Invacare Delta II Service manual

Invacare® Delta II
Service-Anleitung
SERVICE MANUAL
®
Invacare Delta II
This manual includes instructions on
troubleshooting &
repair
Version: 01.02
1
Invacare® Delta II
2
Service-Anleitung
Service-Anleitung
Invacare® Delta II
Table of Contents
Section
1
Page
General Considerations .................................................................................... 5
Before You Start.................................................................................................................................. 5
2
3
1.1
Service Technician Qualification............................................................................................ 5
1.2
The Invacare® Service............................................................................................................ 5
1.3
Transport to the Manufacturer ............................................................................................... 5
Safety and Assembly Guidelines ..................................................................... 6
2.1
Symbols used in this Service Manual .................................................................................... 6
2.2
Before any Inspection andRepair:.......................................................................................... 6
2.3
During Assembly / Disassembly ............................................................................................ 7
2.4
Prior to Operation / After Completion of Service:................................................................... 7
2.5
Tool List.................................................................................................................................. 7
The Invacare® Delta II ........................................................................................ 9
3.1
Arrangement of Modules, Components and Operator Controls ............................................ 9
3.2
Electronic Control Components, Electrics............................................................................ 11
3.3
Module Composition / Variants, Accessories....................................................................... 12
3.3.1
Module Composition, Variants......................................................................................... 12
3.3.2
Accessories...................................................................................................................... 12
4
Inspection Procedures.................................................................................... 14
5
Troubleshooting .............................................................................................. 17
6
7
5.1
General Considerations ....................................................................................................... 17
5.2
Root Causes ........................................................................................................................ 17
Fault Diagnostics with the Status Indicator or the Penny & Giles SP1
Programming Unit ........................................................................................... 19
6.1
Status Indicator Error Codes................................................................................................ 19
6.2
P & G Programming Unit Error Codes ................................................................................. 19
6.3
Fault Types and their possible Root Causes ....................................................................... 21
Repair and Replacement................................................................................. 23
7.1
7.1.1
Replacing Shrouds............................................................................................................... 23
Side Shroud ..................................................................................................................... 23
3
Invacare® Delta II
7.1.2
7.2
Wheels ................................................................................................................................. 26
Driving Wheels................................................................................................................. 26
7.2.2
Front Wheel ..................................................................................................................... 27
7.2.3
Cover, Tube ..................................................................................................................... 28
7.3
Front Wheel Axle-tree .......................................................................................................... 29
7.4
Batteries ............................................................................................................................... 30
7.4.1
Checking Batteries, Battery Cables and Strip Fuse ........................................................ 30
7.4.2
Disassembling the Batteries ............................................................................................ 31
7.4.3
Assembling the Batteries ................................................................................................. 31
Electronic Box and Components.......................................................................................... 32
7.5.1
Disassembling the Electronic Box ................................................................................... 32
7.5.2
Disassembling the Components ...................................................................................... 32
7.6
Seat Unit............................................................................................................................... 33
7.6.1
Seat.................................................................................................................................. 33
7.6.2
Slide Rails ........................................................................................................................ 34
7.6.3
Armrests........................................................................................................................... 34
7.6.4
Seat Plate ........................................................................................................................ 35
7.6.5
Seat Post ......................................................................................................................... 36
7.7
Drive ..................................................................................................................................... 37
7.7.1
Disassembling the Drive Unit........................................................................................... 37
7.7.2
Disassembling the Components ...................................................................................... 37
7.8
Tiller, Console, Keypad ........................................................................................................ 38
7.9
Tiller Shaft Shroud, Tiller Shaft ............................................................................................ 39
7.10
Front Shroud, Front Wheel Fork, Lights, Horn..................................................................... 42
7.11
Chassis................................................................................................................................. 43
Appendix:......................................................................................................... 45
8.1
4
Rear Shroud, Cable Harness/Lights................................................................................ 24
7.2.1
7.5
8
Service-Anleitung
Circuit Diagram .................................................................................................................... 45
Service-Anleitung
1
Invacare® Delta II
General Considerations
Before You Start
This service manual contains information and instructions required to service and repair the Invacare®
Delta II.
You must comply with the instructions in this service manual when attempting any scooter service or
repair. The general service and care instructions included in the operating manual apply.
Please observe the safety guidelines.
Please consult the spare part catalogue for information on ordering spare parts.
1.1
Service Technician Qualification
The Delta II may be serviced and repaired by qualified personnel only. Minimum requirements:
ƒ Relevant training for instance as two-wheel or orthopaedic mechanic or extensive relevant
experience.
ƒ Competent handling of electrical measuring instruments (multimeter).
1.2
The Invacare® Service
If you have any problems or queries, please contact Invacare® Service:
Head Office:
Tel.:
05731-754-0
Fax:
05731-754-111
Service Department:
Tel.:
05731-7545-(70-80)
Fax:
05731-7542-(08-16)
Street Address:
Invacare® Deutschland GmbH TILLVERKARE
Dehmer Str. 66
32549 Bad Oeynhausen
Post Box:
Invacare® Deutschland GmbH
Postfach 60 01 06
32527 Bad Oeynhausen
• Any modifications of the Invacare® Delta II arising from improper or faulty service or repairs will
lead to exclusion of liability from Invacare®.
