Invacare Bora XTR Series Service manual

The electronics modules used are described in Chapter 4.2.

· Charge batteries

See operating manual

· Clean contacts and terminals

Please refer to the safety information

in Chapter 7.7 for

handling batteries

· Replace if necessary

· Check locking system, it must engage completely.

· Remote, status display blinking

· Fixings

· Evaluate error/blink code

· Tighten fixings, replace if necessary

· Cables and connecting plugs

· Drive lever function · Replace drive lever if necessary

· Replace remote if necessary

· Power supply

· Tighten cables and connecting plugs, replace if necessary

· Check drive electronics program version

· Update software if newer version available.

See chapter 7.6.

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6 Operational faults

SERVICE MANUAL

The various electronics modules can be fitted in connection with differing remotes in the mobility device. Rectification of operational faults is dependent on the electronics module fitted.

NOTE:

The tables for rectification of operational faults listed in the following chapters are only an excerpt from the original manufacturer's manuals.

You can obtain the original manuals from Invacare®.

If you have problems with the mobility device, please proceed as follows:

· First assess the possible cause of the problem using the following table.

· Check the remote status display. Evaluate the error code.

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

6.1 Drive fault diagnosis

Problem

Mobility device will not start

Other

Symptoms

The remote status display illuminates normally and does not show an error code.

Remote status display does not illuminate

Possible

Cause

Drive motors disengaged batteries defective

Completely discharge battery

Power supply to remote interrupted

Mobility device judders in drive mode

Remote status display blinking

None

Solution

Engage drive motors

Replace batteries

Pre-charge batteries

Documentation

See operating manual

See operating manual

Remote defective

Various causes

Batteries defective

(unstable voltage)

Drive motor(s) defective

Check master fuse

Check cables between the modules for loose connections and damage

Replace remote

Assess error code See chapter 6.2.

See chapter 7.10.

Replace batteries

Replace motor(s)

See chapter 7.2 .

SERVICE MANUAL

Problem Other

Symptoms

Possible

Cause

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Documentation

Batteries not being charged

Mobility device runs too slowly

Electrical adjustment motor does not react

None

LEDs blinking on charging unit

None

Remote shows a blinking "E", status diode on lighting/actuator module does not go out even if remote is switched off or disconnected.

None

Batteries defective

Charging unit defective

Remote defective

Batteries defective

Lighting / actuator module defective

Cable disconnected or damaged

Replace carbon brushes

See chapter 7.2.4.

Replace batteries

Replace charging unit

Replace remote

Replace batteries

Replace lighting / actuator module

Safeguard cable connection, replace cable if necessary

Check adjusting motor

See charging unit operating manual

Electrical adjusting motor defective

Remote defective

Replace remote

See chapter 7.10.

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6.2 REM24 remote: Error codes and diagnostic codes

SERVICE MANUAL

The drive electronics can automatically rectify some faults. In this case the status display will stop blinking. Switch the remote on and off again several times. Wait around 5 seconds each time before switching the remote on again. If this does not rectify the fault, determine the cause using the blink codes from the following table.

Blink Code

1 x blink

2 x blink

3 x blink

4 x blink

5 x blink

6 x blink

7 x blink

8 x blink

9 or 10 x blink

Possible Cause

Module defective

Accessory error (e.g. short-circuit in adjusting motor)

Lifter too high or too low

(seat not at driving height)

Solution

Replace defective module

Check accessory connections, check accessory

Documentation

See chapter 7.17.

If the lifter is raised, lower it slowly until the status display stops blinking. If the lifter is too low, raise it slowly until the status display stops blinking.

Only drive when the seat is at driving height.

See operating manual

Check connection plug, check motor

Error at right-hand motor

Connection loose/defective or motor defective

Error at left-hand motor

Connection loose/defective or motor defective

Fault/brake fault on righthand motor. Connection loose/defective or motor defective

Fault/brake fault on lefthand motor. Connection loose/defective or motor defective

Check connection plug, check motor

Check connection plug

Completely discharge battery

Pre-charge battery

Battery voltage too high Switch lighting to low battery voltage

Check battery charger

Faulty data transmission between modules

Remove electronic modules except for the power module and the remote. Replace the modules one after another in order to ensure which the one was causing the fault.

See operating manual

See charging unit operating manual

Remove incorrect module See chapter 7.2.9.

SERVICE MANUAL

Blink Code

11 x blink

12 x blink

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Possible Cause

Compatibility problems between modules

Solution Documentation

Drive motors overloaded / overheated

Switch remote on and off

/ wait if necessary

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6.3 VR2 remote: Error codes and diagnostic codes

SERVICE MANUAL

Evaluate the cause using the following blink codes. The following figure shows which LEDs are located on the remote.

1) Battery display

2) Profile indicator

3) Adjusting motors

Error code Possible Cause Solution

1 LED battery display

Batteries discharged

3 LED battery display

Short-circuit in left-hand motor

Charge battery

Check cable to batteries

2 LED battery display

Error at left-hand motor

Connection loose/defective or motor defective

Check connection plug, check motor

Check connection plug, check motor

Documentation

Check connection plug, check motor

4 LED battery display

Error at righthand motor

Connection loose/defective or motor defective

5 LED battery display

Short-circuit in right-hand motor

Check connection plug, check motor

Remove battery charger

6 LED battery display

The mobility device has been blocked by an external signal, for example because the charger is connected.

7 LED battery display

Fault on drive lever

8 LED battery display

Fault in the electronics

Put the drive lever in a central position before switching the remote on.

Check cable

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Error code Possible Cause Solution

9 LED battery display

The parking brake is not working correctly.

Check parking brake

Check cable.

Check cable to batteries

10 LED battery display

Power surges in the control box, e.g. due to bad connection with batteries.

7 LED Battery display plus

5 LED profile indicator

Compatibility problems between modules

Check cable to remote

Replace remote

8 LED Battery display plus

2 LED actuators

Actuator error; if more than one actuator is fitted, locate the defective actuator.

Check cable to actuator

XTR Series

Documentation

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6.4 Shark 2 remote Error codes and diagnostic codes

SERVICE MANUAL

Meaning Solution Documentation Blink

Code

Operating error

Battery error

Fault on left-hand motor (M2)

Set drive lever to neutral central position (just release drive lever) and switch on again

Check battery and mains cable

Charge batteries.

