Invacare® Spectra XTR

Invacare® Spectra XTR
Invacare® Bora/Spectra XTR
SERVICE MANUAL
Edition: 24.07.2013
Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
These instructions contain information about:
Testing work
Repair Instructions
This manual is part of the instructions for use.
Service addresses
Invacare Austria GmbH
(:
+43 6232 5 53 50
Herzog Odilostrasse 101
Fax:
+43 6232 5 53 54
A-5310 Mondsee
@:
Austria
WWW:
Invacare n.v.
(:
Autobaan 22
Fax:
B-8210 Loppem (Brugge)
@:
Belgium
WWW:
Invacare AG
(:
+41 (0)61487 70 80
Benkenstraße 260
Fax:
+41 (0)61487 70 81
CH-4108 Witterswil
@:
Switzerland
WWW:
Invacare Aquatec GmbH
(
Alemannenstraße 10
Fax
88316 Isny
@:
Deutschland
WWW:
Invacare A/S
( (Kundeservice):
+45 (0)36 90 00 00
Sdr. Ringvej 37
Fax (Kundeservice):
+45 (0)36 90 00 01
[email protected]
www.invacare.at
+32 (0)50 83 10 10
+32 (0)50 83 10 11
[email protected]
www.invacare.be
[email protected]
www.invacare.ch
+49 (0)7562 70 00
+49 (0)7562 7 00 66
[email protected]
www.invacare-aquatec.de
DK-2605 Brøndby
@:
Danmark
WWW:
Invacare® SA
(:
+34 (0)972 49 32 00
c/ Areny s/n
Fax:
+34 (0)972 49 32 20
Polígon Industrial de Celrà
@:
E-17460 Celrà (Girona)
WWW:
[email protected]
www.invacare.dk
[email protected]
www.invacare.es
ESPAÑA
2
Invacare® Poirier SAS
(:
+33 (0)247 62 64 66
Route de St Roch
Fax:
+33 (0)247 42 12 24
F-37230 Fondettes
@:
France
WWW:
[email protected]
www.invacare.fr
Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
Invacare® Ltd
( (Customer services):
+44 (0)1656 77 62 22
Pencoed Technology Park
Fax (Customer services):
+44 (0)1656 77 62 20
Pencoed
@:
Bridgend CF35 5HZ
WWW:
[email protected]
www.invacare.co.uk
United Kingdom
Invacare Mecc San s.r.l.
(:
+39 0445 38 00 59
Via dei Pini, 62
Fax:
+39 0445 38 00 34
I - 36016 Thiene (VI)
@:
Italia
WWW:
Invacare Ireland Ltd.
(:
Unit 5 Seatown Business Campus
Fax:
Seatown Rd, Swords
@:
County Dublin
WWW:
[email protected]
www.invacare.it
+353 18 10 70 84
+353 18 10 70 85
[email protected]
www.invacare.ie
Ireland
Invacare® AS
( (Kundeservice):
+47 (0)22 57 95 00
Grensesvingen 9
Fax (Kundeservice):
+47 (0)22 57 95 01
Postboks 6230
@:
[email protected]
Etterstad
@:
[email protected]
N-0603 Oslo
WWW:
www.invacare.no
Norge
Invacare® B.V.
(:
+31 (0)318 69 57 57
Celsiusstraat 46
Fax:
+31 (0)318 69 57 58
NL-6716 BZ Ede
@:
[email protected]
Nederland
@:
[email protected]
WWW:
www.invacare.nl
Invacare Lda
(:
+351 225 10 59 46
Rua Estrada Velha, 949
(:
+351 225 10 59 47
P-4465-784 Leça do Balio
Fax:
+351 225 10 57 39
Portugal
@:
WWW:
[email protected]
www.invacare.pt
3
Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
Återförsäljare:
( (Kundtjänst):
+46 (0)8 761 70 90
Invacare® AB
Fax (Kundtjänst):
+46 (0)8 761 81 08
Fagerstagatan 9
@:
[email protected]
S-163 91 Spånga
@:
[email protected]
Sverige
WWW:
Tillverkare:
MÖLNDAL
Invacare® Deutschland GmbH
(:
+46 (0)31 86 36 00
Kleiststraße 49
Fax:
+46 (0)31 86 36 06
D-32457 Porta Westfalica
@:
www.invacare.se
[email protected]
Deutschland
LANDSKRONA
(:
+46 (0)418 2 85 40
Fax:
+46 (0)418 1 80 89
@:
[email protected]
OSKARSHAMN
Eastern
european
countries
European Distributor
Organisation (EDO)
Kleiststraße 49
D-32457 Porta Westfalica
Deutschland
4
(:
+46 (0)491 1 01 40
Fax:
+46 (0)491 1 01 80
@:
[email protected]
(
+49 (0)5731 75 45 40
Fax
+49 (0)5731 75 45 41
@:
WWW:
[email protected]
www.invacare.de
Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
Contents
Chapter
1
2
Page
Introduction
9
1.1
General information .................................................................................................................. 9
1.2
Notes on transport .................................................................................................................... 9
1.3
Definition and representation of information and safety information in this manual ......10
1.4
Hazard symbols and symbols used ...................................................................................... 11
1.5
Images in this manual ............................................................................................................. 12
Safety and fitting instructions
13
2.1
Before any inspection or repair work .................................................................................... 13
2.2
Personal safety equipment ..................................................................................................... 13
2.3
General safety information and information about fitting / removal ..................................13
3
Tightening torques
16
4
Layout of components and componentry
17
4.1
4.2
Overview ................................................................................................................................... 17
4.1.1
Wheelchair without lifter ................................................................................................ 17
4.1.2
Wheelchair with lifter ..................................................................................................... 19
Electronics modules ............................................................................................................... 21
4.2.1
ACS 1 60A electronics module ..................................................................................... 23
4.2.2
ACS 2 PMB70 / ACS 2 PMB70L electronics module ...................................................23
4.2.3
ACS 2 PMA90LG electronics module ........................................................................... 23
4.2.4
VR2 electronics module ................................................................................................ 23
4.2.5
R-Net electronics module ............................................................................................. 24
4.2.6
Shark electronics module ............................................................................................. 24
4.2.6.1
Shark with 4-pole DCI .............................................................................................. 24
4.2.6.2
Shark with DCI 12-pole ............................................................................................ 24
4.2.7
5
ACT actuator module .................................................................................................... 24
4.2.7.1
ACT 2 actuator module ............................................................................................ 25
4.2.7.2
ACT 4 actuator module ............................................................................................ 25
4.2.8
R-NET ISM lighting and actuator module ..................................................................... 25
4.2.9
Lighting PCB ................................................................................................................. 26
Maintenance plan (1x annually)
27
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Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
6
7
Operational faults
29
6.1
Drive fault diagnosis ............................................................................................................... 29
6.2
REM24 remote: Error codes and diagnostic codes ............................................................. 31
6.3
VR2 remote: Error codes and diagnostic codes .................................................................. 33
6.4
Shark II remote Error codes and diagnostic codes ............................................................. 35
6.5
R-NET remote: Error codes and diagnostic codes .............................................................. 36
Repair work
38
7.1
General warning information about fitting work .................................................................. 38
7.2
Replacing drive components ................................................................................................. 38
7.2.1
Replacing the complete drive unit ................................................................................ 40
7.2.2
Replacing the motor ...................................................................................................... 41
7.2.3
Replacing the jaw clutch ............................................................................................... 42
7.2.4
Replace carbon brushes ............................................................................................... 43
7.2.5
Replacing the motor / gearbox unit (SSD motor)..........................................................44
7.2.6
Replacing or rotating the motor / gearbox unit sealing ring ..........................................46
7.2.7
Replacing the motor / gearbox coupling (SSD motor) ..................................................47
7.2.8
Replacing the carbon brushes (SSD motor) ................................................................. 49
7.2.9
Replacing the drive wheel hub (SSD motor) ................................................................ 51
7.3
Replacing the electronics ....................................................................................................... 53
7.4
Replacing the G-Trac sensor.................................................................................................. 55
7.5
Operating hours counter ........................................................................................................ 57
7.5.1
Replacing the operating hours counter ......................................................................... 57
7.5.2
Replacing the connecting cable of the operating hours counter ..................................59
7.6
Updating software ................................................................................................................... 61
7.7
Replacing batteries ................................................................................................................. 62
7.7.1
Removing the battery cases ......................................................................................... 63
7.7.2
Removing the batteries ................................................................................................. 65
7.7.3
Correct handling of damaged batteries ........................................................................ 69
7.8
Checking and replacing the main fuse .................................................................................. 70
7.9
Checking the cable .................................................................................................................. 72
7.10
Differences when replacing the REM24 remote ................................................................... 74
7.11
Lighting unit ............................................................................................................................. 75
7.11.1 Replacing front headlight completely (LED lighting unit) ..............................................75
7.11.2 Replacing the front bulb holder (LED lighting unit) .......................................................76
7.11.3 Replacing the rear light completely (LED lighting unit) .................................................77
7.12