1.3
Transport to the Manufacturer
If the Invacare® Delta II must be shipped to the manufacturer for major repairs, use the original
packaging for shipping if at all possible.
Include a description of the fault which should be as accurate as possible.
5
Invacare® Delta II
2
Service-Anleitung
Safety and Assembly Guidelines
The safety guidelines are essential for compliance with health and safety regulations and must be
observed at all times.
2.1
9
Symbols used in this Service Manual
NOTE:
This symbol indicates proper servicing procedures as well as particularities and simpler ways
of disassembly/assembly.
WARNING:
The warning symbol indicates possible hazards either to the service
technician or the Invacare® Delta II. It is imperative that you observe any
safety instructions marked with this symbol. The word “Danger!”
indicates that failure to heed the warning may result in significant
personal injury or death.
2.2
Before any Inspection andRepair:
WARNING:
DANGER!
Consider the sometimes significant weight of the components. This is
particular important when disassembling the drive units and batteries.
Ensure that you can safely handle and store the components.
WARNING:
DANGER!
Personal injury may occur! Before you attempt any work on the
batteries, remove your wristwatch and any metal rings, bracelets and
chains. You may short the batteries or cables and components directly
connected to the batteries. A short may cause severe injuries.
Before you attempt any work carefully study this Service Manual and the associated Operating Manual
and comply with the instructions therein. Ensure that you meet the minimum qualification
requirements (refer to “General Considerations” section).
Prior to disassembling any live components, ensure that the Invacare® Delta II has no power. To do
this, first remove the negative and then the positive terminal connector from the batteries and lift out
the batteries.
Use perfect, undamaged tools only.
6
Service-Anleitung
Invacare® Delta II
Avoid shorting out contacts when taking readings on live components.
2.3
During Assembly / Disassembly
Prior to disassembly note and mark the current wheelchair settings (seat, armrest, back, etc.) and the
associated cable connectors. This will simplify later re-assembly. This manual describes the
disassembly procedure.. If no information is given in relation to assembly or mounting, re-assemble
the components in reverse order of disassembly. You will find any differing assembly procedures or
special assembly guidelines after the description of the disassembly procedure.
WARNING:
Before attempting any disassembly or re-assembly secure the lifted
wheelchair with suitable supports.
Do not use “normal” nuts in place of self locking nuts.
Always use the correct size for washers or spacers.
9
2.4
NOTE:
Connectors
All connectors are secured with mechanical locking mechanisms preventing the connector
from working loose during operation.
To remove the connectors push in the locking mechanism. Squeeze the locking mechanism
together on the top and bottom of the connector.
When re-assembling the components, ensure that the connector locking mechanisms are
properly engaged.
Batteries:
If you need to place the Delta II on its side during service remove the batteries before doing
so.
Orientation:
Any instructions involving directions such as “left” and “right” always refer to the direction of
motion assuming the user is standing behind the Delta II.
Prior to Operation / After Completion of Service:
WARNING:
Ensure that all attaching hardware is tightened securely. Verify that all
parts are locked correctly. Operate wheelchair with required tyre
pressure (2.0 bar or 29 psi) only.
Upon completion of the service, verify proper functioning of the
replaced components and test drive the vehicle.
2.5
Tool List
You will need a standard tool kit containing at least the following tools:
7
Invacare® Delta II
ƒ Set of open-jawed and ring spanners
ƒ Set of Allen keys
ƒ Torque wrench (standard)
ƒ Socket spanner set
ƒ Set of screw drivers (flat tip, cross tip, torx)
ƒ Side cutter
ƒ Flat nose pliers
ƒ Round nose pliers
ƒ Pointed pliers
ƒ Crimping tool
ƒ Mallet or plastic mallet
ƒ Tyre repair kit (standard)
ƒ Tire gauge
ƒ Tire pump
ƒ Valve removal tool
ƒ Puller and pressing or hitting tool for ball bearings
ƒ Multimeter with probe tips and various cable clamps
ƒ 30 W soldering iron
ƒ Riveting tool
8
Service-Anleitung
Service-Anleitung
Invacare® Delta II
3
The Invacare® Delta II
3.1
Arrangement of Modules, Components and Operator Controls
9
Invacare® Delta II
10
Service-Anleitung
Service-Anleitung
3.2
Invacare® Delta II
Electronic Control Components, Electrics
11
Invacare® Delta II
3.3
Module Composition / Variants, Accessories
3.3.1
Module Composition, Variants
Service-Anleitung
The Invacare® Delta II can be supplied with the following options:
• Batteries (Section 6.4)
x 12V/50 AH (Sonnenschein)
x 12V/70 AH (MK Batteries)
x 12V/70 AH (Sonnenschein)
• Throttle Control Lever (Section 6.8)
x Foot throttle
• Driving Wheels (Section 7.2.1)
x “Wide” driving wheel 4.10 / 3,50 x 6“
x “Narrow” rear wheel 3.00 x 8“
• Anti-tip Wheels (refer to Operating Manual)
• Front Wheel (Section 7.2.2)
x Front wheel 4.10 / 3,50 x 6“
• Lights (Sections 7.1.2 and 7.10)
• Electric Seat Height Adjustment (see Accessories)
• Back Elements
x Adjustable back element
• Headrest (see Accessories)
• Legrests (see Accessories)
x Manually adjustable legrests with ergonomic length compensation
• Cane Holder (see Accessories)
3.3.2
Accessories
The following accessories are available for the Invacare® Delta II:
• Chargers
x Charger 8 A
x Charger 10 A (MEDICO)
x Charger 12 A
• Basket cpl.
