Invacare Power Tiger Service Instructions Manual

Invacare

®

Dragon

Invacare

®

Tiger

SERVICE INSTRUCTIONS

Edition: 09.07.2013

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

Herzog Odilostrasse 101

A-5310 Mondsee

Austria

(:

Fax:

@:

WWW:

Invacare n.v.

Autobaan 22

B-8210 Loppem (Brugge)

Belgium

Invacare AG

Benkenstraße 260

CH-4108 Witterswil

Switzerland

Invacare Aquatec GmbH

Alemannenstraße 10

88316 Isny

Deutschland

Invacare A/S

Sdr. Ringvej 37

DK-2605 Brøndby

Danmark

Invacare® SA

c/ Areny s/n

Polígon Industrial de Celrà

E-17460 Celrà (Girona)

ESPAÑA

Invacare® Poirier SAS

Route de St Roch

F-37230 Fondettes

France

(:

Fax:

@:

WWW:

(:

Fax:

@:

WWW:

(:

Fax:

@:

WWW:

+32 (0)50 83 10 10

+32 (0)50 83 10 11 [email protected] www.invacare.be

+41 (0)61487 70 80

+41 (0)61487 70 81 [email protected] www.invacare.ch

(

Fax

@:

WWW:

( (Kundeservice):

Fax (Kundeservice):

@:

WWW:

+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

+34 (0)972 49 32 00

+34 (0)972 49 32 20 [email protected] www.invacare.es

(:

Fax:

@:

WWW:

Invacare

®

- Dragon / Tiger

+43 6232 5 53 50

+43 6232 5 53 54 [email protected] www.invacare.at

+33 (0)247 62 64 66

+33 (0)247 42 12 24 [email protected] www.invacare.fr

2

Invacare

®


Invacare® Ltd

Pencoed Technology Park

Pencoed

Bridgend CF35 5HZ

United Kingdom

Invacare Mecc San s.r.l.

Via dei Pini, 62

I - 36016 Thiene (VI)

Italia

Invacare Ireland Ltd.

Unit 5 Seatown Business Campus

Seatown Rd, Swords

County Dublin

Ireland

Invacare® AS

Grensesvingen 9

Postboks 6230

Etterstad

N-0603 Oslo

Norge

Invacare® B.V.

Celsiusstraat 46

NL-6716 BZ Ede

Nederland

Invacare Lda

Rua Estrada Velha, 949

P-4465-784 Leça do Balio

Portugal

( (Customer services):

+44 (0)1656 77 62 22

Fax (Customer services): +44 (0)1656 77 62 20

@:

WWW: [email protected] www.invacare.co.uk

(:

Fax:

@:

WWW:

(:

Fax:

@:

WWW:

( (Kundeservice):

Fax (Kundeservice):

@:

@:

WWW:

(:

Fax:

@:

@:

WWW:

(:

(:

Fax:

@:

WWW:

+39 0445 38 00 59

+39 0445 38 00 34 [email protected] www.invacare.it

+353 18 10 70 84

+353 18 10 70 85 [email protected] www.invacare.ie

+47 (0)22 57 95 00

+47 (0)22 57 95 01 [email protected] [email protected] www.invacare.no

+31 (0)318 69 57 57

+31 (0)318 69 57 58 [email protected] [email protected] www.invacare.nl

+351 225 10 59 46

+351 225 10 59 47

+351 225 10 57 39 [email protected] www.invacare.pt


3


Återförsäljare:

Invacare® AB

Fagerstagatan 9

S-163 91 Spånga

Sverige

Tillverkare:

Invacare® Deutschland GmbH

Kleiststraße 49

D-32457 Porta Westfalica

Deutschland

Eastern european countries

European Distributor

Organisation (EDO)

Kleiststraße 49

D-32457 Porta Westfalica

Deutschland

Invacare

®


( (Kundtjänst):

Fax (Kundtjänst):

@:

@:

WWW:

MÖLNDAL

(:

Fax:

@:

LANDSKRONA

(:

Fax:

@:

OSKARSHAMN

(:

Fax:

@:

(

Fax

@:

WWW:

+46 (0)8 761 70 90

+46 (0)8 761 81 08 [email protected] [email protected] www.invacare.se

+46 (0)31 86 36 00

+46 (0)31 86 36 06 [email protected]

+46 (0)418 2 85 40

+46 (0)418 1 80 89 [email protected]

+46 (0)491 1 01 40

+46 (0)491 1 01 80 [email protected]

+49 (0)5731 75 45 40

+49 (0)5731 75 45 41 [email protected] www.invacare.de

4

Invacare

®


Table of Contents

Chapter


TABLE OF CONTENTS

1 INTRODUCTION

1.1

1.2

1.3

1.4

1.5

General information

Notes on transport

Definition and representation of information and safety information in this manual