Anti-tipping mechanism .......................................................................................................... 78
7.12.1 Replacing the anti-tipping mechanism with screw ........................................................78
7.12.2 Replacing the anti-tipping mechanism with locking spring ...........................................79
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Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
7.12.3 Replacing a defective locking spring ............................................................................ 80
7.13
Replacing the steering head bearings on the steering wheels ..........................................81
7.14
Repairing punctures ................................................................................................................ 84
7.14.1 Repairing the rear tyre (wheel size 3.00-8") ................................................................. 84
7.14.2 Repairing a flat tyre (wheel size 280/250-4) ................................................................. 86
7.15
Replacing a drive wheel .......................................................................................................... 88
7.16
Replacing the splash guard.................................................................................................... 90
7.17
Seat system .............................................................................................................................. 92
7.17.1 Checking an adjusting motor ........................................................................................ 92
7.17.2 Replacing the seat tilting (wheelchair without lifter) .....................................................93
7.17.3 Replacing the lifter ........................................................................................................ 95
7.18
Backrest unit ............................................................................................................................ 97
7.18.1 Replacing the standard backrest .................................................................................. 97
7.18.2 Adjusting backrest former ............................................................................................. 98
7.19
Seat system Modulite .............................................................................................................. 99
7.19.1 Replacing the tilt actuator ............................................................................................. 99
7.19.2 Replacing the lifter actuator ........................................................................................ 100
7.19.3 Replacing the lifter / seat angle adjustment module ...................................................101
7.19.4 Replacing the angle sensor ........................................................................................ 104
7.19.5 Replacing the backrest actuator ................................................................................. 105
7.19.6 Backrest actuator - Removing the adapter ................................................................. 106
7.20
Backrest Modulite .................................................................................................................. 107
7.20.1 Replacing the standard backrest ................................................................................ 107
7.20.2 Replacing the backrest mounting bracket .................................................................. 108
7.20.3 Replacing the backrest mounting bracket for SB 53 ..................................................109
7.21
Adjusting the seat width/ backrest width (Modulite) .........................................................110
7.21.1 Adjusting the seat width .............................................................................................. 110
7.21.2 Adjusting the backrest width ....................................................................................... 112
7.21.3 Adjusting the Flex3 backrest....................................................................................... 114
8
Installing accessories
8.1
8.2
115
Replacing the holding strap ................................................................................................. 115
8.1.1
Standard seat & Flex2 ................................................................................................ 115
8.1.2
Fixed seat unit ............................................................................................................ 116
Replacing seat belts (Modulite seat) ................................................................................... 117
8.2.1
Installation on the backrest mounting bracket (simple backrest)................................117
8.2.2
Installation on the backrest mounting bracket (adjustable seat) ................................118
8.2.3
Installation on the seat frame profile (adjustable seat) ...............................................119
8.3
Luggage carrier ..................................................................................................................... 120
8.4
Further accessories .............................................................................................................. 121
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Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
9
Adjusting the seating position
9.1
9.2
9.3
8
122
Adjusting the lower leg length and seat depth................................................................... 123
9.1.1
Adjusting the lower leg length ..................................................................................... 123
9.1.2
Adjusting the seat depth ............................................................................................. 123
Adjusting the center of gravity of the seat ......................................................................... 125
9.2.1
Standard seat ............................................................................................................. 127
9.2.2
Flex2 seat ................................................................................................................... 129
9.2.3
Modulite seat .............................................................................................................. 130
9.2.3.1
Adjustable seats .................................................................................................... 132
9.2.3.2
Simple seat ............................................................................................................ 133
Check the tipping stability .................................................................................................... 134
Invacare ® - Bora/Spectra XTR
1
Introduction
1.1
General information
1.2
SERVICE MANUAL
·
Service and maintenance work must be carried out taking this service manual into account.
·
It is imperative that you observe safety information.
·
Information about operation or about general maintenance and care work on the mobility device
should be taken from the operating manual.
·
You can find information about ordering spare parts in the spare parts catalogue.
·
Only use original Invacare® spare parts. The guarantee will become invalid if other spare parts
are used!
·
We reserve the right to make any alterations on the grounds of technical improvements.
·
The mobility device may only be maintained and overhauled by qualified personnel.
·
The minimum requirement for service technicians is suitable training, such as in the cycle or
orthopaedic mechanics fields, or sufficiently long-term job experience.
- Experience in the use of electrical measuring equipment (multimeters) is also a requirement.
- Special Invacare training is recommended.
·
Alterations to the mobility device which occur as a result of incorrectly or improperly executed
maintenance or overhaul work lead to the exclusion of all liability on the side of INVACARE.
·
If you have any problems or questions please contact Invacare Service.
Notes on transport
·
If the mobility device has to be shipped back to the manufacturer for major repairs, you should
always use the original packaging for transport.
·
You must include a precise fault description.
9
SERVICE MANUAL
1.3
Invacare ® - Bora/Spectra XTR
Definition and representation of information and safety
information in this manual
Different types of information and signal words are used throughout this manual.
HAZARD!
The signal word "HAZARD!" refers to immediate hazards.
· The following lines in italics refer to actions which serve to avoid such hazards.
WARNING!
The signal word "WARNING!" refers to possibly-occurring hazards which can lead to
death or serious injuries if they are not avoided.
· The following lines in italics refer to actions which serve to avoid such hazards.
ATTENTION!
The signal word "ATTENTION!" refers to possibly-occurring hazards which can lead to
minor injuries and/or material damage if they are not avoided.
· The following lines in italics refer to actions which serve to avoid such hazards.
CAUTION!
The signal word "CAUTION!" refers to hazards which could lead to material damage if
they are not avoided.
· The following lines in italics refer to actions which serve to avoid such hazards.
Note
The signal word "Note" is used to denote general information which simplifies the handling of
your product and refers to special functions.
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Invacare ® - Bora/Spectra XTR
1.4
SERVICE MANUAL
Hazard symbols and symbols used
Different types of hazard symbols and symbols are used throughout this manual.
General hazards
This symbol warns you of general hazards!
· Always follow the instructions to avoid injury to the user or damage to the product!
BURN HAZARD!
This symbol warns you of the danger of chemical burns, for example due to the discharge
of battery acids!
· Always follow the instructions to avoid injury to the user or damage to the product!
DANGER OF CRUSHING!
This symbol warns you of crushing hazards due to inattentive working with heavy
components.
· Always follow the instructions to avoid injury to the user or damage to the product!
EXPLOSION HAZARD!
This symbol warns you of an explosion hazard, which can be caused by excessive tyre
pressure in a pneumatic tyre.
· Always follow the instructions to avoid injury to the user or damage to the product!
Wear safety shoes
The symbol refers to the requirement for wearing safety shoes.
· Wear standardised safety shoes during all work.
Wear eye protection
This symbol refers to the requirement for wearing eye protection, for example when
working with batteries.
· Wear eye protection when this symbol is shown.
Wear safety gloves
This symbol refers to the requirement for wearing safety gloves, for example when
working with batteries.
· Wear safety gloves when this symbol is shown.
Note
This symbol identifies general information which is intended to simplify working with your product
and which refers to special functions.
