Screw position
Seat width
A
B
C
D
530 mm
480 mm
430 mm
380 mm
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SERVICE MANUAL
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Invacare ® - Kite
·
Remove the backrest cushion.
·
Loosen the straps of the sling backrest or remove the Flex3 backrest.
·
Loosen and remove both screws (5) of the actuator fixation bracket.
·
Remove the cover of the actuator fixation bracket.
·
Loosen and remove the screws and nuts (2, 4) on the upper and lower actuator fixation bracket
on both sides.
·
Adjust the backrest fixation (6) for the new backrest width according to the table on page 113.
·
Insert the screws (2) through the cover of the actuator fixation bracket and the corresponding
holes of the backrest fixation to the actuator fixation.
·
Fasten these with the nuts (4).
·
Reposition the cover of the actuator fixation bracket.
·
Insert and tighten the screws (5) again.
·
Adjust the straps of the sling backrest to the new width or install the adjusted Flex 3 backrest.
·
Install the backrest cushion.
·
Perform a function check of the chair.
Invacare ® - Kite
SERVICE MANUAL
8.19.3 Adjusting the Flex3 backrest
Requirements:
· Phillips screwdriver
· 5 mm Allen key
·
Remove the front lateral plates (2 and 4) from the backrest (1) by loosening and removing the
five hexagon socket head screws (3).
·
Remove both Phillips screws (A) on the middle plate.
·
Shift the position of the rear plate halves (three settings are possible using the drill holes).
- Before pulling the Flex3 backrest apart, a "1" will be visible in the
small, rectangular cut-out.
- After pulling the Flex3 backrest apart, a "2" will be visible in the
small, rectangular cut-out.
·
Re-insert the two screws (A) into the middle plate.
·
Fasten the front lateral plates (2 and 4) again.
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SERVICE MANUAL
9
Installing accessories
9.1
Replacing the holding strap
Invacare ® - Kite
Requirements:
· open-ended spanner, 13 mm
· 5 mm Allen key
Note
A nut is fixed between the two washers (2) and (4) as a spacer so that the belt mounting can
rotate freely.
116
·
Remove the plastic cap (5).
·
Loosen the bolt (3) and the associated nut
(in the figure this is covered by the plastic
cap) with a 5 mm Allen key and a 13 mm
socket spanner.
·
Remove the nut.
·
Remove the bolt including safety belt and flat
washers (2) and (4).
·
Remove the flat washers (4).
·
Replace the safety belt (1).
·
Refit the parts in the reverse order.
Invacare ® - Kite
SERVICE MANUAL
9.2
Replacing seat belts (Modulite seat)
9.2.1
Installation on the backrest mounting bracket (simple backrest)
Requirements:
· Socket spanner,13 mm
· 5 mm Allen key
·
The seat belts are attached via the drill hole (1) at the top right.
·
The installation of seat belts is described in chapter 9.1.
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SERVICE MANUAL
9.2.2
Invacare ® - Kite
Installation on the backrest mounting bracket (adjustable seat)
Requirements:
· 5 mm Allen key
118
·
Loosen the screw (1) with a 5 mm Allen key.
·
Remove the screw (1), the corresponding washer (2) and the seat belt and belt winder (3) from
the backrest mounting bracket (4).
·
Replace the safety belt.
·
Refit the parts in the reverse order.
Invacare ® - Kite
9.2.3
SERVICE MANUAL
Installation on the seat frame profile (adjustable seat)
Requirements:
· 5 mm Allen key
·
Loosen the screw (1) with a 5 mm Allen key.
·
Remove the screw (1), the washer (2), the seat belt, the sliding bushing (3) and the sliding
block (4) from the seat frame profile (5).
·
Replace the safety belt.
·
Refit the parts in the reverse order.
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SERVICE MANUAL
9.3
Operating hours counter
9.3.1
Replacing the operating hours counter
Invacare ® - Kite
Requirements:
· Philipps screwdriver, size 2
· 7 mm open-end wrench
The operating hours counter is located in the side
cover.