Hazard symbols and symbols used

Images in this manual

2 SAFETY AND FITTING INSTRUCTIONS

2.1

2.2

2.3

Before any inspection or repair work

Personal safety equipment

General safety information and information about fitting / removal

3 TIGHTENING TORQUES

4 ARRANGEMENT OF THE ASSEMBLY GROUPS AND COMPONENTS

5 SERVICE PLAN (1X ANNUALLY)

6 OPERATIONAL FAULTS

6.1

6.1.1

6.1.2

Operational faults on a wheelchair fitted with Shark electronics

Diagnosis of actuation disorders

Shark error codes and diagnostic codes

7 REPAIR WORK

7.1

7.2

7.3

General warning information on installation work

Replacing the motor

Replacing the Shark Electronics

7.4

Updating the driving program

7.5

7.5.1

7.5.2

Changing the batteries

Removing the batteries

How to handle damaged batteries correctly

Page

5

7

9

10

7

7

8

11

11

11

11

13

14

15

21

21

21

25

27

28

29

30

17

17

17

19

5


7.6

7.7

Checking and replacing the main fuse

Checking the cables

7.8

Replacing the Shark Remote

7.9

7.9.1

7.9.2

Operating hours counter

Replacing the operating hours counter

Replacing the connecting cable of the operating hours counter

7.10

Replacing the steering head bearings on the steering wheels

7.11

Repairing a flat tyre

7.11.1

Repairing the rear tyre (wheel size 12½ x 2¼")

7.11.2

Repairing a flat tyre (wheel size 220/120 x 50)

7.12

Replacing a drive wheel

7.13

Adjusting the seat angle/seat height

7.13.1

Adjustment tables

7.14

Replacing the safety belt

7.15

Testing an actuator motor

Invacare

®


31

33

43

43

45

47

35

37

37

39

41

49

51

54

54

6

Invacare

®


1 Introduction


1.1 General information

· 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.

1.2 Notes on transport

· If the mobility aid has to be shipped back to the manufacturer for major repairs, you should always use the original packaging for transport.

· Please attach a precise description of the fault.

7

SERVICE MANUAL Invacare

®


1.3 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.


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.


CAUTION!

The signal word "CAUTION!" refers to hazards which could lead to material damage if they are not avoided.


Note

The signal word "Note" is used to denote general information which simplifies the handling of your product and refers to special functions.

8

Invacare

®


1.4 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!


DANGER OF CRUSHING!

This symbol warns you of crushing hazards due to inattentive working with heavy components.


EXPLOSION HAZARD!

This symbol warns you of an explosion hazard, which can be caused by excessive tyre pressure in a pneumatic tyre.


Wear safety shoes

The symbol refers to the requirement for wearing safety shoes.

· Wear standardised safety shoes during all work.

Wear eye protection

This symbol refers to the requirement for wearing eye protection, for example when working with batteries.

· Wear eye protection when this symbol is shown.

Wear safety gloves

This symbol refers to the requirement for wearing safety gloves, for example when working with batteries.

· Wear safety gloves when this symbol is shown.

Note

This symbol identifies general information which is intended to simplify working with your product and which refers to special functions.

Requirements:

· This symbol identifies a list of various tools, components and items which you will need in order to carry out certain work. Please do not attempt to carry out the work if you do not have the listed tools available.

Always dispose used or damaged batteries correctly

The symbol refers to information for the correct disposal of used or damaged batteries.

9


1.5 Images in this manual

Invacare

®


The detailed images in this manual are given digits to identify various components. Component numbers in text and operational instructions always relate to the image directly above.

10

Invacare

®


2 Safety and fitting instructions


These safety instructions are intended to prevent accidents at work, and it is imperative that they are observed.

2.1 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)!

2.2 Personal safety equipment

Safety shoes

The mobility device, and some of its components, are very heavy. These parts can result in injuries to the feet if they are allowed to drop.

· Wear standardised safety shoes during all work.

Eye protection

It is possible that battery acid can be discharged when working on defective batteries or when handling batteries improperly.

· Always wear eye protection when working on any defective or possibly defective batteries.

Safety gloves

It is possible that battery acid can be discharged when working on defective batteries or when handling batteries improperly.

· Always wear acid-proof safety gloves when working on any defective or possibly defective

batteries.

2.3 General safety information and information about fitting / removal

WARNING! Danger of crushing!

Various components such as the drive unit, batteries, seat etc are very heavy. This results in injury hazards to your hands!

· Please note the high weight of some components! This applies especially to the removal of

drive units, batteries and the seat.

WARNING!

Injury hazard if the vehicle starts moving unintentionally during repair work!

· Switch the power supply off (ON/OFF key)!

· Engage the drive!

· Before raising the vehicle, secure the wheels by blocking them with wedges!

ATTENTION!

Fire and burn hazard due to electrical short-circuit!

· The mobility device must be completely switched off before removal of voltage-carrying

components! To do this, remove the batteries.

· Avoid short-circuiting the contacts when carrying out measurements on voltage-carrying

components!

11


®


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.

Note

Mark all current settings for the mobility aid (seat, armrests, backrest etc.), and the associated cable connecting plugs, before dismantling. This makes reassembly easier.