11
SERVICE MANUAL
Invacare ® - Bora/Spectra XTR
Requirements:
· This symbol identifies a list of various tools, components and items which you will need in
order to carry out certain work. Please do not attempt to carry out the work if you do not have
the listed tools available.
Always dispose used or damaged batteries correctly
The symbol refers to information for the correct disposal of used or damaged batteries.
1.5
Images in this manual
The detailed images in this manual are given digits to identify various components. Component
numbers in text and operational instructions always relate to the image directly above.
12
Invacare ® - Bora/Spectra XTR
2
SERVICE MANUAL
Safety and fitting instructions
These safety instructions are intended as prevention of accidents at work and it is imperative that
they are observed.
2.1
2.2
Before any inspection or repair work
·
Read and observe this repair manual and the associated operating manual!
·
Observe the minimum requirements for carrying out the work (see chapter entitled "General
information”).
Personal safety equipment
Safety shoes
The mobility device, and some of its components, are very heavy. These parts can result
in injuries to the feet if they are allowed to drop.
· Wear standardised safety shoes during all work.
Eye protection
It is possible that battery acid can be discharged when working on defective batteries or
when handling batteries improperly.
· Always wear eye protection when working on any defective or possibly defective batteries.
Safety gloves
It is possible that battery acid can be discharged when working on defective batteries or
when handling batteries improperly.
· Always wear acid-proof safety gloves when working on any defective or possibly defective
batteries.
2.3
General safety information and information about fitting / removal
WARNING: Danger of crushing!
Various components such as the drive unit, batteries, seat etc are very heavy. This results
in injury hazards to your hands!
· Please note the high weight of some components! This applies especially to the removal of
drive units, batteries and the seat.
WARNING!
Injury hazard if the vehicle starts moving unintentionally during repair work!
· Switch the power supply off (ON/OFF key)!
· Engage the drive!
· Before raising the vehicle, secure the wheels by blocking them with wedges!
13
SERVICE MANUAL
Invacare ® - Bora/Spectra XTR
ATTENTION!
Fire and burn hazard due to electrical short-circuit!
· The mobility device must be completely switched off before removal of voltage-carrying
components! To do this, remove the batteries.
· Avoid short-circuiting the contacts when carrying out measurements on voltage-carrying
components!
CAUTION!
Danger of burns from hot surfaces on the motor!
· Allow the motors to cool down before commencing work on them.
ATTENTION!
Injury hazard and danger of damage to vehicle due to improper or incomplete
maintenance work!
· Use only undamaged tools in good condition.
· Some moving parts are mounted in sockets with PTFE coating (Teflon™). Never grease
these sockets!
· Never use "normal" nuts instead of self-locking nuts.
· Always use correctly-dimensioned washers and spacers
· When reassembling, always replace any cable ties which were cut during dismantling.
· After completing your work / before renewed start-up of the mobility device, check all
connections for tight fitting.
· After completing your work / before renewed start-up of the mobility device, check all parts for
correct locking.
· Only operate the vehicle with the approved tyre pressures (see technical data).
· Check all electrical components for correct function. Please note that incorrect polarity can
result in damage to the electronics.
· Always carry out a trial run at the end of your work.
CAUTION!
Danger of injury and damage to property, if the maximum speed reduction on a
wheelchair with a lifter does not function correctly!
The wheelchair’s control unit must reduce the maximum possible speed as soon as the lifter is
raised.
· Test the maximum speed reduction for correct function after any maintenance work or
modifications to the wheelchair.
ATTENTION!
Danger of injury due to improper retrofitting of electric adjustment options.
Retrofitting electric adjustment options is a fundamental change to the configuration and can
have a negative impact on the driving characteristics and tipping stability of the electric
wheelchair.
· Retrofitting may only be performed by trained Invacare® dealers.
14
Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
Note
Mark all current settings for the mobility device (seat, armrests, backrest etc.), and the
associated cable connecting plugs, before dismantling. This makes reassembly easier.
All plugs are fitted with mechanical safety devices which prevent release of the connecting plugs
during operation. To release the connecting plugs the safety devices must be pressed in. When
reassembling ensure that these safety devices are correctly engaged.
WARNING!
Any changes to the drive program can affect the driving characteristics and the tipping
stability of the vehicle!
· Changes to the drive program may only be carried out by trained Invacare® specialist
dealers!
· Invacare® supplies all mobility devices with a standard drive program ex-works. Invacare®
can only give a warranty for safe vehicle driving behaviour - especially the tipping stability for this standard drive program!
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Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
3
Tightening torques
The tightening torques stated in the following list are based on the thread diameter for the nuts and
bolts for which no specific values have been determined.All values assume dry and de-greased
threads.
Thread
Tightening torque
in Nm ±10%
M4
3 Nm
M5
M6
M8
M10
M12
6 Nm
10 Nm
25 Nm
49 Nm
80 Nm
M14
M16
120 Nm 180 Nm
CAUTION!
Damage can be caused to the mobility device due to improperly tightened screws, nuts or
plastic connections.
· Always tighten screws, nuts etc to the stated tightening torque.
· Only tighten screws or nuts which are not listed here fingertight.
16
Invacare ® - Bora/Spectra XTR
4
Layout of components and componentry
4.1
Overview
4.1.1
Wheelchair without lifter
SERVICE MANUAL
Underneath the seat:
1) Seat disengager
2) Electronics module
The electronics modules used are
described in Chapter 4.2.
Power seat tilting
3) Adjusting motor
17
SERVICE MANUAL
Actuator module
4) Actuator module
The actuator module is fitted under the
seat support.
G-Trac sensor
5) G-Trac sensor
The optional G-Trac sensor is located in
the front, next to the battery connector.
Operation hour counter
6) Operation hour counter
The optional operation hour counter is
mounted laterally on the frame.
18
Invacare ® - Bora/Spectra XTR
Invacare ® - Bora/Spectra XTR
4.1.2
SERVICE MANUAL
Wheelchair with lifter
In front of the batteries under the
plastic cover:
1) Electronics module
2) Lighting PCB (optional)
3) Plastic cover
The electronics modules used are
described in Chapter 4.2.
Actuator module
4) Actuator module 1 (optional)
5) Actuator module 2 (optional)
6) Actuator motor backrest (optional)
The actuator modules are fitted under the
seat support.
Electric seat adjustment
6) Actuator motor backrest (optional)
7) Actuator motor seat tilting
19
SERVICE MANUAL
Electric lifter
8) Lifter motor
G-Trac sensor
9) G-Trac sensor
The optional G-Trac sensor is located in
the front, next to the battery connector.
Operation hour counter
10) Operation hour counter
The optional operation hour counter is
mounted laterally on the frame.
20
Invacare ® - Bora/Spectra XTR
Invacare ® - Bora/Spectra XTR
4.2
SERVICE MANUAL
Electronics modules
A variety of electronics modules can be fitted to the mobility device.
Before you connect any mobility device components such as adjusting motors/actuators or motors
to the electronics modules, you should first ensure that you know exactly which electronics module
has been fitted. Please refer to the following table for an overview.
Electronics module
Designation
Joystick boxes
ACS I 60A
REM24 remote
ACS I 60A with
ACT actuator
module
Notes
The actuator module
is optional.
ACS 2 PMB70
G90A
ACS 2 PMB70L
REM A
ACS 2 PMA90LG
REM B
REM 550
ACS 2 with ACT
actuator modul
The actuator module
is optional.
VR2
VR2 remote
R-Net
R-Net remote
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Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
Electronics module
22
Designation
Joystick boxes
Shark
Shark II remote
Notes
Shark with lighting
PCB
The lighting PCB is
optional.
ACT actuator
module
The actuator module
is optional.
R-NET ISM lighting
and actuator
module
The module is
optional.
Lighting PCB
The lighting PCB is
optional.
G-Trac sensor
The G-Trac sensor is
optional.
Operation hour
counter
The operation hour
counter is optional.