x Basket
x Basket holder
• Cane holder cpl.
x Cane holder bottom
x Cane holder top
x Plug 30 x 15
x Cane holder clamp
x Elastic cord, D = 4 mm, L = 60 mm
x Cane holder support, fender
• Crutch Holder
x Seat mountable
x Fender mountable
• Hip Strap
• Headrest KAB, grey
• Legrest
x RH, LH
• Mirror
12
Service-Anleitung
•
•
•
•
•
•
•
•
•
•
•
Invacare® Delta II
x Basket-mountable
Hour Meter
Spring Module, Standard, cpl.
x Spring module
x Intermediate plate
x Seat plate
Spring Module with Shock Absorber and Slide Rails
x Spring module
Self-adhesive Bags
Programming Unit
x Standard, for customers
x P & G, for technicians
Baby Seat
Wide Angle Mirror
Hand Brake
Trailer
x Trailer coupling
Dust Cover
Additional Horn
13
Invacare® Delta II
4
Service-Anleitung
Inspection Procedures
Component
Shrouds: Rear,
Side, Seat Post
Shroud
Inspection
Action
•
Check for damage
⇒ Replace parts
•
Check shroud attachment ⇒ Tighten or replace screws
Electronics
14
7.1, 7.6.5
Check rear wheels for
side movement and
proper tension
⇒ Check mounting plate
screws and locks
7.11
•
Check front wheel for
proper tension, side
movement and that it is
spinning freely.
⇒ Adjust or replace wheel,
axle, wheel bearing or fork
7.2.2
•
Check front wheel fork
bearing
⇒ Replace bearing
7.10
•
Check tyres
⇒ Re-mount
7.2.3
•
Check for damaged
batteries & corroded
contacts
⇒ Clean contacts, replace
batteries
7.4, 7.5
•
Check contacts,
terminals, cables and
strip fuses
⇒ Tighten, replace if
necessary
•
Check battery voltage
⇒ Charge or replace batteries
•
Check 50 A strip fuses
and 15 A fuses
(electronic box)
⇒ Replace fuses
•
Check battery straps
⇒ Tighten or replace straps
•
Console/keypad
status indicator flashing
⇒ Identify flash code
•
Check cable, cable ties,
connectors
⇒ Tighten, replace
•
Functions
⇒ Diagnostics
6.1, 6.2
•
Voltage supply
⇒ Replace cable, connector
or electronics
7.4
Wheels:
•
Driving Wheels,
Front Wheel
Batteries
Section
6.1
9
Service-Anleitung
•
Fuses
⇒ Replace
•
P & G Electronics
⇒ Diagnostics, replace
•
Delta II starts when
started with depressed
throttle control lever
⇒ Diagnostics, replace
electronics
Seat, Seat Plate, •
Seat Post and
Armrests
Drive, Brake
Tiller, Console,
Tiller Shaft and
Shroud, Front
Shroud
Lights
Invacare® Delta II
⇒ Repair, replace seat
Check for damage.
Check seams, seat angle
adjustment
7.5
6.2
7.6.1
•
Check everything is
secured properly
⇒ Tighten screws
•
Check seat plate,
lubricant
⇒ Lubricate
7.6.4
•
Check gas pressure
spring function
⇒ Replace gas pressure
spring
7.6.5
•
Check armrests are
properly secured and not
damaged.
⇒ Tighten screws, replace
armrests
7.6.3
•
Check working order
while driving or pushing
⇒ If necessary, replace motor
6, 7.7
•
Check brake lever
⇒ Tighten screws, if
necessary, adjust or replace
lever
•
Brake lever in “front”
position: Delta II can be
pushed
⇒ Check brake lever and
drive, adjust or replace if
required
•
Brake lever in “rear”
position: Delta II can be
started or no error
message in status
indicator
⇒ Check electronics and
replace if required
•
Check for damage
⇒ If required, replace parts
•
Check everything is
secured properly
⇒ Tighten screws
•
Play/tiller shaft:
Ball bearing/tiller shaft
⇒ Replace ball bearings,
adjust or replace friction
7.8
7.9
15
Invacare® Delta II
Ball bearing/tiller shaft
shroud, friction swivel
joints
Horn
Service-Anleitung
adjust or replace friction
swivel joints
•
Check function
⇒ If required replace light
bulbs or cables
•
Check cabling
⇒ If required, replace cables
•
Check fuse
⇒ Replace 3 A fuse
7.5
•
Check function
⇒ If necessary replace cable
or horn
7.10
•
Check cabling
⇒ If required replace parts
7.11
Chassis with
•
Rubber Mat,
Edge Strip,
•
Battery Straps
and Gas
Pressure Spring
Plate
Damage
7.1.2,
7.10
Check screws & nuts and ⇒ Tighten screws
battery straps
Reflectors
•
Check hub cab reflector
strips
⇒ Replace if necessary
7.2
Accessories:
Legrests, Antitip Wheels
•
Check function
⇒ Replace if required
3.3
16
Invacare® Delta II
Service-Anleitung
Troubleshooting
4.1
General Considerations
In case of driving or power supply related problems proceed as follows:
ƒ First check the root causes described in section 6.2.