All plugs are fitted with mechanical safety devices which prevent release of the connecting plugs during operation. To release the connecting plugs the safety devices must be pressed in. When reassembling ensure that these safety devices are correctly engaged.

WARNING!

Any changes to the drive program can affect the driving characteristics and the tipping stability of the vehicle!

· Changes to the drive program may only be carried out by trained Invacare® specialist

dealers!

· Invacare® supplies all mobility aids with a standard drive program ex-works. Invacare® can

only give a warranty for safe vehicle driving behaviour - especially tipping stability - for this standard drive program!

12

Invacare

®


3 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 M14 M16

Tightening torque in Nm ±10%

3 Nm 6 Nm 10 Nm 25 Nm 49 Nm 80 Nm 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 finger tight.

13


®


4 Arrangement of the assembly groups and components

Under the seat:

1) Decoupling mechanism

2) Power module

3) Perforated plates for adjusting the seat height and seat angle

Under the battery cover

4) Main battery fuse

14

Under the seat frame

5) Operating hours counter

(optional)

Invacare

®


5 Service plan (1x annually)


Component

Armrests and side panels

Seat unit / seat angle adjustment

Backrest unit mechanical

· Armrest damage and fastening

· Side panel damage and fixing

· Cushion

· Check seat angle adjustment

· Damage and seams

· Fixing

· Check cabling

· Check function

· Tighten screws, replace padding if damaged

· Tighten screws, replace side panels if damaged

· Replace covers / upholstery if damaged

· Replace parts if damaged

· Replace parts if damaged

· Tighten screws

· Replace cable or motor if necessary

Backrest unit electrical (if installed)

Frame (chassis)

/ battery box

Wheel suspension and wheels

· Check fixings, welded seams and battery box

· Check drive wheels for tight fit and side play

· Tighten screws, replace components

· Adjust, replace wheel hubs

· Check steering wheels for tight fit, float, side play and correct torque (15

Nm +/- 1.5 Nm)

· Replace wheels, wheel fork or wheel bearings

See "Replacing a

drive wheel" on page 47

See "Replacing

the steering head bearings on the

steering wheels" on page 41

· Pneumatic tyres (if available)

· Repair or replace if damaged

See "Repairing a

flat tyre" on page

43

Drive units, disengager

Legrests

Electrical footrests (if installed)

· Check functions in drive and push modes

· Check disengager

· Replace motor if necessary

· Tighten screws / nuts, adjust or replace if necessary

· Tighten, replace if necessary

· Check welded seams, interlocking, screws, footplates

· Check cabling

· Check contacts

· Check functions

· Replace cable if necessary

Lighting (if installed)

· Check cabling

· Check function

· Replace bulbs or cables if necessary

Batteries

Check

· Check batteries for damage

Action

· Replace batteries if necessary

Notes

See "Changing the

batteries" on page

28

ü

· Check battery charge

· Charge batteries

See User Manual

15


Component

Remote / electronics

Driving

Programme

Invacare

®


Check

· Check contacts and terminals for corrosion

· Remote, status display blinking

· Fixing

· Cable, connecting plug

· Joystick function

· Power supply

· Check the programme version of the driving electronics.

Is there a newer version available?

Action

· Clean contacts and terminals

· Evaluate flash code

· Tighten, replace

· Replace

· Replace joystick

· Replace cable, connector plug or console

· Update the software.

Notes



28 for safety

information when handling batteries

See "Updating the

driving program" on page 27

ü

16

Invacare

®


6 Operational Faults


6.1 Operational faults on a wheelchair fitted with Shark electronics

Please proceed as follows in the event of operational faults:

· First of all analyse the possible cause of the disorder on the basis of the following tables.

· Check the status display on the remote. Analyse the flashing error code.

· Carry out the necessary checks and repairs as recommended in the following table.

6.1.1 Diagnosis of actuation disorders

Problem

Wheelchair will not start up

Other

Symptoms

Possible Cause

Status display on the remote illuminated as normal and does not indicate a disorder code

Actuation motors may be disengaged

Status display on the remote is not illuminated

Batteries may be faulty

Solution

· Clutch in actuation motors

· Replace the batteries

Status display on remote flashing

Batteries may be almost empty

Power supply to the remote may be interrupted

· Charge batteries

· Check the main fuse

Remote may be faulty

· Check the cable between the modules for any loose connections or damage

· Change the remote on the wheelchair to be able to exclude the remote being the cause of the fault.

Various causes

· Analyse error code

Documentation

See operating instructions



28

See User Manual

See "Checking

and replacing the

main fuse" on page

31

Siehe "Checking

the cables" on page 33

See "Replacing

the Shark Remote" on page 35

See "Shark error

codes and

diagnostic codes" on page 19

17


Problem

Wheelchair jerky in drive operation

Other

Symptoms

None

Batteries not being charged

None

LEDs flashing on charger

Wheelchair drives too

slowly

None

Possible Cause Solution

Invacare

®


Documentation

Batteries may be faulty (instable voltage)

Actuation motor(s) may be faulty


Charger may be faulty



· Replace motor(s)

· Replace batteries

· Replace charger

· Replace batteries



28

See "Replacing

the motor" on page

21



28

See operating instructions for battery charger



28

18

Invacare

®


6.1.2 Shark error codes and diagnostic codes


The actuation electronics can automatically remedy certain disorders. In this case the status display will stop flashing. Please switch the remote on and off several times. Please wait about 5 seconds every time before switching the remote on again. If the error is not remedied by this, please diagnose the cause on the basis on the following flashing codes.