Invacare ® - Bora/Spectra XTR
4.2.1
SERVICE MANUAL
ACS 1 60A electronics module
Connections
1) Motor M2
2) Battery 24V
3) Bus cable (to remote or ACT)
4) Bus cable (to remote or ACT)
5) Motor M1
4.2.2
ACS 2 PMB70 / ACS 2 PMB70L electronics module
Connections
1) Battery 24V
2) Bus cable (to remote or ACT)
3) Bus cable (to remote or ACT)
4) Motor M1
5) Light
6) Motor M2
Rubber stoppers for free slots
2) & 3) Order number: 1552876
4.2.3
ACS 2 PMA90LG electronics module
Connections
1) Battery 24 V
2) Cable to G-Trac sensor (GYRO)
3) Bus cable (to remote or ACT)
4) Motor M1
5) Light
6) Motor M2
Rubber stoppers for free slots
2) & 3) Order number: 1552876
4.2.4
VR2 electronics module
Connections
1) Joystick box
2) Lock (INHIBIT 2)
3) Actuator 1
4) Actuator 2
5) On-board battery charger
6) Motor M1
7) Battery 24V
8) Motor M2
23
SERVICE MANUAL
4.2.5
Invacare ® - Bora/Spectra XTR
R-Net electronics module
Connections
1) Bus
2) Lock (INHIBIT 2)
3) Actuator 1
4) Actuator 2
5) On-board battery charger
6) Motor M1
7) Battery 24V
8) Motor M2
4.2.6
Shark electronics module
4.2.6.1
Shark with 4-pole DCI
BUS C ABLE
Connections
1) Joystick box
2) DCI for actuators (4-pole)
3) Right-hand motor M1
4) Battery 24V
5) Left-hand motor M2
4.2.6.2
Shark with DCI 12-pole
Connections
1) Cable to remote
2) DCI for actuators/lighting (12-pole)
3) Right-hand motor M1
4) Battery 24V
5) Left-hand motor M2
4.2.7
ACT actuator module
A range of adjusting motors, also known as actuators, can be fitted to the mobility device. These
actuators are either connected directly to the electronics module or to a separate actuator module.
The actuator module is connected with the electronics module via a bus cable.
24
Invacare ® - Bora/Spectra XTR
4.2.7.1
SERVICE MANUAL
ACT 2 actuator module
Connections
1) ACI*
2) Bus cable (to remote or ACT)
3) Bus cable (to remote or ACT)
4) Adjusting motor/actuator - Channel 2
5) Adjusting motor/actuator - Channel 1
Rubber stoppers for free slots
1)
Order number: 1555701
2) & 3) Order number: 1552876
4) & 5) Order number: 1555700
* The ACI connection is used for actuator limitation or speed reduction.
4.2.7.2
ACT 4 actuator module
Connections
1) ACI*
2) Bus cable (to remote or electronics
module)
3) Bus cable (to remote or electronics
module)
4) Actuator - Channel 4
5) Actuator - Channel 3
6) Actuator - Channel 2
7) Actuator - Channel 1
Rubber stoppers for free slots
1)
Order number: 1555701
2) & 3) Order number: 1552876
4) to 7) Order number: 1555700
* The ACI connection is used for actuator limitation or speed reduction.
4.2.8
R-NET ISM lighting and actuator module
A range of adjusting motors, also known as actuators, can be fitted to the wheelchair. These
actuators are either connected directly to the electronics module or to a separate actuator module.
The actuator module is connected with the electronics module via a bus cable.
In addition, the lighting can be connected to the R-NET ISM. An additional lighting PCB is not then
required.
25
SERVICE MANUAL
Invacare ® - Bora/Spectra XTR
Connections
1) Bus cable (to remote or ACT)
2) Light left
3) Adjusting motor/actuator - Channel 1
4) Adjusting motor/actuator - Channel 3
5) Adjusting motor/actuator - Channel 5
6) INH 4*
7) INH 5*
8) Adjusting motor/actuator - Channel 6
9) Adjusting motor/actuator - Channel 4
10) Adjusting motor/actuator - Channel 2
11) Light right
12) Bus cable (to remote or ACT)
* The INH connection is used for actuator limitation or speed reduction.
4.2.9
Lighting PCB
The lighting PCB connections are printed on the circuit board itself.
26
Invacare ® - Bora/Spectra XTR
5
SERVICE MANUAL
Maintenance plan (1x annually)
CAUTION!
Danger of injury and damage to property, if the maximum speed reduction on a
wheelchair with a lifter does not function correctly!
The wheelchair’s control unit must reduce the maximum possible speed as soon as the lifter is
raised.
· Test the maximum speed reduction for correct function after any maintenance work or
modifications to the wheelchair.
Component
Check
Remedy
Armrests
· Damage to armrests
· Replace covering
if damaged
· Armrest fixings
· Tighten screws
· Damage to side
panels
· Replace side
panels if damaged
· Side panel fixings
· Tighten screws
Seat lock
· Seat lock defective
· Replace seat lock
Seat angle
adjustment
· Tight seating of SL
fuses
· Replace SL fuses
if necessary
· Damage to backrest
· Replace parts if
damaged
Side panels
Power backrest
(if fitted)
· Seams
· Fixing
· Check cable
Notes
ü
· Tighten screws
· Replace cable
motor if necessary
· Check function
Frames
(chassis) /
battery
mounting
· Check fixings,
welded seams and
battery mounting
· Check drive wheels
Wheel
for tight fit and side
suspension and
play
wheels
· Tighten screws
· Replace
components if
necessary
· Adjust, replace
wheel hubs
See chapter 7.15.
· Check steering
wheels for tight fit,
float and side play
· Replace wheels,
wheel fork or
wheel bearings
See chapter 7.11.
· Pneumatic tyres (if
fitted)
· Repair or replace
if damaged
See chapter 7.14.
27
Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
Component
Check
Remedy
Drive units,
coupling
mechanism
· Check functions in
drive and push
modes
· Replace motor if
necessary.
· Check coupling
mechanism
Legrests
Power legrests
(if fitted)
· Tighten
screws/nuts,
adjust or replace if
necessary
· Check welded
seams, interlocking,
screws, footplates
· Tighten, replace if
necessary
· Check cable
· Replace cable if
necessary
· Check contacts
Notes
· check functions
Lighting (if
fitted)
Batteries
Battery case
Remote /
electronics
module
· Check cable
· Check function
· Replace lamp or
cable if necessary
· Check batteries for
damage
· Replace batteries
if necessary
See chapter 7.7.
· Check battery
voltage
· Charge batteries
See operating
manual
· Check contacts and
terminals
· Clean contacts
and terminals
Please refer to the
safety information
in Chapter 7.7 for
handling batteries
· Check locking
system, it must
engage completely.
· Replace if
necessary
· Remote, status
display blinking
· Evaluate
error/blink code
· Fixings
· Tighten fixings,
replace if
necessary
· Cables and
connecting plugs
· Tighten cables
and connecting
plugs, replace if
necessary
· Drive lever function
· Replace drive
lever if necessary
· Replace remote if
necessary
Drive program
28
· 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.
ü
Invacare ® - Bora/Spectra XTR
6
SERVICE MANUAL
Operational faults
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.
The electronics modules used are described in Chapter 4.2.
NOTE:
The tables for rectification of operational faults listed in the following chapters are only an excerpt
from the original manufacturer's manuals.
You can obtain the original manuals from Invacare®.
If you have problems with the mobility 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
Other
Symptoms
Possible
Cause
Solution
Documentation
Mobility
device will
not start
The remote
status display
illuminates
normally and
does not show
an error code.
Drive motors
disengaged
Engage drive
motors
See operating manual
Remote status
display does not
illuminate
batteries
defective
Replace batteries
See chapter 7.7.
Completely
discharge
battery
Pre-charge
batteries
See operating manual
Power supply
to remote
interrupted
Check master
fuse
See chapter 7.2.9.
Check cables
between the
modules for loose
connections and
damage
See chapter 7.9.
Remote
defective
Replace remote
See chapter 7.10.
Remote status
display blinking
Various
causes
Assess error code
See chapter 6.2.
None
Batteries
defective
(unstable
voltage)
Replace batteries
See chapter 7.7.
Drive motor(s)
defective
Replace motor(s)
See chapter 7.2 .