ƒ Check the keypad status messages and, if required, identify the error codes as described in
section 6.1.
ƒ Carry out the required tests and/or repairs. Refer to and read the associated manual
sections or documentation pointed out in the cross references.
4.2
Root Causes
Delta II does not start
Push brake lever
to front position
Brake lever in „rear“
position
Status display on
keypad not illuminated
Vehicle status
indicator flashes
Batterien
defective
Replace
batteries
Batteries
discharged totally
Pre-charge
batteries
Power supply
interrupted
Check battery
fuse
Sec. 7.4
Check voltage at
keypad
Sec. 4
Check voltage at
batteries
Sec. 7.4
Identify error
code
Sec. 6.1
Error codes 1-10
Sec..7.4
Operating
Manual
17
Invacare® Delta II
Service-Anleitung
Delta II bucks during driving
Drive unit
defective
Replace drive
unit
Batteries empty
Charge batteries
Sec. 7.7
Operating
manual
Batteries cannot be charged
18
Battery defective
Replace battery
Charger defective
Replacer charger
Sec. 7.4
Horn defective
Check horn
Sec. 4, 7.10
Lights defective
Check and replace
cables / bulbs
Sec. 7.10
Invacare® Delta II
Service-Anleitung
5
Fault Diagnostics with the Status Indicator or the
Penny & Giles SP1 Programming Unit
Before you diagnose faults with the P & G programming unit, check the electronics status indicator on
Dellta II keypad, especially if the customer has not done this or is unable to do so.
5.1
Status Indicator Error Codes
Check the status indicator on the keypad. The following list identifies the faults by the number of
flashing LED’s:
1 LED flashing
Under-voltage / faulty battery or cable.
2 LED’s flashing
Faulty cable/motor
3 LED’s flashing
Faulty cable / motor: Short to battery
6 LED’s flashing
Control stuck, maybe due to charger plug.
7 LED’s flashing
Error / throttle control lever
8 LED’s flashing
Error / control
9 LED’s flashing
Error / brake
10 LED’s flashing
Over-voltage / control caused by faulty cable / battery.
5.2
P & G Programming Unit Error Codes
WARNING:
Only service technicians with thorough knowledge of the programming
device may attempt programming or fault diagnostics using the P & G
programming unit. Otherwise you may impair safe operation of the
Delta II due to incorrect programming or diagnosis.
You can identify the faults indicated by the SP1 Programming Unit (Penny & Giles) using the table
below:
Error Code
Error Type
Description
0002
8
Possible control fault
0003
8
Possible control fault
0100
8
Possible control fault
19
Invacare® Delta II
20
Service-Anleitung
0203
8
Possible control fault
0204
8
Possible control fault
0810
7
Error / throttle control lever
1400
3
Faulty cable / motor
1500
9
Fault / Brake
1501
8
Possible control fault
1502
9
Fault / Brake
1600
10
Over-voltage / Battery
1705
8
Possible control fault
1802
8
Possible control fault
1805 1
8
Possible control fault
1B20
8
Possible control fault
1D02
7
Fault / throttle control lever potentiometer
1E03
6
Control blocks drive
2102
8
Possible control fault
2C00
1
Battery voltage low
2C01
1
Battery voltage low
2D01
8
Possible control fault
3100
8
Possible control fault
3102
8
Possible control fault
3210
8
Possible control fault
3211
8
Possible control fault
3212
8
Possible control fault
3213
8
Possible control fault
3600
8
Possible control fault
3601
8
Possible control fault
3602
8
Possible control fault
Invacare® Delta II
Service-Anleitung
3603
8
Possible control fault
3604
8
Possible control fault
3605
8
Possible control fault
3606
8
Possible control fault
3607
8
Possible control fault
3608
8
Possible control fault
3609
8
Possible control fault
360A
8
Possible control fault
360B
8
Possible control fault
360C
8
Possible control fault
360D
8
Possible control fault
360E
8
Possible control fault
3B01
2
Motor / broken connection
7000
4
Brake
001
4
Brake
Once you have identified the error type, consult the sections below for information on the possible root
causes.
5.3
Fault Types and their possible Root Causes
Should the information and fault type description fail to rectify the problem it may be possible that the
P & G programming unit itself is faulty. If you suspect this to be the case, please contact your Penny
and Giles Service Partner.
WARNING:
Any manipulation of the P & G Programming Unit will void the warranty.