Flashing

Code

1

2

3

4

5

6

7

8

Meaning Solution Documentation

Operational error

· Please ensure that the joystick is in neutral central position (simply release joystick) and switch on again.

Battery error

· Check battery and power cable.

See "Checking the

cables" on page 33

· Charge batteries. If you switch the wheelchair off for a few minutes the batteries are often able to re-charge sufficiently to enable a short journey.

You should, however, only use this solution in an emergency as this leads to the batteries discharging excessively.


See operating instructions



28

Error on the left motor (M2)

· Check the motor cable and Uconnector.

· Check the motor.



See "Replacing the

motor" on page 21

Error on the right motor (M1)

· Check the motor cable and Uconnector.

· Check the motor.




motor" on page 21

Fault on the left

(M2) motor brake

· Check cable and connector.



Fault on the right

(M1) motor brake

· Check cable and connector.



Fault on the Shark remote

· Check the bus cable on the remote and U-connector.

· Replace the remote.




Shark Remote" on page 35

Fault on Shark main module

· Check all cables and connectors on the Shark system.

· Replace the main module.




Shark Electronics" on page 25

19


®


Flashing

Code

9

10

11

Meaning Solution Documentation

Communication error on the Shark system

Unknown error

Incompatible remote

· Check all cables and connectors on the Shark system.

· Replace the remote.





· Check all cables and U-connectors.



· An incorrect remote has been connected. Ensure that main module and remote code are concordant.




Shark Electronics" on page 25

20

Invacare

®


7 Repair Work

7.1 General warning information on installation work


CAUTION!

Danger of damage to vehicle! 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!

7.2 Replacing the motor

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.

ATTENTION: Injury hazard caused by uncontrolled movement of the mobility device!

· Switch the power supply off (ON/OFF key).

· Engage the drive.

· Before raising the vehicle, secure the wheels by blocking them with wedges.

· Prevent the mobility device tipping by propping it up on a wooden block which is long and wide

enough under the battery case! If the wooden block is too short or too high, the mobility device can still tip!

WARNING!

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.

Pre-requisites:

· Small, flat screwdriver

· 5 mm Allen key

· 8 mm Allen key

· 11 mm open-ended spanner


· Aglet, diameter 2.5 mm (for knocking the splint out of the decoupling leverage)

· Small hammer

· Edge cutter

· Cable binder

· Wooden chock (approx. 12 x 12 x 30 cm) for jacking up the vehicle

Note

Please take care of the small parts and observe the sequence in which the component parts are installed. Please set them out in an orderly fashion so that they can be installed again easily in the correct sequence.

21


· Jack up the vehicle using the wooden chock.

· Loosen the socket head screw (1) using a

5 mm Allen key.

· Remove the screw and the hub cap.

· Pull the complete wheel from the wheel hub.

Invacare

®


· Remove the battery cover.

· Pull off the battery pole caps and push back to gain access to the battery poles.

· Loosen the battery pole clips with the 11 mm open-ended spanner.

· Remove the batteries.

22

Invacare

®


· In order to remove the motor, the front decoupling rod connection (1) must be disconnected. Release the retaining ring (1) using the small, flat screwdriver and pull out.

· Unscrew handwheels (screws) (1) on both sides of the panelling for the electronics.

· Remove the panelling for the electronics.


· Pull the motor plug on the motor to be replaced out of the electronics.

· The motor cable is secured to the frame with a cable binder. Use the edge cutter to cut through the cable binder.

· Loosen the motor suspension (1) using the

8 mm Allen key and the 19 mm open-ended spanner and remove.

· Remove the motor from the suspension in a downward direction.

23


· Loosen the four screws (1) on the motor suspension and remove.

Invacare

®


· Use the aglet and the hammer to carefully knock the splint (2) out of the decoupling leverage (1).

· Remove the decoupling leverage (1) together with the decoupling rod (cannot be seen in the picture on the right) from the old motor.

CAUTION!

Damage to the motor is possible!

· Only apply moderate pressure to the decoupling lever when fitting to the metal rod on the new

motor.

· Do not use a hammer!

Note

The simplest way to install the decoupling lever is to do this before the motor and other parts are assembled together.

· Carefully press the decoupling leverage (1) onto the rod (2) protruding from the new motor.

· Press the splint (3) in.

24

· The motor is installed in the reverse order.

· Secure the motor cable by means of a new cable binder.