Mobility
device
judders in
drive mode
29
Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
Problem
Batteries
not being
charged
Other
Symptoms
Possible
Cause
Documentation
Replace carbon
brushes
See chapter 7.2.4.
None
Batteries
defective
Replace batteries
See chapter 7.7.
LEDs blinking
on charging unit
Charging unit
defective
Replace charging
unit
See charging unit
operating manual
Mobility
device
runs too
slowly
None
Remote
defective
Replace remote
See chapter 7.10.
Batteries
defective
Replace batteries
See chapter 7.7.
Electrical
adjustment
motor
does not
react
Remote shows
a blinking "E",
status diode on
lighting/actuator
module does
not go out even
if remote is
switched off or
disconnected.
Lighting /
actuator
module
defective
Replace lighting /
actuator module
See chapter 7.2.9.
None
Cable
disconnected
or damaged
Safeguard cable
connection,
replace cable if
necessary
See chapter 7.9.
Electrical
adjusting
motor
defective
Check adjusting
motor
See chapter 7.17.
Remote
defective
30
Solution
Replace remote
See chapter 7.10.
Invacare ® - Bora/Spectra XTR
6.2
SERVICE MANUAL
REM24 remote: Error codes and diagnostic codes
The drive electronics can automatically rectify some faults. In this case the status display will stop
blinking. Switch the remote on and off again several times. Wait around 5 seconds each time
before switching the remote on again. If this does not rectify the fault, determine the cause using
the blink codes from the following table.
Blink Code
Possible Cause
Solution
Documentation
1 x blink
Module defective
Replace defective
module
See chapter 7.2.9.
2 x blink
Accessory error (e.g.
short-circuit in adjusting
motor)
Check accessory
connections, check
accessory
See chapter 7.17.
Lifter too high or too low
(seat not at driving
height)
If the lifter is raised, lower See operating
it slowly until the status
manual
display stops blinking. If
the lifter is too low, raise
it slowly until the status
display stops blinking.
Only drive when the seat
is at driving height.
3 x blink
Error at right-hand motor
Connection
loose/defective or motor
defective
Check connection plug,
check motor
See chapters 7.9
and 7.2
4 x blink
Error at left-hand motor
Connection
loose/defective or motor
defective
Check connection plug,
check motor
See chapters 7.9
and 7.2
5 x blink
Fault/brake fault on righthand motor. Connection
loose/defective or motor
defective
Check connection plug
See chapters 7.9
and 7.2
6 x blink
Fault/brake fault on lefthand motor. Connection
loose/defective or motor
defective
Check connection plug
See chapters 7.9
and 7.2
7 x blink
Completely discharge
battery
Pre-charge battery
See operating
manual
8 x blink
Battery voltage too high
Switch lighting to low
battery voltage
See charging unit
operating manual
Check battery charger
9 or 10 x blink
Faulty data transmission
between modules
Remove electronic
modules 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 chapter 7.2.9.
31
Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
32
Blink Code
Possible Cause
Solution
11 x blink
Drive motors overloaded / Switch remote on and off
overheated
/ wait if necessary
12 x blink
Compatibility problems
between modules
Documentation
-
Remove incorrect module See chapter 7.2.9.
Invacare ® - Bora/Spectra XTR
6.3
SERVICE MANUAL
VR2 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) Profile indicator
3) Adjusting motors
Error code
Possible Cause
Solution
Documentation
1 LED battery display
Batteries
discharged
Charge battery
Check cable to batteries
See chapter 7.9.
2 LED battery display
Error at left-hand
motor
Connection
loose/defective
or motor
defective
Check connection plug, check See chapters 7.9
motor
and 7.2
3 LED battery display
Short-circuit in
left-hand motor
Check connection plug, check See chapters 7.9
motor
and 7.2
4 LED battery display
Error at righthand motor
Connection
loose/defective
or motor
defective
Check connection plug, check See chapters 7.9
motor
and 7.2
5 LED battery display
Short-circuit in
right-hand motor
Check connection plug, check See chapters 7.9
motor
and 7.2
6 LED battery display
The mobility
device 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
See chapter 7.9.
33
Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
34
Error code
Possible Cause
Solution
9 LED battery display
The parking
Check parking brake
brake is not
Check cable.
working correctly.
Documentation
See chapter 7.9.
10 LED battery display
Power surges in
the control box,
e.g. due to bad
connection with
batteries.
Check cable to batteries
See chapter 7.9.
7 LED Battery display
plus
5 LED
profile indicator
Compatibility
problems
between
modules
Check cable to remote
Replace remote
See chapter 7.9.
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
See chapter 7.9.
Invacare ® - Bora/Spectra XTR
6.4
SERVICE MANUAL
Shark II remote Error codes and diagnostic codes
The drive electronics can automatically rectify some faults. In this case the status display will stop
blinking. Switch the remote on and off again several times. Wait around 5 seconds each time
before switching the remote on again. If this does not rectify the fault, determine the cause using
the following link codes:
Blink
Code
Meaning
Solution
1
Operating error
Set drive lever to neutral central
position (just release drive lever) and
switch on again
2
Battery error
Check battery and mains cable
Documentation
See chapter 7.9.
Charge batteries.
See operating manual
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.
3
Fault on left-hand
motor (M2)
Replace batteries
See chapter 7.7.
Check motor cable and connecting
plug.
See chapters 7.7 and
7.2
Check motor.
4
Fault on right-hand Check motor cable and connecting
motor (M1)
plug.
See chapters 7.7 and
7.2
Check motor.
5
Fault at left-hand
(M2) motor brake
Check cable and plug.
See chapter 7.7.
6
Fault right-hand
(M1) motor brake
Check cable and plug.
See chapter 7.7.
7
Error in Shark
remote
Check bus cable in remote and
connecting plug.
See chapter 7.7.
Replace remote.
8
Error in Shark
power module
Check all the cables and plugs in the
Shark system.
See chapters 7.7 and
7.2.9
Replace electronics module
9
Communication
error in Shark
system
Check all cables and connecting plugs
in the Shark system.
10
Unknown error
Check all cables and connecting plugs.
11
Incompatible
remote
The wrong remote has been connected. See chapter 7.2.9.
Ensure that electronic module code and
the remote code match.
See chapters 7.7 and
7.2.9
Replace remote.
See chapter 7.7.
35
Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
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
36
Error code
Possible Cause
Solution
Documentation
1 LED battery display
Batteries
discharged
Charge battery
Check cable to batteries
See chapter 7.9.
2 LED battery display
Fault in left-hand Check connection plug, check See chapters 7.9
motor;
motor
and 7.2
connection
loose/defective or
motor defective
3 LED battery display
Short-circuit in
left-hand motor
4 LED battery display
Fault in right-hand Check connection plug, check See chapters 7.9
motor;
motor
and 7.2
connection
loose/defective or
motor defective
5 LED battery display
Short-circuit in
right-hand motor
6 LED battery display
The wheelchair
Remove battery charger
has been blocked
by an external
signal, for
example because
the charger is
connected.
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
Check cable.
correctly.
Check connection plug, check See chapters 7.9
motor
and 7.2
Check connection plug, check See chapters 7.9
motor
and 7.2
See chapter 7.9.
See chapter 7.9.
Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
Error code
Possible Cause
Solution
Documentation
10 LED battery display
Power surges in
the control box,
e.g. due to bad
connection with
batteries.
Check cable to batteries
See chapter 7.9.
7 LED Battery display
plus
5 LED
profile indicator
Compatibility
Check cable to remote
problems
Replace remote
between modules
See chapter 7.9.
Actuator LEDs blinking
Actuator error
See chapter 7.9.
If more than one actuator is
fitted, locate the defective
actuator.
Check cable to actuator
37
SERVICE MANUAL
Invacare ® - Bora/Spectra XTR
7
Repair work
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
38
Invacare ® - Bora/Spectra XTR
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
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.
39
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.
40
·
Lift the complete drive unit up.
·
The drive unit is reassembled in reverse order
to disassembly.
Invacare ® - Bora/Spectra XTR
Invacare ® - Bora/Spectra XTR
7.2.2
SERVICE MANUAL
Replacing the motor
·
Loosen the motor screw (1) with the 5 mm
Allen key.