In addition, the safety of the Delta II can no longer be guaranteed which
may give rise to serious liability claims against the person or
organisation who caused the defects.
Fault Type 1 – Battery Voltage Low
Occurs when the battery voltage is below 18 V.
Check the condition of battery and connecting cables.
Fault Type 2 – Motor / Connection Faulty
21
Invacare® Delta II
Service-Anleitung
The connection to the motor is faulty.
Check motor and cable connections.
Check the brake lever position.
Fault Type 3 – Motor / Faulty Cable
There is a fault in the motor power supply. This is often caused by a short with a battery cable.
Check motor and cable connections.
Fault Type 4 - Brake
This fault occurs if the brake lever is engaged during driving or if the brake lever is still in the incorrect
position (rear) when the Delta II is started. Check the brake lever position.
If the brake lever position is correct, check the input voltage with a suitable instrument. If the voltage
readings are not OK as shown below, check the cable connection to the brake:
Voltage for brake / battery earth:
0V±0.5V in free-wheeling position (rear)
5V±0.5V in driving position (front)
Fault Type 5 – Not Assigned
Fault Type 6 – Control Blocks Drive
This fault occurs if the controller detects activation of the lock. Locking is mainly used to stop the
vehicle drive when the charger is connected. Verify that no charger is connected.
For detailed information on this fault type refer to the Solo and Egis Controller manual („SP1b
Programmer for Solo and Egis Controllers – Programming and Fault Finding“), pages 17f and 31f.
Fault Type 7 – Throttle Control Lever
Possible defect of the throttle control lever potentiometer or of the cable connections. Check working
order of the potentiometer, in particular return to 0.
Check the following voltage readings for a rocker throttle control lever or a unidirectional throttle
control lever. Ensure that the throttle control lever is in 0 position and the Delta II is set to maximum
speed. The nominal voltage readings should be as follows:
Rocker throttle control lever
Max against battery earth:
4.75 V
Grinder against battery earth: 2.5 V
Min against battery earth:
0.25 V
Unidirectional throttle control lever
Max against battery earth:
4.75 V
Grinder against battery earth: 0.25 V*
Min against battery earth:
0.25 V,
* the nominal value is 0.188 V for a 10 kOhm test resistance
Fault code 1805 refers in particular to the Egis controller which detects conductive deposits on the
throttle control lever potentiometer connections.
Fault Type 8 – Possible Control Fault
P & G Programming Unit fault Have the device checked by an authorised service partner.
Fault Type 9 - Brake
Brake or cable connections faulty. Check the brake and associated cable connections. If the brake
functions correctly, you should get the following voltage readings:
Brake + after brake -:
0V ± 0.5 V in free-wheeling position
battery voltage ± 1 V in parking position
22
Service-Anleitung
6
Repair and Replacement
6.1
Replacing Shrouds
6.1.1
Side Shroud
Invacare® Delta II
Disassembling the Side Shroud
1.
Turn the two turn-lock fasteners in direction of
motion and lift the shroud from the fasteners.
The recess (see arrow) eases lifting the shroud.
2.
A bolt (1.) connects to each lower side of the shroud
through a recess. . Lift the shroud in those locations
and pull off in direction of the corner (2.).
Assembling the Side Shroud
1.
Position the side part to align the shroud corner
recess with the locking screw (see arrow).
2.
Insert the rear edge of the side part under the mud
guard plate. At the same time ensure that the lower
bolts are connected correctly to the side part and
align the top recesses with the turn-lock fasteners.
23
Invacare® Delta II
3.
Secure the side part by turning the turn-lock
fasteners by 90 degrees.
6.1.2
Rear Shroud, Cable Harness/Lights
Disassembling the Rear Shroud
1.
Disengage the rear light connector safety on the
electronic box and pull the remove the connector.
2.
Remove the thumb screws on both sides of the rear
shroud.
3.
Put brake lever into front position.
4.
Carefully lift the rear shroud from the driving wheels
and pull off backwards.
24
Service-Anleitung
Service-Anleitung
Invacare® Delta II
Disassembling the Cable Harness
1.
Mark the individual wires in the cable harness and
take note of their positions.
2.
Pull off the rear light and direction indicator lamp
cap connectors.
3.
Remove cable ties.
4.
Lift out cable harness and place next to the rear
shroud as indication how the new cable routing
should look like.
Assembling the Cable Harness
1.
Install the new cable harness with the cable ties
guided by the old cable harness and your notes.
Colour coding?
Replacing lamps described in BDA?
Assembling the Rear Shroud
1.
Install the rear shroud as shown ensuring that the
shroud is positioned between the drive mounting
plates.
Check fit.
2.
Attach rear shroud with the thumbscrews.
3.
Route cable under the brake leaver to the electronic
box and plug in connector until you hear the safety
lock engage.
25
Invacare® Delta II
4.
Insert side parts (see above).
6.2
Wheels
6.2.1
Driving Wheels
Service-Anleitung
WARNING:
Prepare the vehicle by putting it on its side onto a support (which
shouldn’t be too soft) or securely jack up the vehicle so that no load
applies to the driving wheels.