Invacare

®


7.3 Replacing the Shark Electronics


Pre-requisites:

· Phillips screwdriver

· To modify a drive program you will need: Programming software or a Handheld Programmer and the Installation Manual of the Shark Electronics (Part Number 1436160), available from

Invacare®.

Note

All electronic modules are supplied with a standard drive program. If the driving program has been customised, then you will have to perform this customisation again, after installing the new electronic module.

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!

· Unscrew the handwheels (screws) (1) on both sides of the panelling for the electronics.

· Remove the electronic panelling.

· Disengage all the plugs (1) on the electronic module.

25


· Remove the screws (1) on both sides of the power module.

· Pull out the module.

Invacare

®


· Installation of the electronics is carried out in the reverse order.

· Update the software, in case a newer version is available.

· Customise the driving program with the programming software, if required.

· Check all vehicle functions.

26

Invacare

®


7.4 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.

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/.

27


7.5 Changing the batteries

Invacare

®


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:





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!

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7.5.1 Removing the batteries


ATTENTION:





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.

Requirements:

· Open-end spanner 11 mm


· Pull the battery pole caps (1) upward and push back in order to reach the battery poles.

· Use the open-ended spanner to loosen the battery pole clamps.

· Remove the batteries to the rear.

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7.5.2 How to handle damaged batteries correctly

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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:

· Safety goggles

· Acid-resistant gloves

· Acid-resistant receptacle for transportation

· Always wear appropriate safety clothing when handling damaged batteries.

· Place damaged batteries in an acid-resistant receptacle immediately after removing them.

· Only ever transport damaged batteries in an appropriate acid-resistant receptacle.

· Wash all objects that have come into contact with acid with lots of water.

Always dispose used or damaged batteries correctly

Used and damaged batteries will be taken back by your medical equipment supplier or

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7.6 Checking and replacing the main fuse


CAUTION: Fire hazard!

A short circuit can cause extremely high currents which can result in spark formation and fire!

· 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 ever assemble the fuse in the order shown in the

illustration at right!

· Always tighten nuts to between 3.3 and 3.5 Nm!

Until 03.2004

1. Fuse

2. Fuse compartment

After 03.2004

1. Fuse

2. Fuse compartment

3. Washer

4. Nut M5

3. Nut DIN 6923

Pre-requisites:

· 8mm open-ended spanner

· 40A strip fuse

Information

If the fuse holder is damaged this can be replaced completely together with the battery cables.


31


· The fuse holder of the Shark electronic system is located on top of the batteries (1).

· Open the fuse holder cover.

· If the strip fuse has blown, determine the cause of the fault and remedy if necessary.

The main fuse should only be replaced when the fault has been remedied.

· Use the 8mm open-ended spanner to unscrew the nuts (2) on the strip fuse.

· Replace the strip fuse.

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· Installation is carried out in the reverse order.


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7.7 Checking the cables



· Check all cables for visible damage and crushing. Replace damaged cables.

· Pull on each plug (1) carefully. It must not come out of the socket.

· If a plug is loose, apply slight pressure to push the plug into the socket. It must lock in place.

· Check whether the plug is now fitted firmly inside the socket. If not, please repeat the preceding work step.



· Check the battery cables (1) for visible damage and crushing. Replace damaged cables.

33


· Re-install the panelling for the electronics and the battery cover.


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7.8 Replacing the Shark Remote

Pre-requisites:

· 3 mm Allen key

· Switch off the remote.

· Loosen the wing screw (1).

· Pull the remote out of the guide together with the remote holder.

· Use the Allen key to unscrew both screws (1) on the remote holder.




35


· Disengage the remote plug.

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· The installation of the remote and the panelling for the electronics is carried out in the reverse order.


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7.9 Operating hours counter

7.9.1 Replacing the operating hours counter

Requirements:

· Philipps screwdriver, size 2

· 10 mm open-end wrench

· Switch off the electronics.

· Remove the legrests.

· Loosen and remove the thumb screws (1) on both sides of the electronics cover.

· Remove the electronics cover.

The operating hours counter is attached to the frame with a Velcro strip.

· Disconnect the cable of the operating hours counter from the drive motor.

· Pull the operating hours counter off of the frame.

· Turn the operating hours counter over.

· Loosen and remove the four Philipps head screws of the casing.

· 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.


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CAUTION!

Property damage can result if the counter is incorrectly 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.

· The operating hours counter is installed in reverse order.

· Connect the plug on the blue wire (-) to the pin on the operating hours counter which is marked with a “minus” symbol.

· Connect the plug on the brown wire (+) to the pin on the operating hours counter which is marked with a “plus” symbol.

The brown wire is additionally marked with a yellow sleeve with a “plus” symbol on it.

· Close the casing and reattach it to the wheelchair with the Velcro fastening.

· Reinstall all remaining components in reverse order.

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- Dragon / Tiger SERVICE MANUAL

7.9.2 Replacing the connecting cable of the operating hours counter

Requirements:

· Philipps screwdriver, size 2

· Side cutters

· Cable ties

· Switch the electronics OFF.

· Remove the legrests.