·
Remove the motor from the transmission.
·
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.
41
SERVICE MANUAL
7.2.3
42
Replacing the jaw clutch
·
Loosen the motor screw (1) with the 5 mm
Allen key.
·
Remove the motor from the transmission.
·
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.
Invacare ® - Bora/Spectra XTR
Invacare ® - Bora/Spectra XTR
7.2.4
SERVICE MANUAL
Replace carbon brushes
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.
43
SERVICE MANUAL
7.2.5
Invacare ® - Bora/Spectra XTR
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:
44
·
Switch the electronics OFF on the remote.
·
Remove the rear battery boxes, as described in chapter 7.7.1.
·
Pull the motor plug out of the power module.
·
Open the cable clamps and expose the motor cable.
·
Remove the drive wheel as described in chapter 7.15.
·
Remove the wheel hub as described in chapter 7.2.9.
·
Remove the splash guard as described in chapter 7.16.
Invacare ® - Bora/Spectra XTR
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°.
45
SERVICE MANUAL
7.2.6
Invacare ® - Bora/Spectra XTR
·
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.
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:
46
·
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.
Invacare ® - Bora/Spectra XTR
7.2.7
SERVICE MANUAL
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
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.
47
SERVICE MANUAL
Invacare ® - Bora/Spectra XTR
Installing the motor / gearbox coupling:
48
·
Place the new clutch (7) on the motor axle. Pay attention to the position of the groove.
·
Position the locking ring (5) on the motor (4) or the gearbox (1).
·
Carefully insert the motor into the gearbox. Pay attention to the position of the groove in the
axle of the gearbox. If necessary, rotate the motor and gearbox to the correct position.
·
Insert the carriage bolt through the locking ring. Do not forget the spacer sleeve (2)!
·
Install the washer and the self-locking nut.
·
Do not tighten the self-locking nut completely, as the motor orientation must be adjusted during
installation.
·
Install the motor / gearbox unit, as described in chapter 7.2.5.
Invacare ® - Bora/Spectra XTR
7.2.8
SERVICE MANUAL
Replacing the carbon brushes (SSD motor)
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.
·
Disengage the motor (1) by setting the engaging lever to “Push“.
Note
In the case of the SSD motor, you can unto the bolt (5) with a 10 mm socket spanner and then
turn the motor around so that you can access the rear carbon brushes more easily.
49
SERVICE MANUAL
Invacare ® - Bora/Spectra XTR
·
Loosen and remove all four plastic caps (3) using a blade screwdriver.
·
Note the fixing position and location of the carbon brushes.
Note
Used carbon brushes need to the refitted exactly in the same position from which they were taken
in order to guarantee optimum contact to the collector.
·
Make a marking on the motor and the carbon brushes in order to guarantee correct refitting.
·
Remove the carbon brushes completely from the mounting (2).
·
Check the carbon brush and spring for the level of wear, broken components or discolouration.
Refitting the carbon brushes:
·
Depending on the condition of the brush and the spring:
- either replace the brushes in exactly the same position from which they were taken or
- fit new brushes.
·
Refit the plastic caps and tighten them firmly.
·
Turn the motor round in position so that the engaging lever can be set both to the "Push" and
the "Travel" position.
·
Now retighten the bolt (5) fingertight.
·
Refit the drive wheels as described in chapter 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.
50
·
Lift the wheelchair on one side and place a 14 cm high wooden block underneath it so that the
drive wheel is off the ground and can rotate freely. Use proper lifting techniques.
·
Also repeat this on the other side of the mobility aid.
·
Allow the motors to run for an hour in forward direction.
·
Allow the motors to cool down for 30 minutes.
·
Allow the motors to run for an hour in reverse direction.
·
Lift the mobility aid off the wooden blocks.
Invacare ® - Bora/Spectra XTR
7.2.9
SERVICE MANUAL
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.
51
SERVICE MANUAL
Invacare ® - Bora/Spectra XTR
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.
52
·
Assemble the parts of the wheel hub in reverse order.
·
Use a thin film of lubricant to replace the wheel hub on the axle.
Invacare ® - Bora/Spectra XTR
7.3
SERVICE MANUAL
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.
53
SERVICE MANUAL
54
·
Remove all plugs (1) from the electronics
module.
·
Mark the positions of individual plugs for later
reassembly.
·
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.
Invacare ® - Bora/Spectra XTR
Invacare ® - Bora/Spectra XTR
7.4
SERVICE MANUAL
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.
·
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.
55
SERVICE MANUAL
56
·
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.
Invacare ® - Bora/Spectra XTR
Invacare ® - Bora/Spectra XTR
7.5
Operating hours counter
7.5.1
Replacing the operating hours counter
SERVICE MANUAL
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.
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.
57
SERVICE MANUAL
Invacare ® - Bora/Spectra XTR
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.
58
·
Close the casing and reattach it to the
wheelchair with the Velcro fastening.
·
Reinstall all remaining components in reverse
order.
Invacare ® - Bora/Spectra XTR
7.5.2
SERVICE MANUAL
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.
59
SERVICE MANUAL
Invacare ® - Bora/Spectra XTR
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.
60
·
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.
Invacare ® - Bora/Spectra XTR
7.6
SERVICE MANUAL
Updating software
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 ACS 2 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 ACS 2 remote. For more
information, refer to the user manual of the Wizard software and the installation instructions for
the electronic modules
61
SERVICE MANUAL
7.7
Invacare ® - Bora/Spectra XTR
Replacing batteries
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!
62
Invacare ® - Bora/Spectra XTR
7.7.1
SERVICE MANUAL
Removing the battery cases
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.
63
SERVICE MANUAL
·
64
Pull the front battery case backwards using
the belt and pull it out using the handles.
Invacare ® - Bora/Spectra XTR
Invacare ® - Bora/Spectra XTR
7.7.2
SERVICE MANUAL
Removing the batteries
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).
65
SERVICE MANUAL
·
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.
·
66
Remove the terminal cover from the battery
terminals (1).
Invacare ® - Bora/Spectra XTR
Invacare ® - Bora/Spectra XTR
·
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).
·
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.
SERVICE MANUAL
67
SERVICE MANUAL
68
·
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.
Invacare ® - Bora/Spectra XTR
Invacare ® - Bora/Spectra XTR
7.7.3
SERVICE MANUAL
Correct handling of damaged batteries
WARNING: BURN HAZARD!
Injury hazard due to discharged acid.
· Always wear acid-proof protective gloves when handling batteries.
· Always wear protective goggles when handling batteries.
What to do if acid is discharged:
· Always take clothing which has been soiled by or dipped in acid off immediately!
· Rinse any areas of your skin which has come into contact with battery acid off immediately
with plenty of water!
If contact with eyes is made:
· Rinse the affected eye under running water for several minutes! You should also consult an
eye specialist immediately afterwards!
Requirements:
· protective goggles
· acid-proof gloves
· acid-proof transport container
·
If handling damaged batteries, always wear suitable protective clothing.
·
Always deposit damaged batteries in suitable acid-proof containers immediately after removal.
·
Only transport damaged batteries in suitable acid-proof containers.
·
Always wash any objects which were contacted by acid in plenty of fresh water.
Always dispose of used or damaged batteries correctly
Used and damaged batteries will be taken back by your medical equipment supplier or
Invacare®.
69
SERVICE MANUAL
7.8
Invacare ® - Bora/Spectra XTR
Checking and replacing the main fuse
CAUTION: Fire hazard!
A short circuit can cause extremely high currents which can result in spark formation and
fire!
· Always use an original strip fuse with the approved amperage.
· If the main fuse has blown, first rectify the cause before fitting a new one.
CAUTION: Fire hazard!
Fitting the incorrect strip fuse causes a fire hazard!
· Only 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.
70
·
Remove both battery cases as described in
Chapter 7.7.1.
·
Remove the covers on both battery cases as
described in Chapter 7.7.2.
Invacare ® - Bora/Spectra XTR
·
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.
·
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.