If you switch the mobility device off for a few minutes, the batteries can often charge themselves up enough to enable a short journey. You should, however, only use this solution in emergency situations because it results in excessive battery discharging.

See operating manual

Replace batteries

Check motor cable and connecting plug.

Check motor.

Fault on right-hand motor (M1)

Check motor cable and connecting plug.

Check motor.

Check cable and plug. Fault at left-hand

(M2) motor brake

Fault right-hand

(M1) motor brake

Check cable and plug.

Error in Shark remote

Error in Shark power module

Communication error in Shark system

Unknown error

Incompatible remote

Check bus cable in remote and connecting plug.

Replace remote.

Check all cables and connecting plugs. See chapter 7.7.

Check all the cables and plugs in the

Shark system.

Replace electronics module

Check all cables and connecting plugs in the Shark system.

Replace remote.

The wrong remote has been connected.

Ensure that electronic module code and the remote code match.

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XTR Series

6.5 R-NET remote: Error codes and diagnostic codes

Evaluate the cause using the following blink codes. The following figure shows which LEDs are located on the remote.

1) Battery display

2) Actuators

3) Profile indicator

Error code Possible Cause Solution

1 LED battery display

Batteries discharged

Charge battery

Check cable to batteries

Documentation

2 LED battery display

Fault in left-hand motor; connection loose/defective or motor defective

Check connection plug, check motor

3 LED battery display

Short-circuit in left-hand motor

Check connection plug, check motor

4 LED battery display

Fault in right-hand Check connection plug, check motor; connection motor loose/defective or motor defective

5 LED battery display

Short-circuit in right-hand motor

Check connection plug, check motor

6 LED battery display

The wheelchair has been blocked by an external signal, for example because the charger is connected.

Remove battery charger

7 LED battery display

Fault on drive lever

Put the drive lever in a central position before switching the remote on.

8 LED battery display

Fault in the electronics

Check cable

9 LED battery display

The parking brake Check parking brake is not working correctly.

Check cable.

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Error code Possible Cause Solution

10 LED battery display

Power surges in the control box, e.g. due to bad connection with batteries.

7 LED Battery display plus

5 LED profile indicator

Compatibility problems between modules

Check cable to batteries

Check cable to remote

Replace remote

Actuator LEDs blinking Actuator error If more than one actuator is fitted, locate the defective actuator.

Check cable to actuator

SERVICE MANUAL

Documentation

SERVICE MANUAL

7 Repair work

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7.1 General warning information about fitting 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!

CAUTION!

Danger of injury and damage to property, if the maximum speed reduction on a wheelchair with a lifter does not function correctly!

The wheelchair’s control unit must reduce the maximum possible speed as soon as the lifter is raised.

· Test the maximum speed reduction for correct function after any maintenance work or

modifications to the wheelchair.

7.2 Replacing drive components

ATTENTION: Danger of crushing!

The mobility and the seat are very heavy. Danger of injury hazard to hands and feet caused by uncontrolled tilting oder other movement!

· Use proper lifting techniques.

· Remove the seat and place the mobility device upside down so that the wheels are facing

upwards! This guarantees mobility device stability during repair work!

· Please see the following work steps for further important information.

ATTENTION!

Fire and burns hazard if battery terminal is bypassed!

· Please take great care to ensure that the battery terminals are never short-circuited with tools

or mechanical mobility device parts!

· Ensure that the battery terminal caps have been replaced if you are not working on the battery

terminals.

Requirements:

· small flat screwdriver

· Torx TX40 spanner

· Allen key 5 mm

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

· hairdryer

· high-strength screw blocker system, e.g. Loctite 270

· oblique pliers

· Cable binder

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XTR Series SERVICE MANUAL

Note

When disassembling, take care of small parts such as screws and washers. Put all small parts down so that they can be reassembled in the right sequence.

· Remove legrests.

· Release seat (1) and tilt forwards.

· Disconnect the remote bus cable from the electronics module or ACT.

· Lift the seat out of the front anchorage and remove it. The seat has a heavy weight. Use proper lifting techniques.

· Remove both battery cases as described in

· Remove the rear battery boxes, as described in chapter 7.7.1.

· Disconnect the motor plug from the motor to be replaced from the electronics module.

· The motor cable is secured inside the frames with cable ties. Remove the cable ties with the oblique pliers.

· Place the vehicle upside down so that the wheels are facing upwards. The vehicle has a heavy weight. Use proper lifting techniques.

· Remove the wheel as described in Chapter

7.15.

SERVICE MANUAL

7.2.1 Replacing the complete drive unit

· Loosen the six drive unit screws with the

6 mm Allen key.

3 screws are located on the outside of the drive unit as shown in the figure.

The other 3 screws are located on the inside of the drive unit.

· Lift the complete drive unit up.

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· The drive unit is reassembled in reverse order to disassembly.

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7.2.2 Replacing the motor

· Loosen the motor screw (1) with the 5 mm

Allen key.

· Remove the motor from the transmission.

SERVICE MANUAL

· The motor is reassembled in reverse order to disassembly.

· The motor must be carefully inserted into the transmission to avoid damage. Observe the position of the groove (1) in the transmission.

· The cable must be routed so that it does not rub or get trapped.

· Insert the motor plug into the electronics module.

· Secure the motor cable to the frame with cable ties.

SERVICE MANUAL

7.2.3 Replacing the jaw clutch

· Loosen the motor screw (1) with the 5 mm

Allen key.

· Remove the motor from the transmission.

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· Remove the clutch (2) from the motor (1) using the screwdriver

· Place a new clutch on the motor. Observe the position of the groove (3) on the motor.

· The motor is reassembled in reverse order to disassembly.

· Insert the motor carefully into the transmission to avoid damage. Observe the position of the groove (1) in the transmission.

· The cable must be routed so that it does not rub or get trapped.

· Insert the motor plug into the electronics module.

· Secure the motor cable with cable ties.

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7.2.4 Replace carbon brushes

SERVICE MANUAL

Note

The carbon brushes are located under plastic caps outside each motor. This makes them easily accessible so that they can be replaced without removing the motor.

Always replace the carbon brushes on both motors.

· Carefully remove the plastic cap (1) on the motor with the screwdriver.

· Remove the plastic cap (1) and the carbon brushes (3).

· Insert new carbon brushes (3) through the openings (2) on the motors. In doing so, the spring must face upwards.