·
Disconnect the plug-in connection of the
operating hours counter from the drive
motor.
·
Remove the side cover, as described in
chapter 8.1.3.
·
Detach the operating hours counter from the
side cover.
·
Disconnect the plugs (+) & (-).
·
Remove the nut (4) including the locking
washer.
·
Pull the operating hours counter (6) forwards
out of the casing (1). Pay attention to the
mounting bracket (5) and the retaining frame
(7).
·
Replace the operating hours counter.
CAUTION!
Property damage can result if the counter is wrongly connected. If the plus and minus
wires are connected the wrong way, it will damage the electronic components of the
operating hours counter.
· Make sure the cable is connected correctly.
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Invacare ® - Kite
·
Assembly of the operating hours counter is
carried out in the reverse order.
·
Connect the plug of the blue wire (-) to the
plug contact of the operating hours counter
which is marked with a "2".
·
The blue wire is additionally marked with a
minus symbol.
·
Connect the plug of the brown wire (+) to the
plug contact of the operating hours counter
which is marked with a "1".
·
The blue wire is additionally marked with a
sleeve, which has a plus symbol on it.
·
Assemble all remaining parts again in
reverse order.
SERVICE MANUAL
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SERVICE MANUAL
9.3.2
Replacing the connecting cable of the operating hours counter
Requirements:
· Philipps screwdriver, size 2
· Side cutters
· Cable ties
122
Invacare ® - Kite
·
The operating hours counter is located in the
side cover.
·
Disconnect the plug-in connection of the
operating hours counter from the drive
motor.
·
Remove the side cover, as described in
chapter 8.1.3.
·
Detach the operating hours counter from the
side cover.
·
Turn the operating hours counter around.
·
Loosen and remove the four Phillips screws
of the housing.
·
Disconnect the plugs (+) & (-).
·
Remove the cable ties (4).
·
Carefully pull the connecting cable (2) of the
operating hours counter out of the casing
(1).
·
Replace the cable of the operating hours
counter.
Invacare ® - Kite
SERVICE MANUAL
CAUTION!
Property damage can result if the counter is wrongly connected. If the plus and minus
wires are connected the wrong way, it will damage the electronic components of the
operating hours counter.
· Make sure the cable is connected correctly.
·
·
Assembly of the operating hours counter is
carried out in the reverse order.
·
Protect the cable from tension using a cable
tie (3).
·
Connect the plug of the blue wire (-) to the
plug contact of the operating hours counter
which is marked with a "2".
·
The blue wire is additionally marked with a
minus symbol.
·
Connect the plug of the brown wire (+) to the
plug contact of the operating hours counter
which is marked with a "1".
·
The blue wire is additionally marked with a
sleeve, which has a plus symbol on it.
·
Assemble all remaining parts again in
reverse order.
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SERVICE MANUAL
9.4
Invacare ® - Kite
Luggage carrier
Requirements:
· 5 mm Allen wrench
· 10 mm open-ended wrench
124
·
If no conventional lighting system is installed:
Loosen and remove both hexagon socket head screws (4) together with the washer.
·
If a conventional lighting system is present:
Loosen and remove both of the hexagon socket head screws (4) including the washers, spacer
sleeve, etc. Also see chapter 8.7.9.
·
Install the luggage carrier fixation bracket (3).
·
If a conventional lighting system is present:
Install the light bracket. Also see chapter 8.7.9.
·
Install both hexagon socket head screws (4) together with the washers, spacer sleeve, etc.
·
Repeat these work steps on the other side of the wheelchair.
·
Open the clamping levers (5) of the luggage carrier fixation bracket.
·
Push the brackets onto the luggage carrier (1).
·
Install the luggage carrier with the brackets. When tightening the screws (2), make sure that
the luggage carrier is correctly centered.