· Loosen and remove the thumb screws (1) on both sides of the electronics cover.

· Remove the electronics cover.

The operating hours counter is attached to the frame with a Velcro strip.

· Disconnect the cable of the operating hours counter from the drive motor.

· Pull the operating hours counter off of the frame.

· Turn the operating hours counter over.

· Loosen and remove the four Philipps head screws of the casing.

· Disconnect the plugs (+) & (-).

· Remove the cable binder.

· Carefully pull the cable (2) of the operating hours counter out of the casing (1).

· Replace the operating hours counter cable.

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CAUTION!

Property damage can result if the counter is incorrectly 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.

· The cable of the operating hours counter is installed in reverse order.

· Connect the plug on the blue wire (-) to the pin on the operating hours counter which is marked with a “minus” symbol.

· Connect the plug on the brown wire (+) to the pin on the operating hours counter which is marked with a “plus” symbol.

The brown wire is additionally marked with a yellow sleeve with a “plus” symbol on it.

· Secure the cable with a cable tie (3), thereby protecting it from being pulled off unintentionally.

· Close the casing and reattach it to the wheelchair with the Velcro fastening.

· Reinstall all remaining components in reverse order.

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- Dragon / Tiger SERVICE MANUAL

7.10 Replacing the steering head bearings on the steering wheels


· Pay attention to the hand and feet.

· Use proper lifting techniques.

CAUTION: Injury hazard caused by uncontrolled movement of the mobility device!




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!

Required parts/tools:

· 19 mm socket wrench

· Torque spanner

· Large screwdriver, flat

· Wooden chock (approx. 12 x 12 x 30 cm) for jacking up the vehicle

· Use the wooden chock (1) to jack up the wheelchair on the side on which the ball bearings are to be replaced.

· Carefully remove the plastic cap (1) using the large screwdriver.

41


· Use the socket wrench to loosen and remove the 19 mm nut. Hold the wheel in such a way that it is not able to rotate when the nut is removed.

· Pull the steering head shaft downward and out of the steering head tube.

· Remove the shim and the ball race from the head of the tube. The other ball race should be on the shaft.

IMPORTANT ASSEMBLY INFORMATION!

The illustrations show the wide edge on the outside of the ball race (A) and the narrow edge on the inside (B).

The bearings must always be installed in such a way that the narrow edges are facing each other (inside). The steering head bolt and the nut must always press against the wide outside edges. The bearings would otherwise be pressed apart by the bolt pressure.

The steering wheels should be able to rotate freely after assembly, but there must not be any clearance on the bearings.

· Tighten the nut primarily to 20 Nm +/- 2 Nm.

· Slacken the nut slightly.

· Re-tighten to 15 Nm +/- 1.5 Nm.

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7.11 Repairing a flat tyre


WARNUNG: Injury hazard if the vehicle starts moving unintentionally during repair work.







7.11.1 Repairing the rear tyre (wheel size 12½ x 2¼")

Pre-requisites:

· Torque wrench with

- Allen key Bit 5 mm

- Torx Bit R40

· Mounting kit

· Wooden block (approx.12 x 12x 30 cm for propping up vehicle)

· Repair kit for tyre repair or a new inner tube.

· Talcum powder

Dismantling the wheel:

· Lift the vehicle up and place a wooden block underneath it to keep it in a raised position.

· Remove the four countersunk head screws

TX40 (1) using the Torx bit.

· Pull the wheel from the hub.

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Repairing the tyre

ATTENTION: Explosion hazard!

The wheel will explode if you do not let the air out of the tyre before removing the wheel rim!

· Always allow the air to escape completely from the wheel before you remove the rim.

· Remove the valve cap.

· Exhaust the air from the tyre by pressing the spring pin in the valve.

· Remove the 5 cylinder head bolts (reverse side of the wheel, 2) using the Allen key.

· Remove the rim halves from the tyre.

· Remove the inner tube from the tyre.

· Repair inner tube and replace, or insert new.

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.

Note

Refit the wheel in reverse order. Please ensure that the wheel is re-fitted on the same side and in the same running direction as removed.

· Re-insert the rim halves into the tyre.

· Pump a little air into the tyre.

· Insert the socket head screws into the rim and tighten the screws to 10 Nm.

Make sure the inner tube is not crushed between the two rim halves.

· Make sure that the tyre is situated directly on the rim.

· Inflate the tyre to the recommended pressure.

· Check that the tyre is still situated directly and correctly on the rim.

· Screw the valve cap back on.

Installing the wheel:

ATTENTION! Danger of injury if the wheels come off.

If the drive wheels are insufficiently attached during assembly, they can come off during driving.

· Tighten the TX40 countersunk screws to 30 Nm when mounting the drive wheels.

· Always use new screws with undamaged coating.

· Re-install the wheel.

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7.11.2 Repairing a flat tyre (wheel size 220/120 x 50)


Pre-requisites:



· Repair kit for inner tube tires or a new inner tube

· Talcum powder

Removing the wheel

ATTENTION! Danger of crushing to the hands and feet by the weight of the wheelchair!