Disassembling the Wheel
1.
Remove the hexagon nut.
2.
Take off wheel (wheel may sit very tightly!)
Assembling the Wheel
1.
Place wheel cut-out onto the feather key.
2.
Screw in hexagon nut (including washer) and
tighten with torque wrench (25 –30 Nm?).
26
Service-Anleitung
6.2.2
Invacare® Delta II
Front Wheel
WARNING:
Prepare the vehicle by putting it on its side onto a support (not too soft)
so that no load applies to the front wheel and it can be easily accessed
from both sides or, alternatively, jack up vehicle securely.
Disassembling the Front Wheel
1.
Loosen the left Allen screw on the front wheel, but
do not yet remove it completely.
2.
Loosen the right Allen screw, applying counterpressure to the shaft with a spanner.
3.
Now remove the right and then the left screw and
take the wheel out of the fork.
4.
Take off hub cabs.
Assembling the Front Wheel
1.
Place hub cab on the new wheel.
2.
Install front wheel and tighten screws.
27
Invacare® Delta II
6.2.3
Service-Anleitung
Cover, Tube
WARNING:
Prepare the vehicle by putting it on its side onto a support (not too soft)
so that no load applies to the front wheel / the driving wheels and they
can be easily accessed from both sides or, alternatively, jack up vehicle
securely. You must remove the front wheel first in order to replace the
cover or tube (see above).
WARNING:
DANGER!
Before you take off the wheel, take off the valve cap and relieve the
pressure by pressing the valve lifter.
Disassembling the Tube
1.
Take off wheel.
2.
Unscrew the hexagon screws.
3.
Remove rim from the cover.
4.
Remove tube.
28
Service-Anleitung
6.3
Invacare® Delta II
Front Wheel Axle-tree
WARNING:
Prepare the vehicle by putting it on its side onto a support (not too soft)
so that no stress applies to the front wheel and it can be easily
accessed from both sides or jack up vehicle securely.
Removing the Front Wheel Axle-tree
1.
Take off front wheel.
2.
Take off the hub cabs from the removed front wheel.
3.
Remove the axle locking rings.
4.
Carefully take out the axle using a rubber mallet.
Disassembling the Wheel Bearings
1.
Pull off wheel bearing with a puller.
Assembling the Wheel Bearings
1.
Drive in wheel bearing with a metal tube (D =
diameter of the outer ring/wheel bearing) or press in
using a press.
Assembling the Front Wheel Axle-tree
1.
Re-insert the axle using the rubber mallet.
2.
Secure axle with new locking rings.
29
Invacare® Delta II
6.4
Service-Anleitung
Batteries
WARNING:
Observe the safety guidelines (refer to section 2). Do not short-out the
battery terminals; otherwise you may cause a short. Be careful when
lifting the battery to avoid injury. Remove any rings and metal jewellery
from hands and wrists.
Always take off and remove the battery’s negative connector before the
positive connector.
Charging the Batteries: Refer to Notes/Operating Manual.
6.4.1
Checking Batteries, Battery Cables and Strip Fuse
1.
Verify total voltage with a multimeter at the
console’s charger port.
Voltage below 24V: Charge batteries.
2.
Voltage below 18 V: Check the individual battery
voltage.
3.
Disconnect battery terminals.
4.
Check voltage at the battery terminals.
5.
Battery voltage below 9 V: Charge relevant battery.
If charging does not rectify undervoltage: replace
relevant battery.
9
NOTE:
If the individual voltage readings at the battery
terminals are correct, however, the total voltage at
the charger port is not, check cables and strip fuses.
6.
Open the strip fuse holder carefully with a small
screw driver.
7.
Remove two nuts and take out the 50 A strip fuses.
8.
Replace the faulty strip fuse.
30
Service-Anleitung
Invacare® Delta II
6.4.2
Disassembling the Batteries
1.
Remove the side shrouds (refer to section 7.1.1).
2.
Remove connector on the electronic box.
3.
Lift plastic caps from the battery terminals and
remove the hexagon nuts.
4.
Remove the terminal clamps from the battery
terminals.
5.
Loosen battery straps and lift battery from the
frame.
6.4.3
Assembling the Batteries
1.
Insert new battery.
2.
Plug in the removed connectors on the electronic
box (the plastic safeties must engage).
3.
Close strap and tighten.
4.
Attach terminal clamps to the battery terminals.
Ensure that polarity and cone of the terminal clamps
is correct.
5.
Tighten hexagon nuts and put on plastic caps.
9
6.
NOTE:
Ensure that you do not over-tighten the terminal
clamp hexagon nuts to prevent damage to the
battery terminals.
Re-install the side shrouds (refer to section 7.1.1).
31
Invacare® Delta II
6.5
Service-Anleitung
Electronic Box and Components
WARNING:
Remove Batteries.
WARNING:
Prepare the vehicle by putting it on its side onto a support (not too soft)
so that the underbody under the electronic box can be easily accessed
or, alternatively, jack up vehicle securely.
6.5.1
Disassembling the Electronic Box
1.