· Carefully screw in the plastic cap (1) on the motor with the screwdriver.

SERVICE MANUAL Invacare

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XTR Series

7.2.5 Replacing the motor / gearbox unit (SSD 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.

Danger of injury due to uncontrolled movement of the wheelchair!

· Switch the vehicle's power system off (ON-/OFF key).

· Engage the drive motors.

· Secure the vehicle against rolling away by placing wedges under the wheels.

CAUTION: Danger of crushing!

The motor / gearbox unit is very heavy. Danger of injury to the hands!

· Pay attention to the heavy weight.

Requirements:

· 5 mm Allen key

· 10 mm socket wrench

· 13 mm socket wrench

· Torque wrench 0 – 10 Nm (or similar)

· Torque wrench 5 – 30 Nm (or similar)

· Torque wrench 10 – 80 Nm (or similar)

· Two oblong wooden blocks, at least 14 x 14 x 30 cm

Uninstalling the motor / gear box unit:

· Switch the electronics OFF on the remote.

· Pull the motor plug out of the power module.

· Open the cable clamps and expose the motor cable.

· Remove the drive wheel as described in chapter 7.15.

· Remove the wheel hub as described in chapter 7.2.9.

· Remove the splash guard as described in chapter 7.16.

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XTR Series SERVICE MANUAL

· Use a 13 mm open-end wrench and a 13 mm socket wrench to loosen and remove the three hexagon socket head screws (1).

· Remove the screws together with the washers.

· Pull the motor/gear box unit (3) rearward out of its holder (2). Take into account the heavy weight of the unit.

Installing the motor / gearbox unit:

· Replace the defective components.

· Before installing a new motor / gearbox unit, make sure the sealing ring (2) is correctly mounted. The sealing ring securely attaches the motor (3) and the gearbox (5). The ring must be installed such that the self-locking nut (4) is located on the outside.

· If the sealing ring is incorrectly installed, rotate it around as described in chapter 7.2.6.

· Install the motor / gearbox unit in reverse order.

· Use the scale to align the motor to the centre axis (1):

2-pole motors:

- Left: 200°

- Right: 280°.

4-pole motors:

- Left: 280°

- Right: 280°.

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XTR Series

· Make sure that the motor cable cannot be pinched or bent, and that it is not exposed to chafing in any place. The coupling lever must be able to move to the positions "Driving" as well as

"Pushing".

· Tighten the self-locking nut (4) of the sealing ring to a torque of 4 Nm.

· Connect the motor cable plug.

· Reinstall all components that were removed beforehand in reverse order.

· To conclude, you should always carry out a trial run to test the vehicle functions.

7.2.6 Replacing or rotating the motor / gearbox unit sealing ring

CAUTION: Danger of crushing!

The motor / gearbox unit is very heavy. Danger of injury to the hands!

· Pay attention to the heavy weight.

Requirements:

· 10 mm socket wrench

Uninstalling the sealing ring:

· Uninstall the motor / gearbox unit, as described in chapter 7.2.5.

· Use the 10 mm socket wrench to loosen and remove the self-securing nuts (4) including the washers.

· Remove the carriage bolt, which secures the sealing ring (2).

· Carefully bend the sealing ring apart and remove it.

Installing the sealing ring:

· Install the sealing ring so that the square hole for the carriage bolt is on the inside of the wheelchair.

· Insert the carriage bolt through the sealing ring.

· Install the washer and the self-locking nut.

· Do not tighten the self-locking nut completely, as the motor orientation must be adjusted during installation.

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7.2.7 Replacing the motor / gearbox coupling (SSD motor)

CAUTION: Danger of crushing!

The motor / gearbox unit is very heavy. Danger of injury to the hands!

· Pay attention to the heavy weight.

Requirements:

· 10 mm socket wrench

SERVICE MANUAL

Uninstalling the motor / gearbox coupling:

· Uninstall the motor / gearbox unit, as described in chapter 7.2.5.

· Use the 10 mm socket wrench to loosen and remove the self-securing nut (4).

· Remove the carriage bolt, which secures the sealing ring (2).

· Carefully bend the sealing ring apart and remove it.

WARNING!

Danger of damage to the wheelchair if the coupling is not serviced correctly.

· Be careful not to damage the coupling mechanism during maintenance work.

· Carefully pull the motor (3) and the gearbox (1) apart.

· Remove the component parts of the coupling.

· If necessary replace the coupling.

SERVICE MANUAL

Installing the motor / gearbox coupling:

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· Place the new clutch (7) on the motor axle. Pay attention to the position of the groove.

· Position the locking ring (5) on the motor (4) or the gearbox (1).

· Carefully insert the motor into the gearbox. Pay attention to the position of the groove in the axle of the gearbox. If necessary, rotate the motor and gearbox in the same position as before assembly.

· Insert the carriage bolt through the locking ring. Do not forget the spacer sleeve (2)!

· Install the washer and the self-locking nut.

· Do not tighten the self-locking nut completely, as the motor orientation must be adjusted during installation.

· Install the motor / gearbox unit, as described in chapter 7.2.5.

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7.2.8 Replacing the carbon brushes (SSD motor)

SERVICE MANUAL

Note

The wheelchair can be equipped with 2- or 4-pole motors.

Always replace all carbon brushes on both motors at the same time.

Use only the same type of carbon brushes.

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

· Pay attention to the hand and feet.

· Use proper lifting techniques.

Requirements:

· 6 mm Allen key

· 10 mm socket wrench

· Blade screwdriver

· Two oblong wooden blocks, at least 14 x 14 x 30 cm

Uninstalling carbon brushes:

· Switch the wheelchair off.

· Remove the drive wheels, as described in chapter 7.15.

· Disconnect the motor (1) by setting the clutch lever or the clutch rotary knob (from 08/2014) to

"push".

Note

In the case of the SSD motor, you can unto the bolt (5) with a 10 mm socket spanner and then turn the motor around so that you can access the rear carbon brushes more easily.

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· Loosen and remove all four plastic caps (3) using a blade screwdriver.

· Note the fixing position and location of the carbon brushes.

XTR Series

Note

Used carbon brushes need to the refitted exactly in the same position from which they were taken in order to guarantee optimum contact to the collector.

· Make a marking on the motor and the carbon brushes in order to guarantee correct refitting.

· Remove the carbon brushes completely from the mounting (2).

· Check the carbon brush and spring for the level of wear, broken components or discolouration.