· Jack up the vehicle (place a wooden wedge under the frame).

· Loosen and remove the screw (1) using the 12 mm socket wrench on the outside and the 13 mm socket wrench on the inside (to counter).

· Pull the wheel from the fork

NOTE

Installation is carried out in reverse order. Please ensure that the wheel is re-fitted on the same side and in the same running direction as removed.

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Repairing a flat tyre

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 evacuate all the air from the tyre.

· Press the release pin in the valve inwards and evacuate all the air from the tyre.

· Unscrew the valve cap.

· Exhaust the air from the tyre by pressing the spring pin in the valve.

· Loosen and remove the four screws (1) using the 12 mm socket wrench on the outside and the 13 mm socket wrench on the inside (to counter).

· Remove the tire with the inner tube from the rim halves.

· Repair the tube and re-fit or fit new tube

Note

If the old inner-tube is to be repaired and re-fitted and has become wet during repair work, powdering the hose with some talcum powder can simplify the fitting procedure.

· Re-insert the rim halves into the tire from the outside.

· Pump a little air into the inner tube.

· Re-position the screws and screw rim together tightly. Make sure the inner tube does not get pinched between the rims halves!

· Check the exact fit of the shoe.

· Inflate the tyre to the prescribed air pressure.

· Re-check the exact fit of the shoe.

· Screw on the valve cap.

· Re-install the wheel.

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7.12 Replacing a drive wheel





WARNING: Injury hazard caused by uncontrolled movement of the mobility device!




· Prevent the mobility device tipping by propping it up on a wooden block which is long and wide

enough under the battery case! If the wooden block is too short or too high, the mobility device can still tip!


· Torx Bit TX40 spanner

· Mounting kit

· Wooden chock (approx. 12 x 12 x 30 cm) for jacking up the vehicle.

Note

Please take care of the small parts and observe the sequence in which the component parts are installed. Please set them out in an orderly fashion so that they can be installed again easily in the correct sequence.

· Jack up the vehicle using the wooden chock

(1).

· Loosen the 4 screws fastening the wheel (1) using the Torx Bit TX40.

· Remove the wheel from the hub.

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ATTENTION: Danger of injury if the wheels come off!

If the drive wheels are insufficiently attached during assembly, they can come off during driving.

· Tighten the TX40 countersunk screws to 30 Nm when mounting the drive wheels.

· Always use new screws with undamaged coating.

Note

Please ensure that the wheel is re-fitted on the same side and in the same running direction as removed.

· Refit the wheel in reverse order.

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7.13 Adjusting the seat angle/seat height


There are three perforated plates under the seat for adjusting the seat angle and the seat height.

These perforated plates, in connection with the adjustable rear holding plates, result in a multitude of different adjustment possibilities.

The adjustable range of the seat height (at 0° seat angle) is 42.5 cm to 50 cm. The adjustable range of the seat angle is -12° to 22°. Please observe: The higher the seat adjustment, the smaller the adjustable range of the seat angle!

Pre-requisites:

· 5 mm Allen key

· 6 mm Allen key


· Torque spanner

· Loctite (medium-hard)

· The picture on the right shows the position of the perforated plates (1) and the fastening screws on the holding plates (2) for adjusting the seat height and the seat angle.

The picture on the right shows the front perforated plates. The approach is similar for the rear perforated plates. To adjust the front perforated plates a 13 mm open-ended spanner is required in addition to the 5 mm Allen key.

· To adjust the seat height/seat angle loosen the screw (1) with the spanners and pull out.

· Set the perforated plates to the desired height/angle.

· Apply the Loctite to the screw, re-insert the screw and tighten to 40 Nm using the spanners.

49


The seat height and seat angle can also be adjusted via the rear holding plates.

· Loosen the rear fastening screw on one side (in threaded bush 1) so that the holding plate can be swivelled upward or downward.

· Loosen the front fastening screw and remove

(depending on the position the screw is either in threaded bush 2 or 3).

· Repeat the procedure on the other side.

· Low adjustment = Hole combination 1 and 2.

· High adjustment = Hole combination 1 and 3.

· Apply the Loctite to the screw, re-position the screws and tighten to 25 Nm +/- 3 Nm.

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50

The rear swivelling perforated plates have five positions. In the illustration on the right these are marked by the letters A to E.

If the holding plates are in the low position (see above), all five positions can be used.

Only positions B, C, D and E are possible in the high position. In position A there would be a collision between the holding plate and the seat frame.

This results in the following seat heights:

Holding plate in the low position:

Position of the perforated plate / seat height:

·

·

·

·

·

·

·

·

·

A / 42.5 cm

B / 44 cm

C / 44 cm

D / 45 cm

E / 45.5 cm

Holding plate in the high position:

Position of the perforated plate / seat height:

B / 49 cm (at a seat angle of 6°)

C / 47 cm

D / 48 cm

E / 50 cm

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7.13.1 Adjustment tables


All combination possibilities of the perforated plates are shown in the following tables. These values refer to a seat frame that has been secured in the second drill hole from the front.