SERVICE MANUAL
71
SERVICE MANUAL
7.9
Invacare ® - Bora/Spectra XTR
Checking the cable
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.
72
·
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
Chapter 7.7.1.
·
Remove the covers on both battery cases as
described in Chapter 7.7.2.
Invacare ® - Bora/Spectra XTR
·
Check all battery cables for visible damage
and crushing. Replace damaged cables.
·
Reassembly takes place in the reverse order.
·
To complete, check all vehicle functions.
SERVICE MANUAL
73
SERVICE MANUAL
7.10
Invacare ® - Bora/Spectra XTR
Differences when replacing the REM24 remote
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!
74
Invacare ® - Bora/Spectra XTR
7.11
SERVICE MANUAL
Lighting unit
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
Chapter 7.7.1.
·
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.
75
SERVICE MANUAL
Invacare ® - Bora/Spectra XTR
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
76
·
Loosen the nut (2) with a 7 mm jaw spanner
and a 3 mm Allen key and remove.
·
Remove the front headlight (1) from the lamp
holder (3) and place it carefully to the side.
·
Undo and remove the two screws (4) with a
TX25 torx screwdriver.
·
Replace the lamp holder (3).
·
Reassembly takes place in the reverse order.
·
To complete, check all vehicle functions.
Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
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
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
Chapter 7.7.1.
·
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.
77
SERVICE MANUAL
7.12
Invacare ® - Bora/Spectra XTR
Anti-tipping mechanism
7.12.1 Replacing the anti-tipping mechanism with screw
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)
78
·
Insert screw.
·
Re-position the self-securing nut and tighten.
Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
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.
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SERVICE MANUAL
Invacare ® - Bora/Spectra XTR
7.12.3 Replacing a defective locking spring
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
80
·
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.
Invacare ® - Bora/Spectra XTR
7.13
SERVICE MANUAL
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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SERVICE MANUAL
·
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
·
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.
Invacare ® - Bora/Spectra XTR
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!
82
Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
The illustrations show the wide border of the ball bearing on the
outside of the ball race (A) and the narrow ball bearing edge on
the inside (B).
After assembly, the steering wheels should rotate freely but the
bearings should have no play.
·
First tighten the nuts to 20 Nm +/- 2 Nm.
·
Then loosen them slightly.
·
Then retighten to 15 Nm +/- 1.5 Nm.
83
SERVICE MANUAL
7.14
Invacare ® - Bora/Spectra XTR
Repairing punctures
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:
84
·
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
Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
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.
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SERVICE MANUAL
Invacare ® - Bora/Spectra XTR
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.
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.
86
Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
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.
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SERVICE MANUAL
7.15
Invacare ® - Bora/Spectra XTR
Replacing a drive wheel
ATTENTION: Danger of crushing to the hands and feet by the weight of the wheelchair!
· Pay attention to the hand and feet.
· Use proper lifting techniques.
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.
88
·
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
Chapter 7.7.1.
·
Place the vehicle upside down so that the
wheels are facing upwards. The vehicle has a
heavy weight. Use proper lifting techniques.
Invacare ® - Bora/Spectra XTR
·
Under the 4 bolts which secure the wheel (1)
using the Torx TX40 spanner.
·
Remove the wheel from the hub.
·
Reassembly takes place in the reverse order.
SERVICE MANUAL
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.
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SERVICE MANUAL
7.16
Invacare ® - Bora/Spectra XTR
Replacing the splash guard
ATTENTION: Danger of crushing to the hands and feet by the weight of the wheelchair!
· Pay attention to the hand and feet.
· Use proper lifting techniques.
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.
90
·
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
Chapter 7.7.1.
·
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.
Invacare ® - Bora/Spectra XTR
·
A further reinforcing plate (1) is located under
the splash guard.
·
Reassembly takes place in the reverse order.
When reassembling, ensure that screw (1) is
shorter than screw (2).
SERVICE MANUAL
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SERVICE MANUAL
7.17
Seat system
7.17.1 Checking an adjusting motor
Requirements:
· Multimeter
92
·
Remove legrests.
·
Release seat (1) and tilt forwards.
·
Remove the adjusting motor plug from the
electronics module or ACT (see Chapter 4.2).
·
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.
Invacare ® - Bora/Spectra XTR
Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
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 ACS 2 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
Chapter 7.7.1.
·
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.
93
SERVICE MANUAL
94
·
Remove the SL fuse (2) on the bottom fixing
bolt (1) with the screwdriver.
·
Pull the fixing bolt (1) out.
·
Remove the SL fuse (2) on the top fixing bolt
(1) with the screwdriver.
·
Pull the fixing bolt (1) out.
·
Pull the adjustment spindle 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.
Invacare ® - Bora/Spectra XTR
Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
7.17.3 Replacing the 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 ACS 2 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
Chapter 7.7.1.
·
Open the lifter energy chain. To this, lift the
cover (1) up on each chain link and pull the
clip (2) out.
·
Pull the cable out of the chain and expose
completely.
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SERVICE MANUAL
· Use the Phillips screwdriver to loosen the screws (1).
· Remove the power supply chain (2).
· Use the Phillips screwdriver to loosen the screws (4).
· Additionally the sensor (5) is secured with nuts.
Loosen the nuts while holding a 6 mm wrench against.
· Remove the magnet (3).
· Remove the sensor (5).
96
·
Loosen the four bolts (1) with a 5 mm Allen
key and a 13 mm jaw spanner and remove.
·
Loosen the two bolts (2) with a 24 mm jaw
spanner and a 24 mm ring spanner and
remove.
·
Lift the lifter out of the vehicle frame and
replace.
·
Reassembly takes place in the reverse order.
·
To complete, check all vehicle functions.
Invacare ® - Bora/Spectra XTR
Invacare ® - Bora/Spectra XTR
7.18
SERVICE MANUAL
Backrest unit
7.18.1 Replacing the standard backrest
Requirements:
· 5 mm Allen key
· open-ended spanner, 10 mm
· open-ended spanner, 13 mm
Dismantling the backrest unit:
· Remove the backrest cushion.
· Undo and remove the handwheels (3).
· Use two 13 mm socket spanners to undo the bolts (4) including the nuts and washers on the
left-hand and right-hand side of the chair.
· Remove the backrest tube (1) from the backrest holders (2).
· If the backrest holders also need to be replaced: Undo and remove the Allen screws (5)
including the nuts and washers on the left-hand and right-hand side of the chair. To do this, use
a 5 mm Allen key and a 10 mm socket spanner.
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SERVICE MANUAL
Invacare ® - Bora/Spectra XTR
Refitting the backrest unit:
· Replace the parts in the reverse order.
· To conclude, you should always carry out a trial run to test the vehicle functions.
7.18.2 Adjusting backrest former
The backrest former can be individually adapted to the user's back shape.
98
·
Pull the front and rear faces of the backrest upholstery (1) apart and remove. The backrest
upholstery front and rear faces are held together using Velcro fastenings.
·
Open the backrest belt (2) Velcro fastenings and adjust to the required length.
·
Reattach the backrest upholstery and fix with Velcro fastenings.
Invacare ® - Bora/Spectra XTR
7.19
SERVICE MANUAL
Seat system Modulite
7.19.1 Replacing the tilt actuator
Note
Replacing the actuator for the seat angle adjustment in the lifter / seat tilt adjustment module is
also described.
Requirements:
· Screwdriver, flat, width 6 mm
· 13 mm jaw spanner (2x)
· Slotted screwdriver
·
Remove legrests.
·
Switch the electronics OFF on the remote.
·
Disconnect the actuator cable from the cable
harness
Variant actuator - tilt:
· Bottom fixing bolt (3) with nut (4) –
Loose the nut with the open-ended wrenches.
Remove the nut and bolt.
·
Top fixing bolt (2) secured with snap rings (1) –
Remove a snap ring using a screwdriver and
remove the bolt.
·
Pull the actuator out.
·
Insert a new actuator.
·
Reassembly takes place in the reverse order.
·
Connect the actuator cable to the cable harness.