Refitting the carbon brushes:

· Depending on the condition of the brush and the spring:

- either replace the brushes in exactly the same position from which they were taken or

- fit new brushes.

· Refit the plastic caps and tighten them firmly.

· Turn the motor into position so that the clutch lever or clutch rotary knob

(from 08/2014) can be set either to the "push" or "drive" position.

· Now retighten the bolt (5) fingertight.

· Refit the drive wheels as described in chapter 7.15.

Note

The following procedure is necessary to run the carbon brushes in after replacement and thus guarantee maximum performance.

WARNING: Risk of accidents!

Hazards to workers, surroundings and mobility device!

· Do not leave the mobility device unattended during the following procedure!

· Make sure that BOTH drive wheels are raised and CANNOT touch the ground.

· Secure the area.

· Lift the mobility aid up on one side and get a second person to place a wooden block around

14 cm high underneath it so that the drive wheel is suspended freely.

· Also repeat this on the other side of the mobility aid.

· Allow the motors to run for an hour in forward direction.

· Allow the motors to cool down for 30 minutes.

· Allow the motors to run for an hour in reverse direction.

· Lift the mobility aid off the wooden blocks.

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XTR Series SERVICE MANUAL

7.2.9 Replacing the drive wheel hub (SSD motor)

CAUTION!

Possible material damage to mobility device! Collisions can be caused if the adjusting washers are removed during fitting work to the drive wheels!

· Adjusting washers are often fitted between the drive shaft and the wheel hub to even out

tolerances. If these adjusting washers are removed and not replaced again, collisions can be caused.

· Always replace the adjusting washers exactly as they were before you started dismantling.

Requirements:

· Torque wrench with 19 mm socket spanner

· Blade screwdriver

· Mounting kit

Uninstalling a drive wheel hub:

· Remove the hub cover with the screwdriver

· Use the 19 mm socket wrench to loosen and remove the nuts (7).

· Remove the washer (6).

· Remove the distance ring (5).

· Pull the wheel hub (4) off of the axle (2).

· Remove the shim ring (3).

· Remove the feather key (1) from the axle.

SERVICE MANUAL Invacare

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XTR Series

Installing a drive wheel hub:

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 nuts to 70 Nm when mounting the drive wheel hubs.

· Always use new nuts with undamaged clamping parts.

· Assemble the parts of the wheel hub in reverse order.

· Use a thin film of lubricant to replace the wheel hub on the axle.

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7.2.10 Fitting the clutch rotary knob (SSD motor)

SERVICE MANUAL

Note

When replacing the clutch rotary knob, you must ensure that the correct fitting position is used during assembly.

Requirements:

· 3 mm Allen key

· Screw the shim on to the grub screw.

· Place the screw joint in the rotary knob

(rear side (1)).

· Check to ensure that the screw joint (4) is positioned precisely in the rotary knob.

· Place the nonwoven fabric (3) in the rotary knob (rear side (1)).

· When installing the rotary knob (5) ensure that the position (6) is correct.

· Tighten the bolt using a 3 mm Allen key.

· Checked to ensure that the clutch rotary knob can be turned to the "push" position (clockwise) and "drive" position (counterclockwise).

SERVICE MANUAL Invacare

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XTR Series

7.3 Replacing the electronics

The various electronics modules can be fitted to the mobility device with a range different remotes.

The possible electronics modules are described in Chapter 4.2.

Replacement is described below using the Shark electronics module as an example. The course of action is the same for other electronics modules. The only difference is the terminal layout.

WARNING!

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

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

· Invacare® can only give a warranty for safe mobility device driving behaviour - especially the

tipping stability - for unaltered standard drive programs!

Note

All electronics modules are delivered with a standard drive program. If you have carried out customer-specific modifications to the drive program, you will have to make these changes again after installing the new electronics module.

Requirements:

· Phillips screwdriver

· To adapt the drive program: programming software or hand programming device and system installation manual, available from Invacare®.

· Remove legrests.

· Release seat (1) and tilt forwards.

· Disconnect the remote bus cable from the electronics module or ACT.

· Lift the seat out of the front anchorage and remove it. The seat has a heavy weight. Use proper lifting techniques.

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XTR Series

· Remove all plugs (1) from the electronics module.

· Mark the positions of individual plugs for later reassembly.

SERVICE MANUAL

· Loosen the screws (1) on both sides of the electronics module with the Phillips screwdriver and remove them.

· Remove the electronics module.

· Reassembly of the electronics module takes place in reverse order.

· Update the drive program if a new software version is available as described in Chapter

7.6.

· Adapt the drive program using the programming software if necessary.

· To complete, check all vehicle functions.

SERVICE MANUAL

7.4 Replacing the G-Trac sensor

Requirements:

· 5 mm Allen key

· 10 mm socket wrench

· Switch the electronics OFF.

· Remove the legrests.

· Release the seat (1) and tilt forward.

· Disconnect the remote bus cable from the electronics module or ACT.

· Lift the seat up out of its forward mounting and remove completely. The seat has a heavy weight. Use proper lifting techniques.

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XTR Series

· Remove the battery boxes, as described in

chapter 7.7.1.

· Disconnect the cable of the G-Trac sensor from the electronics module.

· Loosen and remove the nuts (3).

· Remove the G-Trac sensor holder (1) together with the G-Trac sensor (2).

· Loosen and remove the self-locking nut (4) and Allen screw (3), including the washers.

· Remove the G-Trac sensor (2) from the

G-Trac sensor holder (1).

· Replace the G-Trac sensor.

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· Installation of the G-Trac sensor is done in reverse order.

· The G-Trac sensor must be installed with the cable pointing upwards. The sensor has a guide (2) that must fit exactly into the

G-Trac sensor holder (1).

· Test all functions of the vehicle.

SERVICE MANUAL

7.5 Operating hours counter

7.5.1 Replacing the operating hours counter

Requirements:

· Philipps screwdriver, size 2

· 10 mm open-end wrench

· Switch the electronics OFF.

· Remove the legrests.

· Release the seat (1) and tilt forward.

· Disconnect the remote bus cable from the electronics module or ACT.

· Lift the seat up out of its forward mounting and remove completely. The seat has a heavy weight. Use proper lifting techniques.

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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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XTR Series SERVICE MANUAL

CAUTION!