Invacare ® - Kite
9.5
SERVICE MANUAL
·
Close both of the clamping levers.
·
Make sure that the luggage carrier does not collide with the backrest or seat when adjusting
the backrest angle or seat tilt to any setting.
·
If collisions can occur:
- Open the clamping levers of the luggage carrier fixation bracket.
- Push the luggage carrier slightly towards the rear.
- Close the clamping levers of the luggage carrier fixation bracket.
Further accessories
Note
The installation instructions for additional accessories are available at your Invacare® specialist
supplier or directly from Invacare®.
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SERVICE MANUAL
10
Invacare ® - Kite
Adjusting the seating position
In order to adapt the mobility device optimally to the requirements of the user, we recommend that
you ask your authorised Invacare® the dealer toadjust the seat depth individually.
Adapting the seat to the user's seating position depends on which seat has been fitted, and should
be carried out in the following sequence.
1.
2.
3.
4.
5.
Adjusting the lower leg length and seat depth, see chapter 10.1.
Adjusting the seat height, see chapter 10.2.
Adjusting the center of gravity of the seat frame, see chapter 10.3.
Checking that the swivel castors can move freely
Repetition of steps 3 to 4, if necessary
WARNING!
Danger of injury hazard after tilting of mobility caused by blocked steering wheels.
· Always check the seat depth settings for both forward and reverse movement.Make sure that
steering wheels can rotate freely and have not contact to any fixed mobility device component.
CAUTION!
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!
WARNING: Danger of crushing!
The seat is very heavy. Danger of injury to hands and feet.
· Pay attention to the hand and feet
· Use proper lifting techniques
126
Invacare ® - Kite
10.1
SERVICE MANUAL
Adjusting the lower leg length and seat depth
10.1.1 Adjusting the lower leg length
Invacare® offers a range of legrests which can be adjusted individually.
See operation manual.
10.1.2 Adjusting the seat depth
A: Seat depth
B: Center of gravity of the seat/ seat position
Standard seat
The Seat depth is adjusted by moving the seat back.
The backrest holders (see Section 8.16) can be mounted in 3 different positions on the seat plate
(see Section 10.3.1).
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SERVICE MANUAL
Flex2 seat
The Flex2 seat is fixed directly to the base frame.
·
Rear drillholes (1)
·
Front drillholes (2)
Note
For adjusting the seat depth should be first the
seat frame secured in the median position on the
base frame.
To adjust the seat depth, proceed as follows:
·
Loosen screws (3)
·
Push the front seat section forwards or
backwards
·
Retighten the screws (3)
Modulite seat
The seat depth is adjusted by shifting the position of the backrest.
See User Manual.
10.2
Adjusting the seat angle
The seat height is adjusted via the seat angle and the actuator holder.
There are two kinds of the seat angle adjustment:
A = 12°- Seat angle adjustment (Standard seat and Flex2 seat)
B = 20°- Seat angle adjustment (Flex2 seat and Modulite seat)
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Invacare ® - Kite
SERVICE MANUAL
10.2.1 12° Adjusting the seat angle with Standard seat or Flex2 seat
Requirements:
· 4 mm Allen wrench
· 13 mm open-ended wrench
· Screwdriver, flat, width approx. 6 mm
· Small hammer
ATTENTION: Danger of crushing!
The seat is very heavy. Danger of injury to hands and feet!
· Use proper lifting techniques.
Overview of the fixations points, depending on the desired seat height and the seat which is
installed:
12° tilt with standard seat
Seat
height
in cm
A
42
X
44
B
C
48
50
a
X
b
c
X
X
X
X
12° tilt with Flex2 seat
A
d
X
48
46
D
X
46
Seat
height
in cm
Actuator holder
B
C
Actuator holder
D
X
a
b
c
d
X
X
X
X
X
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SERVICE MANUAL
Adjusting the actuator holder on the chassis
Detailed instructions on the actuator can be found
in chapter 8.15.1.