Remove all connectors from the electronic box.
2.
Remove the screws securing the box to the
underbody (4 Allen screws).
6.5.2
Disassembling the Components
1.
Before removing any components, mark and take
note of the connections of the components to be
replaced.
2.
Remove P & G Electronics
a)
3.
4.
32
Remove the two Allen screws at the rear panel
of the casing.
P & G Cable Set with jacks
a)
Remove cable ties and connectors.
b)
Route the new cable harness (also refer to
overview in section 2.2) and secure with cable
ties.
Fuse holder
a)
Take note of fuse position and specifications.
b)
Take off fuse holder cover.
c)
Take out 3 A (lights, indicators) or 15 A
Service-Anleitung
Invacare® Delta II
(charging) fuses.
d)
Remove two hexagon socket nuts at the
casing rear panel and lift out fuse holder
including the two spacers.
6.6
Seat Unit
6.6.1
Seat
WARNING:
Fold back fully to the front onto the seat to prevent tipping after
removing the screws.
Disassembling the Seat
1.
Remove the two front Allen screws. To be able to
remove the rear nuts you must push the seat to the
very front.
Take note of the number and position of the
washers for later reassembling.
2.
Lift the seat from the seat plate and place on a
stable support.
Assembling the Seat
1.
Take note of the number and type of washers. Use
new self-locking nuts only.
33
Invacare® Delta II
6.6.2
Service-Anleitung
Slide Rails
WARNING:
Take care when handling slide rails, adjusting levers and springs to
prevent injury.
Disassembling the Slide Rail
1.
Turn over the removed seat with folded back.
2.
Remove four Allen screws.
3.
You can loosen the top screw in the slide rail
through the cut-out in the rail (see picture, circle),
however, this screw cannot be fully removed.
Assembling the Slide Rail
1.
Secure screws additionally with Loctite.
6.6.3
Armrests
1.
Disassembling the Armrests
Remove two Allen screws and lift off armrest
together with spacers.
34
Service-Anleitung
6.6.4
Seat Plate
1.
Remove the seat (see 7.6.1)
2.
Take off the seat plate.
Invacare® Delta II
35
Invacare® Delta II
6.6.5
Service-Anleitung
Seat Post
WARNING:
DANGER!
Before you disassemble the seat post ensure that the seat is fully
extended. If this is not the case the gas pressure spring will be
pressurised.
9
NOTE:
In any case, the gas pressure spring will retain some pressure to give a lift of a few
millimetres which is required for its proper function. It will be easier to remove the seat post if
the electronic box has been taken out first.
Disassembling the Seat Post
1.
Remove the seat (see 7.6.1)
2.
Take off the seat plate.
3.
Unscrew the cover screws.
4.
Remove the seat post screws, 4 Allen screws.
Assembling the Seat Post
1.
36
Before installing the seat post, put back the cover.
Ensure tight fit of the seat post screws.
Service-Anleitung
6.7
Invacare® Delta II
Drive
WARNING:
Jack up vehicle securely. In order to be able to remove the drive you
must have a ground clearance of at least 150 mm. Be aware of the drive
unit weight, otherwise personal injury may occur. Once servicing has
been completed, carry out a function test and test drive the vehicle.
Danger of Accident!
6.7.1
Disassembling the Drive Unit
1.
Remove rear shroud.
2.
Disconnect drive connectors.
3.
Unlock drive unit (if necessary ask for assistance)
and lower.
4.
Press the lower mounting plate bolts down through
the frame.
6.7.2
Disassembling the Components
1.
Fender
a)
2.
3.
Remove two Allen screws each on the right
and on the left hand side.
Drive
a)
Remove the driving wheels (see section 7.2.1)
b)
Remove three Allen screws each on the right
and left securing the mounting plates.
Handle for brake
a)
Remove two Allen screws.
37
Invacare® Delta II
6.8
Service-Anleitung
Tiller, Console, Keypad
WARNING:
Upon completion of service on the throttle control lever or keypad carry
out function test and test drive the vehicle. Danger of Accident!
Disassembling the Tiller, Console & Keypad
1.
2.
3.
38
Throttle Control Lever
a)
Remove two Philips screws.
b)
Unlock the connector and disconnect.
Keypad
a)
Remove four Allen screws.
b)
Lift off connector strip.
c)
Separate charger port connector coupling.
Tiller
a)
Work tiller plug from the left and right steering
pillar tubes.
b)
Unscrew throttle control lever (see above) and
throttle control lever dummy.
c)
Pull off steering pillar pad.
d)
Unscrew keypad.
e)
Remove steering pillar screws (see figure
above).
Service-Anleitung
4.
Invacare® Delta II
Console
a)
Disassemble tiller and keypad (see above)
b)
Remove cable ties.
c)
Remove screws connecting the console to the
tiller shaft (see figure)
d)
Pull console from the tiller shaft, carefully lift
out connector strips.
Assembling the Tiller, Console & Keypad
1.
Ensure that you do not pinch or damage the cable
harness when guiding the screw through the tiller
shaft.