Property damage can result if the counter is wrongly connected. If the plus and minus wires are connected the wrong way, it will damage the electronic components of the operating hours counter.

· Make sure the cable is connected correctly.

· 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.

SERVICE MANUAL Invacare

- Bora

/Spectra

XTR Series

7.5.2 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.

· Release the seat (1) and tilt forward.

· Disconnect the remote bus cable from the electronics module or ACT.

· Lift the seat up out of its forward mounting and remove completely. The seat has a heavy weight. Use proper lifting techniques.

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 ties (4).

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

· Replace the cable of the operating hours counter.

Invacare

- Bora

/Spectra

XTR Series SERVICE MANUAL

CAUTION!

Property damage can result if the counter is wrongly connected. If the plus and minus wires are connected the wrong way, it will damage the electronic components of the operating hours counter.

· Make sure the cable is connected correctly.

· 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.

SERVICE MANUAL

7.6 Updating software

Invacare

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/Spectra

XTR Series

The drive programs for mobility devices are continually being further developed and improved by

Invacare. For this reason, you should always check whether the drive program version number is up-to-date when carrying out any repairs or regular maintenance.

If a newer version is available, the drive program should be updated. The procedure for updating the drive program is described in the wizard software operating manual.

Note

The electronic system is supplied with a standard drive program. If the driving program has been customised, you have to perform this customisation again, after installing the new driving program. This also applies to the customer-specific options of the seat setting for ACS2 remotes, which are activated ex works.

WARNING!

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

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

· Invacare® can only give a warranty for safe mobility device driving behaviour - especially the

tipping stability - for unaltered standard drive programs!

Requirements:

· Dynamic® Wizard software

· Operating manual for Wizard software

· Further requirements, such as a minimum system configuration for the PC used for programming, required programming cables etc. can be taken from the Wizard software operating manual.

Note

When an electrical adjustment option is retrofitted, such as electrical legrests, then this option needs to be activated in the driving program as well if you have an ACS2 remote. For more information, refer to the user manual of the Wizard software and the installation instructions for the electronic modules

Invacare

- Bora

/Spectra

XTR Series

7.7 Replacing batteries

SERVICE MANUAL

ATTENTION!

Injury hazard and possible material damages if batteries are handled improperly!

· The installation of new batteries may only be carried out by authorised specialists.

· Observe the warning information on the batteries.

· Only use battery versions stated in the specifications.

ATTENTION!

Fire and burns hazard if battery terminal is bypassed!

· Please take great care to ensure that the battery terminals are never short-circuited with tools

or mechanical mobility device parts!

· Ensure that the battery terminal caps have been replaced if you are not working on the

battery terminals.

ATTENTION: Danger of crushing!

The batteries are extremely heavy. This results in injury hazards to your hands.

· Bear in mind that the batteries are sometimes very heavy!

· Please handle the batteries with care.

WARNING: BURN HAZARD!

Injury hazard due to discharged acid.

· Always wear acid-proof protective gloves when handling batteries.

· Always wear protective goggles when handling batteries.

What to do if acid is discharged:

· Always take clothing which has been soiled by or dipped in acid off immediately!

· Rinse any areas of your skin which has come into contact with battery acid off immediately

with plenty of water!

If contact with eyes is made:

· Rinse the affected eye under running water for several minutes! You should also consult an

eye specialist immediately afterwards!

SERVICE MANUAL

7.7.1 Removing the battery cases

Invacare

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XTR Series

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.

Note

A spare fuse is located behind the Invacare logo on the rear battery.

· Pull the rear battery case backwards using the belt. The locking device opens automatically when doing so.

· Pull the battery cases out using the side handles.

Invacare

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/Spectra

XTR Series

· Pull the front battery case backwards using the belt and pull it out using the handles.

SERVICE MANUAL

7.7.2 Removing the batteries

Invacare

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/Spectra

XTR Series

ATTENTION!

Fire and burns hazard if battery terminal is bypassed!

· Please take great care to ensure that the battery terminals are never short-circuited with tools

or mechanical mobility device parts!

· Ensure that the battery terminal caps have been replaced if you are not working on the battery

terminals.

ATTENTION: Danger of crushing!

The batteries are extremely heavy. This results in injury hazards to your hands.

· Bear in mind that the batteries are sometimes very heavy!

· Please handle the batteries with care.

Requirements:

· Phillips screwdriver

· Bend the tabs (1) on the cover lightly to the outside and loosen the battery case covers.

· Open the battery case (remove cover).

Invacare

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XTR Series

· Pull the battery case socket / plug out of the guide.

· The rear battery is only fitted with a battery case socket at the front.

· The front battery is fitted with a battery case socket at the front (flange central) and with a battery case plug at the rear (flange flush).

· Note the fixing position of the battery and the battery case sockets/plugs. The new battery must be refitted in exactly the same position as the old one.

· The batteries can be pulled upwards out of the battery cases by their handles.

SERVICE MANUAL

· Remove the terminal cover from the battery terminals (1).

SERVICE MANUAL

· Loosen the battery terminal clamps (1) with the

Phillips screwdriver.

· First undo the screw on the negative terminal

(black cable) with the Phillips screwdriver.

· After this, undo the bolt on the positive terminal (red cable).

Invacare

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/Spectra

XTR Series

· Reassembly of the batteries takes place in reverse order

· Ensure that the battery cage sockets/plugs have been correctly refitted. A polarity diagram is located in each battery case cover.

· Front battery

· The battery case socket is located at the front

(flange central).

· Socket side A is on the left in the direction of travel.

· Socket side B is on the right in the direction of travel.

· The battery case plug is located at the rear

(flange flush).

· Plug side A is on the left in the direction of travel.

· Plug side B is on the right in the direction of travel.

· Rear battery

· The battery case socket is located at the front

(flange central).

· Socket side A is on the left in the direction of travel.

· Socket side B is on the right in the direction of travel.

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XTR Series

· The battery needs to be inserted tightly into the battery case. Use the foam sections supplied to ensure this.

· To complete, check all vehicle functions.

SERVICE MANUAL

7.7.3 Correct handling of damaged batteries

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/Spectra

XTR Series

WARNING: BURN HAZARD!

Injury hazard due to discharged acid.

· Always wear acid-proof protective gloves when handling batteries.

· Always wear protective goggles when handling batteries.

What to do if acid is discharged:

· Always take clothing which has been soiled by or dipped in acid off immediately!