130
·
Use the screwdriver to remove the SLretainer (1) of the lower holding bolt.
·
Place a support under the seat.
·
Pull the holding bolt.
·
Adjust the actuator with holding bolt to the
desired height, according to the table S. 129.
·
Secure the holding bolt with the SL-retainer.
·
Use the open-end wrench to loosen and
remove the self-securing nut (1). Pay
attention to the washer while doing so.
·
Place a support under the seat.
·
Pull the screw (2). Pay attention to the
washers while doing so.
·
Adjust the seat with the screw (2) to the
desired height, according to the above
table.
·
Re-position the nut (1) and tighten.
Invacare ® - Kite
Invacare ® - Kite
SERVICE MANUAL
10.2.2 20° Adjusting the seat angle Flex2 seat or Modulite seat
Requirements:
· 5 mm Allen wrench
· Screwdriver, flat, width approx. 6 mm
· Small hammer
ATTENTION: Danger of crushing!
The seat is very heavy. Danger of injury to hands and feet!
· Use proper lifting techniques.
Overview of the fixation points, depending on desired seat height:
20° tilt with Flex2 seat
Seat
height
in cm
B
46
X
48
C
Actuator holder
D
b
c
d
X
X
50
X
X
X
Adjusting the actuator holder on the chassis
Detailed instructions on the actuator can be found in
chapter 8.15.1.
·
Use the screwdriver to remove the SL-retainer (1)
of the lower holding bolt.
·
Place a support under the seat.
·
Pull the holding bolt.
·
Adjust the actuator with holding bolt to the desired
height, according to the above table.
·
Secure the holding bolt with the SL-retainer.
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SERVICE MANUAL
Flex2 seat
·
Place a support under the seat.
·
Use the Allen wrench to loosen the screw (1)
and remove. Pay attention to the washer
while doing so.
·
Adjust the seat with the screw (1) to the
desired height, according to the table S.131.
·
Tighten the screw (1).
Modulite seat
132
Invacare ® - Kite
10.3
SERVICE MANUAL
Adjusting the center of gravity of the seat
The center of gravity of the seat can be adjusted by mounting the seat frame farther towards the
front or the rear on the seat.
CAUTION!
The seating system of the electric wheelchair is delivered ex works with an optimally
adjusted center of gravity. Any change in this adjustment setting can negatively influence
the stability of the electric wheelchair.
· You must perform an individual risk analysis every time you change the center of gravity of
the seating position, in order to ensure the safety and stability of the electric wheelchair.
A: Seat depth
B: Center of gravity of the seat/ seat position
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SERVICE MANUAL
Invacare ® - Kite
Note
The user weight and seat depth have strong influences on the choice of the Center of gravity of
the seat. If the user is heavy and the seat depth is greater, the focus should be the farther back.
For best possible driving characteristics of rear-wheel drive wheelchairs, the weight to be
distributed: 30 – 40 % front and 60 - 70 % rear.
WARNING!
Danger of damage due to collisions of the legrests with other parts of the wheelchair!
· Set the legrests to the smallest angle before adjusting the seat center of gravity.
· Pay attention with adjusting the seat center of gravity that the legrests do not touch any other
parts of the wheelchair. This ensures that the legrests can not collide with other parts of the
wheelchair.
134
Invacare ® - Kite
SERVICE MANUAL
Screw fixation positions of various seats and tilt modules
12° tilt module
1 – Screw fixation positions of the standard seat
2 – Screw fixation positions of the Flex2
A – Screw fixation variations Flex2,
see details below
20° tilt module
2 – Screw fixation positions of the Flex2
A – Screw fixation variations Flex2,
see details below
Screw fixation variations Flex2
1 – Rear
2 – Middle
3 – Front
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SERVICE MANUAL
20° tilt module Modulite
Because of the oblong holes (1) there is no fixed
screw fixation position at the modulite.