The measurements were carried out as follows:

· Adjust the rear swivelling perforated plates (hole A to E)

· Move the front perforated plate to the lowest possible position.

· Change the seat angle and the seat height via the front perforated plate.

7.13.1.1 Table 1

The first table refers to the rear holding plates in the low position (see illustration on the right).

C

B

Position of the rear swivelling perforated plates

A

Seat angle in °

3

5

6

7

8

13

-2

0

1

0

2

3

5

7

8

9

10

11

9

11

12

14

15

18

-5

-3

-1

0

Seat height in cm

51

42.5

43.5

44.5

45.5

47

47.5

48

48.5

42.5

43.5

44.5

45.5

47

47.5

48

49

50

50

51

51.5

52.5

53.5

55

41.5

42.5

43.5

44

51


E

D


Seat angle in °

6

7

8

10

12

14

16

1

2

3

4

-6

-4

-3

-2

0

9

10

12

13

16

17

22

-8

5

6

7

1

3

4

0

1

2

3

4

6

7

9

10

-5

-4

-3

-1

20

-11

-10

-7

13

14

18

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Seat height in cm

49

50

50.5

51.5

53

54.5

55.5

41

42

43

44

45

46

46.5

47.5

48

45.5

46.5

47

47.5

48.5

49.5

50.5

51

52

53

55

56

58

39.5

45.5

46.5

47

47.5

48.5

49.5

50

51

52

57.5

38.5

39.5

41

42

43

43.5

44.5

54

55

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7.13.1.2 Table 2

The second table refers to the rear holding plates in the high position (see illustration on the right).


E

D

C


B

Seat angle in °

-5

-3

0

3

7

11

-10

-7

-5

-3

0

2

5

6

8

10

14

-5

-3

1

2

6

5

9

-12

-8

-7

Seat height in cm

51.5

54

42

43.5

44.5

46

48

50

49

50.5

52

54.5

44

45

46.5

48

50

46

48

50

51

54

51

54

42

44

45

53


7.14 Replacing the safety belt

Requirements:

· 10 mm socket spanner

· 4 mm Allen key

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Dismantling the safety belt:

· Remove the plastic cap (5).

· Loosen the bolt (3) and the associated nut (in the figure this is covered) with a 4 mm Allen key and a 10 mm socket spanner.

· Remove the nut incl. the washer.

· Remove the screw incl. the safety belt, the washer (2) and the washer arranged behind.

Note

Another nut is fixed between the two washers (2) and (4) as a spacer so that the belt mounting can rotate freely.

· Replace the safety belt (1).

Refitting the safety belt:

· Refit the parts in reverse order.

7.15 Testing an actuator motor


· Multimeter

· The electric resistance of the adjustment motor is to be checked at the connection assembly.

In case this is close to infinite, the motor is probably burnt out. If it is less than 1

W, the motor has short-circuited. In either case the motor must be replaced.

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Invacare Power Tiger Service Instructions Manual

Assistant Bot

Invacare

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Dragon

Invacare

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Tiger

SERVICE INSTRUCTIONS

Service addresses

Table of Contents

Chapter

Page

1 Introduction

1.1 General information

1.2 Notes on transport

1.3 Definition and representation of information and safety information in this manual

1.4 Hazard symbols and symbols used

1.5 Images in this manual

2 Safety and fitting instructions

2.1 Before any inspection or repair work

2.2 Personal safety equipment

2.3 General safety information and information about fitting / removal

3 Tightening torques

4 Arrangement of the assembly groups and components

5 Service plan (1x annually)

6 Operational Faults

6.1 Operational faults on a wheelchair fitted with Shark electronics

6.1.1 Diagnosis of actuation disorders

6.1.2 Shark error codes and diagnostic codes

7 Repair Work

7.1 General warning information on installation work

7.2 Replacing the motor

7.3 Replacing the Shark Electronics

7.4 Updating the driving program

7.5 Changing the batteries

7.5.1 Removing the batteries

7.5.2 How to handle damaged batteries correctly

7.6 Checking and replacing the main fuse

7.7 Checking the cables

7.8 Replacing the Shark Remote

7.9 Operating hours counter

7.9.1 Replacing the operating hours counter

7.9.2 Replacing the connecting cable of the operating hours counter

7.10 Replacing the steering head bearings on the steering wheels

7.11 Repairing a flat tyre

7.11.1 Repairing the rear tyre (wheel size 12½ x 2¼")

7.11.2 Repairing a flat tyre (wheel size 220/120 x 50)

7.12 Replacing a drive wheel

7.13 Adjusting the seat angle/seat height

7.13.1 Adjustment tables

7.14 Replacing the safety belt

7.15 Testing an actuator motor

Key Features

Frequently Answers and Questions

What safety precautions should I take when working on the wheelchair?

How do I update the driving program?

What should I do if the main fuse blows?

How do I replace the batteries?

How do I replace the Shark remote?

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