· Rinse any areas of your skin which has come into contact with battery acid off immediately

with plenty of water!

If contact with eyes is made:

· Rinse the affected eye under running water for several minutes! You should also consult an

eye specialist immediately afterwards!

Requirements:

· protective goggles

· acid-proof gloves

· acid-proof transport container

· If handling damaged batteries, always wear suitable protective clothing.

· Always deposit damaged batteries in suitable acid-proof containers immediately after removal.

· Only transport damaged batteries in suitable acid-proof containers.

· Always wash any objects which were contacted by acid in plenty of fresh water.

Always dispose of used or damaged batteries correctly

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

Invacare®.

Invacare

- Bora

/Spectra

XTR Series

7.8 Checking and replacing the main fuse

SERVICE MANUAL

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 fix the strip fuses in the sequence shown in the image on the right!

· Tighten the nuts with 3.3 to 3.5 Nm!

1. Strip fuse

2. Spade terminal

3. DIN 6923 nut

Requirements:

· Phillips screwdriver

· Strip fuse

· socket spanner, 8 mm

· torque wrench 0-20 Nm (or similar)

Note

A spare fuse is located behind the Invacare logo on the rear battery.

Note

If the fuseholder is damaged, you can replace this complete with the battery cables.

· Remove both battery cases as described in

described in Chapter 7.7.2.

· Remove the covers on both battery cases as

SERVICE MANUAL

· The fuseholder (1) is located on top of the batteries.

· Open the fuseholder cover.

· If the strip fuse has blown, you must first ascertain and rectify the cause of the fault.

· The main fuse may only be replaced once the fault has been rectified.

Invacare

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XTR Series

· Undo the strip fuse nuts (2) with the Phillips screwdriver.

· Replace the strip fuse.

· Reassembly takes place in the reverse order.

· To complete, check all vehicle functions.

Invacare

- Bora

/Spectra

XTR Series

7.9 Checking the cable

SERVICE MANUAL

The following images show checking the cable using the Shark controller as an example. The plug positions are different for both the DX2 and VR2 controllers. The procedure for checking is otherwise identical.

The position of the plugs is described in Chapter 4.2.

· Remove legrests.

· Release seat (1) and tilt forwards.

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

· Pull each plug (1) carefully. The plug should not come out of the socket.

· If the plug is loose, press the plug into the socket with slight pressure. The plug must engage.

· Check whether the plug is now firmly located in the socket, otherwise repeat the previous step.

· Remove both battery cases as described in

described in Chapter 7.7.2.

· Remove the covers on both battery cases as

SERVICE MANUAL

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

Invacare

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/Spectra

XTR Series

· Reassembly takes place in the reverse order.

· To complete, check all vehicle functions.

Invacare

- Bora

/Spectra

XTR Series

7.10 Differences when replacing the REM24 remote

SERVICE MANUAL

Requirements:

· To adapt the drive program: programming software or hand programming device and REM24 electronics system installation manual, available from Invacare®.

Note

All REM24 remotes are delivered with a standard drive program. If you have carried out customer-specific modifications to the drive program, you will have to make these changes again after installing the new electronics module.

WARNING!

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

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

· Invacare® can only give a warranty for safe mobility device driving behaviour - especially the

tipping stability - for unaltered standard drive program!

SERVICE MANUAL

7.11 Lighting unit

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/Spectra

XTR Series

7.11.1 Replacing front headlight completely (LED lighting unit)

Note

Replacing an individual LED is not possible. If there is a defect, replace the entire front headlight.

Requirements:

· Jaw spanner 7 mm

· Allen key 3 mm

· oblique pliers

· cable binder

The position of the plugs is described in Chapter 4.2.

· Remove legrests.

· Release seat (1) and tilt forwards.

· Disconnect the remote bus cable from the electronics module or ACT.

· Lift the seat out of the front anchorage and remove it. The seat has a heavy weight. Use proper lifting techniques.

· Remove both battery cases as described in

The position of the plugs is described in Chapter 4.2.

· Remove the front headlight plug from the lighting PCB.

· Free the cable or remove any cable ties.

· Loosen the nut (2) with a 7 mm jaw spanner and a 3 mm Allen key.

· Remove the front headlight (1) from the lamp holder (3).

· Reassembly takes place in the reverse order.

· To complete, check all vehicle functions.

Invacare

- Bora

/Spectra

XTR Series

7.11.2 Replacing the front bulb holder (LED lighting unit)

Requirements:

· Jaw spanner 7 mm

· Allen key 3 mm

· TX25 torx screwdriver

· oblique pliers

· cable binder

· Loosen the nut (2) with a 7 mm jaw spanner and a 3 mm Allen key and remove.

· Remove the front headlight (1) from the lamp holder (3) and place it carefully to the side.

SERVICE MANUAL

· Undo and remove the two screws (4) with a

TX25 torx screwdriver.

· Replace the lamp holder (3).

· Reassembly takes place in the reverse order.

· To complete, check all vehicle functions.

SERVICE MANUAL Invacare

- Bora

/Spectra

XTR Series

7.11.3 Replacing the rear light completely (LED lighting unit)

Note

Replacing an individual LED is not possible. If there is a defect, replace the entire rear light.

Requirements:

· Phillips screwdriver

· TX40 torx screwdriver

· oblique pliers

· cable binder

· Remove legrests.

· Release seat (1) and tilt forwards.

· Disconnect the remote bus cable from the electronics module or ACT.

· Lift the seat out of the front anchorage and remove it. The seat has a heavy weight. Use proper lifting techniques.

· Remove both battery cases as described in

· The position of the plugs is described in Chapter 4.2.

· Remove the drive wheel as described in

Chapter 7.15.

· Remove the rear light plug from the lighting

PCB.

· Free the cable or remove any cable ties.

· Undo the Phillips screw (1) with a Phillips screwdriver and remove it together with the washer.

· Remove the rear light (1) from the splash guard and replace it.

· Reassembly takes place in the reverse order.

· To complete, check all vehicle functions.

Invacare

- Bora

/Spectra

XTR Series SERVICE MANUAL

7.11.4 Replacing the complete tail light assembly (conventional lighting system)

Requirements:

· 8 mm socket wrench

Uninstalling the tail light:

· Switch the electronics OFF on the remote.

· Take exact note of the positions of all cables and the sockets that they are connected to. Mark the connectors and sockets or take a photograph with a digital camera.