The seat angle adjustment depends on the
measurements as described in chapter 10.3.3.
136
Invacare ® - Kite
Invacare ® - Kite
SERVICE MANUAL
10.3.1 Standard seat
Requirements:
· 4 mm Allen wrench
· 5 mm Allen wrench
· 13 mm open-ended wrench
· Flat screwdriver
· Smal hammer
ATTENTION: Danger of crushing!
The seat is very heavy. Danger of injury to hands and feet!
· Use proper lifting techniques.
The pictures show the standard seat without
seat covering from above (A) and below (B).
·
Rear bolts (1)
·
Front bolts (2)
·
Seat plate (3)
·
Seat frame (4)
The seat plate can be fixed in three different
positions on the seat frame.
·
Front fixing (V)
·
Centre fixing (M)
·
Rear fixing (H)
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SERVICE MANUAL
The picture shows where the drillholes for fixing
the seat frame (3) are located on the base frame.
·
Rear drillholes (1)
·
Front bolts (2)
·
The seat frame can only be fixed in one
position on the base frame.
10.3.2 Flex2 seat
Requirements:
· 4 mm Allen wrench
· 5 mm Allen wrench
· 13 mm open-ended wrench
· Flat screwdriver
· Smal hammer
ATTENTION: Danger of crushing!
The seat is very heavy. Danger of injury to hands and feet!
· Use proper lifting techniques.
The illustration shows the Flex2 seat from above
without seat covering.
138
Invacare ® - Kite
Invacare ® - Kite
SERVICE MANUAL
· Loosen the fixation screws at the appropriate
positions (2).
12° tilt
20° tilt
139
SERVICE MANUAL
·
Invacare ® - Kite
Slide the Flex2 seat forward or rearward until
the fixation screws can be inserted into the
corresponding variation holes:
1 – Hinten
2 – Mitte
3 – Vorne
With the three holes on the seat frame five
variants are possible.
·
Replace the fixation screws and tighten.
·
Re-install all seat components.
CAUTION!
Danger of injury and damage to property!
If the castor wheels collide with parts of the wheelchair, the castor wheels can become
jammed, causing the wheelchair to tip.
· After adjusting the seat depth, always check that the castor wheels can move freely during
forward and backward driving and do not touch static parts of the wheelchair.
·
140
Check all functions during a test-drive.
Invacare ® - Kite
SERVICE MANUAL
10.3.3 Modulite seat
The Modulite seat is available in two versions:
· Adjustable seats (plate and strap):
Adjustment of the center of gravity via the lateral profiles, as described in chapter 10.3.3.1.
· Simple seat:
Adjustment of the center of gravity via the oblong holes of the seat adaptor, as described in
chapter 10.3.3.2.
CAUTION!
Increased danger of tipping over, if the center of gravity is shifted too far towards the rear.
There must ALWAYS be at least 46 mm clearance between the backrest and the rear axle.
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SERVICE MANUAL
Invacare ® - Kite
Note
The front edge of the seat frame profile should be located 15 to 17 mm in front of the steering
heads of the castors.
If you decrease this value, make sure that
· you decrease the seat depth by the same value and
· there are no collisions between the legrests and the castors.
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SERVICE MANUAL
10.3.3.1 Adjustable seats
Requirements:
· 6 mm Allen key
· Remove the seat plate or sling seat (1), see chapter 8.19.1.
· Loosen the socket head screws (2) in the front and rear, left and right – DO NOT remove.
· Shift the position of the seat.
· Re-tighten the screws.
· Install the seat plate or the sling seat again.
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SERVICE MANUAL
Invacare ® - Kite
10.3.3.2 Simple seat
Requirements:
· 6 mm Allen key
· Remove the seat plate (1) or the sling seat, see chapter 8.19.1.
· Loosen the socket head screws (2) in the front and rear, left and right – DO NOT remove.
· Shift the position of the seat frame.
· Re-tighten the screws.
· Install the seat plate again.
144
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