6.9
Tiller Shaft Shroud, Tiller Shaft
Disassembling the Tiller Shaft Shroud and the Tiller Shaft
1.
Turn and pull the shock absorber holder off the tiller
shaft.
2.
Pull off top and bottom shock absorber.
3.
Tilt the tiller shaft backwards and remove the 4
friction swivel joint torx screws with tool T 30.
4.
Remove the shroud from the tiller shaft, if necessary
use a rubber mallet.
5.
Remove the inner lock ring with round nose pliers.
6.
Take out ball bearing with puller.
7.
Unscrew friction swivel joint.
39
Invacare® Delta II
Disassembling the Friction Swivel Joints
9
NOTE:
Disassembly is possible without first removing the
tiller shaft shroud..
1.
Slide the lower shock absorber onto the tiller shaft
shroud.
2.
Loosen the side screws & nuts of the inner or outer
swivel joint somewhat (Allen screw and nut).
3.
Tilt the tiller shaft shroud backwards and remove the
screws attaching the friction swivel joints to the front
shroud with the torx driver T 30.
4.
Right the tiller shaft shroud You will need an angled
T 30 tool to remove the screws securing the friction
swivel joints to the tiller shaft cover
9
NOTE:
Adjust the movability of the friction swivel joints after
completion of assembly by twisting the side screws
of the inner and outer joints (see picture above).
Disassembling the Tiller Shaft
1.
Remove the console and tiller shaft shroud (see
above)
2.
Drive out the spacer with a spike (D = 5mm).
3.
Remove cable ties and pull cable out of the tiller
shaft.
Assembling the Tiller Shaft
1.
Position tiller shaft on the forked axle and fit spacer.
2.
Secure cable harness with cable ties.
9
40
NOTE:
Ensure that the cable harness has enough play,
Service-Anleitung
Service-Anleitung
Invacare® Delta II
adjust with the tiller shaft in vertical position.
Assembling the Tiller Shaft Shroud and the Tiller Shaft
1.
Screw the friction swivel joints to the tiller shaft
shroud and install the shroud.
2.
Screw the friction swivel joints to the front shroud
(see picture).
3.
Insert ball bearing and inner locking ring.
4.
Insert top and bottom shock absorber and shock
absorber holder.
41
Invacare® Delta II
6.10
Front Shroud, Front Wheel Fork, Lights, Horn
Disassembling the Front Shroud
1.
Remove console, tiller shaft shroud and tiller shaft
(refer to sections 7.8 and 7.9).
2.
Unplug connector from headlight and indicator
lights.
3.
Remove cable tie and pull cable harness out of the
front shroud..
4.
Remove the vertical screws at the underbody (see
picture, arrows).
5.
Remove the upper locking ring from the forked axle.
6.
Remove the front wheel fork with a spike (< 20 mm)
from the ball bearings.
7.
Remove the lower locking ring.
8.
Disassemble ball bearing with a puller.
9.
Remove the horizontal front shroud screws (see
picture, circles). If required, support chassis.
10.
Remove lights and horn (see below).
Disassembling the Front Wheel Fork
WARNING:
Jack up vehicle securely.
1.
Remove front wheel (section 7.2.2)
2.
Disassemble the front wheel fork as described
above (section on front shroud, see also picture).
9
42
Service-Anleitung
NOTE:
In order to install the ball bearings and the front
wheel fork it might be beneficial to put the vehicle on
its side. Decide whether this is the case in your
situation.
Service-Anleitung
Invacare® Delta II
Disassembling the Light Components
1.
Unplug headlight and indicator light connectors.
2.
Pull off indicator lights.
3.
Unscrew the headlights from the plate (see figure).
4.
Replacing the Bulbs
5.
6.11
a)
Unscrew the lamp reflectors.
b)
Pull the indicator light socket from the rubber
sleeve.
Horn
a)
Remove the connector from the horn and untie
the cable tie at the plate.
b)
Remove torx screw with T 25 tool.
Chassis
WARNING:
Prepare this job by jacking up the vehicle securely at the front and rear
end allowing sufficient ground clearance (min. 150 mm). Ensure that the
lower (vertical) screws attaching the front shroud to the frame remain
accessible. It is imperative to disassemble the parts in the order stated;
otherwise the vehicle might tip.
Disassembling the Chassis
1.
Remove batteries (Section 7.4)
2.
Remove drive (Section 7.7)
3.
Remove electronics box (Section 7.5)
4.
Disconnect all connectors and remove the cable
harness up to the front shroud.
5.
Support front wheel and remove front shroud
screws (s. picture in section 7.10 and picture
below).
6.
Lift front shroud with electronics box cable harness.
7.
Remove seat, seat plate and seat post (s. sections
43
Invacare® Delta II
7.6.1, 7.6.4 and 7.6.5).
8.
Remove 4 Allen screws and unscrew gas pressure
spring plate (see picture).
9.
Loosen battery straps.
10.
Remove the drive locking springs.
11.
Unscrew the drive locks.
44
Service-Anleitung
Service-Anleitung
7
Appendix:
7.1
Circuit Diagram
Invacare® Delta II
45
Invacare® Delta II
46
Service-Anleitung