· Disconnect the cable of the affected tail light from the lighting circuit board.

· Remove both plastic covers (6).

· Use the 8 mm socket wrench to loosen the four nuts (5).

· Remove the nuts and the washers (4).

· Pull the tail light (1) towards the rear and remove both bushings (3) including the lamp protector (2).

Installing the tail light:

· Assemble all parts again in reverse order.

· Tighten the screws hand-tight.

· Check all vehicle functions.

SERVICE MANUAL Invacare

- Bora

/Spectra

XTR Series

7.11.5 Replacing the tail light bracket (conventional lighting system)

Requirements:

· 5 mm Allen key

Uninstalling the tail light bracket:

· Remove the complete tail light, as described in chapter 7.11.4.

· Loosen the two Allen screws (4) with a 5 mm Allen key and remove these including the washers (3) and self-locking nuts (2) from the battery support.

· Replace the lamp bracket (1).

Installing the headlight bracket:

· Slide the lamp bracket (1) between the frame and battery support.

· Assemble all parts again in reverse order.

· Check all vehicle functions.

Invacare

- Bora

/Spectra

XTR Series

7.12 Anti-tipping mechanism

7.12.1 Replacing the anti-tipping mechanism with screw

SERVICE MANUAL

CAUTION!

Danger of tipping over if the anti-tipping mechanism is incorrectly installed.

· Always install the anti-tipping mechanism in the first drill hole (long adjustment) on a

wheelchair with a lifter.

Requirements:

· 10 mm socket wrenches (two of them)

· Loosen and remove the self-securing nut (3).

· Remove screw.

· Pull the anti-tipping mechanism (1) rearward out of the support tube (2).

· Insert the anti-tipping mechanism into the support tube.

- Wheelchair with a lifter:

first drill hole (long adjustment)

- Wheelchair without a lifter:

second drill hole (short adjustment)

· Insert screw.

· Re-position the self-securing nut and tighten.

SERVICE MANUAL Invacare

- Bora

/Spectra

XTR Series

7.12.2 Replacing the anti-tipping mechanism with locking spring

CAUTION!

Danger of tipping over if the anti-tipping mechanism is installed using a locking spring on a chair with a lifter.

· Always install the anti-tipping mechanism using a screw in the first drill hole (long adjustment)

on a chair with a lifter, as described in chapter 7.12.1.

Requirements:

· Bar or Stab Phillips screwdriver

· Press the locking spring (2) together. Only the bolts in the support tube (3) are visible.

· Pull the anti-tipping mechanism out (1).

· Check the locking spring.

· Replace the locking spring if it is broken or has insufficient tension.

· Replace the anti-tipping mechanism.

· Insert the (possibly new) locking spring (4) into the anti-tipping mechanism up to the second hole.

· Insert the anti-tipping mechanism into the support tube. To do this, press the locking spring together slightly.

· Insert the anti-tipping mechanism into the support tube as far as it will go.

· Make sure that the locking spring latches into the holes provided for this purpose in the support tube.

Invacare

- Bora

/Spectra

XTR Series

7.12.3 Replacing a defective locking spring

SERVICE MANUAL

CAUTION!

Danger of tipping over due to defective locking springs. Defective locking springs can lead to loss or failure of the anti-tipping mechanism!

· Check carefully that the locking springs are intact.

Requirements:

· A rod or Phillips screwdriver

· If necessary press the defective locking spring together.

· Pull the anti-tipping mechanism (1) rearward out of the support tube (3).

· Remove the defective locking spring.

If it is not possible to remove the defective locking spring, push the defective locking spring (2) into the support tube using the rod or Phillips screwdriver.

· Insert a new locking spring (4) into the antitipping mechanism up to the second hole.

· Insert the anti-tipping mechanism into the support tube again as far as it will go. To do this, press the locking spring together slightly.

· Make sure that the locking spring latches into the holes provided for this purpose in the support tube.

SERVICE MANUAL Invacare

- Bora

/Spectra

XTR Series

7.13 Replacing the steering head bearings on the steering wheels

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

· Pay attention to the hand and feet.

· Use proper lifting techniques.

Danger of injury due to uncontrolled movement of the wheelchair!

· Switch the vehicle's power system off (ON-/OFF key).

· Engage the drive.

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

CAUTION!

Incorrect reassembly can damage the bearings and cause the steering wheels to fall out!

The single-row angular ball bearing rings are not identical on both sides! There is only one correct way to insert them!

· Follow the assembly instructions precisely!

Requirements:

· open-ended spanner, 19 mm

· Torque wrench

· large screwdriver, flat

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

Note

When disassembling, take care of small parts such as screws and washers. Put all small parts down so that they can be reassembled in the right sequence.

· Place the wooden block under the vehicle on the side on which the ball bearing is to be replaced.

· The wheel on the side where the bearing is to be replaced must have enough ground clearance to enable it to be pulled out of the bearing.

· Secure the vehicle against rolling away.

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

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XTR Series

· Loosen the 19 mm nut (1) with the socket spanner and remove it. Hold the wheel so that it does not rotate when the nut is being removed.

· Pull the steering head shaft upwards out of the steering head tube.

· Take the washers out of the tube.

· Take the ball bearing out of the tube.

· The adjacent figure shows an overview of the individual parts.

· Plastic cap

· 19 mm nut

· Ball bearing

SERVICE MANUAL

· Reassembly takes place in reverse order to disassembly

· Ensure that you insert the ball bearings exactly as described below.

· Also ensure that the washers are correctly replaced.

CAUTION!

Incorrect reassembly can damage the bearings and cause the steering wheels to fall out!

The single-row angular ball bearing rings are not identical on both sides! There is only one correct way to insert them!

· The bearings must always be assembled so that the narrow borders of the ball bearings are

facing each other (inside)!

· The steering head bolts and nuts must always be pressing against the wide (outside) border of

the ball bearings! Otherwise, the bearings will be pressed apart and damaged by the bolts!

SERVICE MANUAL Invacare

- Bora

/Spectra

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

XTR Series

After assembly, the steering wheels should rotate freely but the bearings should have no play.

· First tighten the nuts to 20 Nm +/- 2 Nm.

· Then loosen them slightly.

· Then retighten to 15 Nm +/- 1.5 Nm.

Invacare

- Bora

/Spectra

XTR Series

7.14 Repairing punctures

SERVICE MANUAL

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: 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.

7.14.1 Repairing the rear tyre (wheel size 3.00-8")

Requirements:

· 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

SERVICE MANUAL Invacare

- Bora

/Spectra

XTR Series

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 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.

· Insert the four new countersunk screws and tighten them to a torque of 30 Nm.

Invacare

- Bora

/Spectra

XTR Series

7.14.2 Repairing a flat tyre (wheel size 280/250-4)

Requirements:

· Allen key 6m

· jaw spanner 13 mm

· 2 x small ring spanners or flat screwdrivers (for pulling off tyres)

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

· Talcum powder

Removing the wheel:

· Block up the vehicle (place wooden blocks under frame).

· Undo the bolt (1) and remove it using the Allen key on one side and the jaw spanner on the other (as a counter).

· Pull the wheel out of the fork.

SERVICE MANUAL

Note

Re-assembly is done in reverse order. Ensure that the tyre is replaced on the same side and in the same travel direction as it was previously mounted.

SERVICE MANUAL Invacare

- Bora

/Spectra

XTR Series

Repairing the 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 valve cap.

· Depressurise tyre by pressing in the pin in the valve.

· Unscrew the 5 Allen screws (back of the wheel, 2).

· 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.

· Put the tyre back on the rim.

· Ensure that the tyre outer is seated correctly.

· Pump the tyre up to the prescribed pressure.

· Check that the tyre is seated correctly once again.

· Screw the valve cap back on.

· Refit the wheel.

Invacare

- Bora

/Spectra

XTR Series

7.15 Replacing a drive wheel

SERVICE MANUAL

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.

WARNING: 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!

Requirements:

· Torx TX40 spanner

· Mounting kit

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

Note

Take careful note of small parts and the sequence in which components are fitted. Arrange these carefully so that they are always refitted in the correct sequence.

· Remove legrests.

· Release seat (1) and tilt forwards.

· Disconnect the remote bus cable from the electronics module or ACT.

· Lift the seat out of the front anchorage and remove it. The seat has a heavy weight. Use proper lifting techniques.

· Remove both battery cases as described in

· Place the vehicle upside down so that the wheels are facing upwards. The vehicle has a heavy weight. Use proper lifting techniques.

SERVICE MANUAL

· Under the 4 bolts which secure the wheel (1) using the Torx TX40 spanner.

· Remove the wheel from the hub.

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XTR Series

· Reassembly takes place in the reverse order.

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

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.

Invacare

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/Spectra

XTR Series

7.16 Replacing the splash guard

SERVICE MANUAL

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.

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!

Requirements:

· 5 mm Allen key

· Mounting kit

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

Note

If the splash guard is replaced, the existing motor bracket screws are reused. Ensure that the screws are inserted in the correct position.

· Remove legrests.

· Release seat (1) and tilt forwards.

· Disconnect the remote bus cable from the electronics module or ACT.

· Lift the seat out of the front anchorage and remove it. The seat has a heavy weight. Use proper lifting techniques.

· Remove both battery cases as described in

electronics module or ACT (see Chapter 4.2).

· Undo and remove the four screws (1) & (2) on the motor bracket which hold the splash guard

(4) using a 5 mm Allen key.

· Remove the reinforcing plate (3).

· Remove and replace the splash guard.

SERVICE MANUAL

· A further reinforcing plate (1) is located under the splash guard.

Invacare

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XTR Series

· Reassembly takes place in the reverse order.

When reassembling, ensure that screw (1) is shorter than screw (2).

Invacare

- Bora

/Spectra

XTR Series

7.17 Seat system

7.17.1 Checking an adjusting motor

Requirements:

· Multimeter

· Remove legrests.

· Release seat (1) and tilt forwards.

· Remove the adjusting motor plug from the

SERVICE MANUAL

· Check the electrical resistances at the adjusting motor plug (1).

The plug may have a different shape to that shown in the picture.

· If the resistance is close to infinity, the motor is probably burnt out.

· If the resistance is below 1 W, the motor has a short-circuit.

· The motor must be replaced in both cases.

SERVICE MANUAL Invacare

- Bora

/Spectra

XTR Series

7.17.2 Replacing the seat tilting (wheelchair without lifter)

Note

When an electrical adjustment option is retrofitted, then this option needs to be activated in the driving program as well if you have an ACS2 remote.

Requirements:

· flat screwdriver, blade width approx. 6 mm

· oblique pliers

· small hammer

· cable binder

· Remove legrests.

· Release seat (1) and tilt forwards.

· Disconnect the remote bus cable from the electronics module or ACT.

· Lift the seat out of the front anchorage and remove it. The seat has a heavy weight. Use proper lifting techniques.

· Remove both battery cases as described in

· Pull the adjusting motor plug out of the electronics module.

· The adjusting motor cable is secured inside the frames with cable ties. Remove the cable ties with the oblique pliers.

Invacare

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XTR Series

· Remove the SL fuse (2) on the bottom fixing bolt (1) with the screwdriver.

· Pull the fixing bolt (1) out.

SERVICE MANUAL

· Remove the SL fuse (2) on the top fixing bolt

(1) with the screwdriver.

· Pull the fixing bolt (1) out.

· Pull the adjustment spindle with adjusting motor out.

· Insert a new adjustment spindle with adjusting motor.

· Reinsert the fixing bolts and SL fuses. Fix the

SL fuses securely to the fixing bolt with the hammer.

· Reinsert the adjusting motor plug into the electronics module.

· Secure the adjusting motor cable to the frame with cable ties. The cable must be routed so that it does not rub or get trapped.

· To complete, check all seat tilting functions.

SERVICE MANUAL

7.17.3 Replacing the lifter

Invacare

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XTR Series

Note

When an electrical adjustment option is retrofitted, then this option needs to be activated in the driving program as well if you have an ACS2 remote.

Requirements:

· small blade screwdriver

· 13 mm jaw spanner

· 24 mm jaw spanner

· 6 mm jaw spanner

· 24 mm ring spanner

· Allen key 5 mm

· oblique pliers

· cable binder

· Run the lifter up to the top position if possible.

· Tilt the seat tilting completely to the rear if possible.

· Remove legrests.

· Remove all plugs from the electronic module and actuator module.

· Loose and remove the four screws (2) with a

13 mm jaw spanner.

· Lift the seat support (1) down from the lifter

(3).

· Remove both battery cases as described in