·
To complete, check all seat tilting function
Variant seat angle adjustment actuator in the
lifter/seat angle adjustment module:
· Bottom fixing bolt (3) with slot –
Loosen the fixing bolt with a screwdriver.
Remove the bolt.
·
Top fixing bolt (2) secured with snap rings (1) –
Remove a snap ring using a screwdriver and
remove the bolt.
·
Pull the actuator out.
·
Insert a new actuator.
·
Reassembly takes place in the reverse order.
·
Connect the actuator cable to the cable harness.
·
To complete, check all seat tilting function.
99
SERVICE MANUAL
Invacare ® - Bora/Spectra XTR
7.19.2 Replacing the lifter actuator
Requirements:
· Screwdriver flat, width 6 mm
· Large screwdriver
· Flat screwdriver
·
Remove legrests.
·
Run the lifter up to if possible.
·
Switch the electronics OFF on the remote.
·
Secure the seat.
·
Pull the plug from the actuator.
·
Bottom fixing bolt (2) secured with snap
rings – Remove a snap ring using a
screwdriver and remove the bolt.
·
Top fixing bolt (3) with slot –
Loosen the fixing bolt with a screwdriver.
Remove the bolt.
·
Replace actuator.
·
Reassembly of the actuator takes place in
the reverse order.
·
Connect the plug of the actuator cable to the
actuator.
·
To complete, check all seat tilting function.
If the lifter cannot be raised, a cover can be removed from the upper rear side of the module. This
way it is possible to reach the lower fixation bolt of the actuator.
100
Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
7.19.3 Replacing the lifter / seat angle adjustment module
Note
Replacement of the seat angle adjustment module is performed in the same manner.
ATTENTION: Danger of crushing!
The seat/seat frame is very heavy. Danger of injury to hands and feet!
· Use proper lifting techniques
Requirements:
·
·
·
·
·
·
10 mm Allen wrench
13 mm open-ended wrench
24 mm open-ended wrench
24 mm box wrench
Side cutting pliers
Cable ties
· Remove legrests.
· Tilt the seat tilting completely to the rear if
possible.
· Switch the electronics OFF on the remote.
· Loosen and remove the screws on both sides,
which secure the lateral seat plates (A).
· Remove the lateral seat plates (B).
· Loosen and remove the screws, which secure
the middle seat plate (C).
· Remove the middle seat plate (D).
or
· Remove the seat cushion.
· Loosen and remove the screws on both sides,
which secure the sling seat (A).
· Remove the sling seat (B).
101
SERVICE MANUAL
102
Invacare ® - Bora/Spectra XTR
·
Remove the seat frame by removing the screws (1).
·
Disconnect the actuator cable and microswitch cable from the cable harness.
Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
·
Loosen the screws (2) and remove the screws and washers.
·
Lift the module of the seat angle adjustment (1) from the adapter and replace it.
·
Reassembly takes place in the reverse order.
·
To complete, check all seat tilting function.
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SERVICE MANUAL
Invacare ® - Bora/Spectra XTR
7.19.4 Replacing the angle sensor
Voraussetzungen:
· 5 mm Allen wrench
· PH1 Phillips screwdriver
Dismantling the angle sensor:
·
Remove the plug (3) from the sensor (1).
·
Open the cover of the sensor box by loosening and removing both Phillips screws (4).
·
Loosen the two Allen screws (5) and remove the sensor (1) from mounting plate (2).
·
Replace the angle sensor.
Refitting the angle sensor:
· Assemble the parts in the reverse order
104
Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
7.19.5 Replacing the backrest actuator
Requirements:
· 8 mm Allen key
· open-ended spanner, 10 mm
· open-ended spanner, 13 mm
Dismantling the backrest actuator:
·
Pull the cable off directly where it is connected to the actuator (2).
·
Detach the bracket of the actuator at the top and bottom; to do this, slide the bolts (4) to the
side using the lever (5) and tilt the actuator (2) out of the backrest clamp (3).
·
Replace actuator.
Note
To increase the angle of the backrest, you can remove the adapter (1). See chapter 7.19.6.
Refitting the backrest actuator:
· Assemble the parts in the reverse order.
105
SERVICE MANUAL
Invacare ® - Bora/Spectra XTR
7.19.6 Backrest actuator - Removing the adapter
The Modulite seat is shipped ex works with an adapter on the backrest actuator, which allows a
backrest angle of 75 to 105 degrees. This is done for safety reasons, in order to ensure tipping
stability in cases of heavy user weight or tall users with a corresponding shift in their center of
gravity.
Smaller or lighter users can use the full range of backrest angles from 90 to 120 degrees.
The adapter (1) must be removed to allow this.
Note
The tipping stability must be checked afterwards, to determine the safety and stability of the
electric wheelchair. See chapter 9.3.
106
·
Slide the bolts (6) to the side using the lever (5) and tilt the actuator out of the upper bracket.
·
SL fuse (2) incl. Remove the washer (3) of the fixation bolt (4).
·
Pull the fixing bolt (4) out.
·
Remove adapter (1).
Invacare ® - Bora/Spectra XTR
7.20
SERVICE MANUAL
Backrest Modulite
7.20.1 Replacing the standard backrest
Requirements:
· 5 mm Allen key
Dismantling the backrest unit:
·
Remove the backrest cushion.
·
Loosen the fixation lever (2) of the backrest tube.
·
Remove the backrest tube.
·
Use the Allen key to loosen and remove the hexagon socket head screws (3) including the
nuts and washers on the left and right side of the chair.
Refitting the backrest unit:
·
Replace the parts in the reverse order.
·
To conclude, you should always carry out a trial run to test the vehicle functions.
107
SERVICE MANUAL
Invacare ® - Bora/Spectra XTR
7.20.2 Replacing the backrest mounting bracket
Requirements:
· 5 mm Allen key
Dismantling the backrest unit:
·
Remove the backrest cushion.
·
Loosen the fixation levers (2) of the corresponding backrest tube (1), depending on the
version.
There are two versions:
(2) - for the manual backrest
(3) - for the electrically adjustable backrest
·
Remove the backrest tube.
·
Loosen and remove the two hexagon socket head screws (4) to the sliding block (5) on the left
and right side of the chair..
Refitting the backrest unit:
108
·
Replace the parts in the reverse order.
·
To conclude, you should always carry out a trial run to test the vehicle functions.
Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
7.20.3 Replacing the backrest mounting bracket for SB 53
Requirements:
· 5 mm Allen key
Dismantling the backrest unit:
·
Remove the backrest cushion.
·
Loosen the fixation levers (2) of the corresponding backrest tube (1), depending on the
version.
There are two versions:
(2) - for the manual backrest
(3) - for the electrically adjustable backrest
·
Remove the backrest tube.
·
Loosen and remove the two hexagon socket head screws (4) to the sliding block (5) on the left
and right side of the chair.
Refitting the backrest unit:
·
Replace the parts in the reverse order.
·
To conclude, you should always carry out a trial run to test the vehicle functions.
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SERVICE MANUAL
7.21
Invacare ® - Bora/Spectra XTR
Adjusting the seat width/ backrest width (Modulite)
7.21.1 Adjusting the seat width
You can only adjust the seat width for the adjustable seat plate or for the adjustable sling seat.
The sling seat is available in two widths:
- for a seat width of 38-43 cm and
- for a seat width of 48-53 cm.
When modifying the seat width, the backrest width must also be correspondingly adapted. See
chapter 7.21.2.
Requirements:
· 1x Allen key 3 mm
· 1x Allen key 5 mm
· 1x Open-ended spanner 13 mm
· Remove the backrest cushion.
· Remove the backrest from the backrest
mounting bracket.
See chapter 7.20.
· Loosen and remove the screws on both sides,
which secure the lateral seat plates (A).
· Remove the lateral seat plates (B).
· Loosen and remove the screws, which secure
the middle seat plate (C).
· Remove the middle seat plate (D).
or
· Remove the seat cushion.
· Loosen and remove the screws on both sides,
which secure the sling seat (A).
· Remove the sling seat (B).
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Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
· Loosen and remove the screws of the seat
frame adjustment (A).
· Loosen and remove the screws of the
fixation of the legrest mounting brackets
(B).
· Adjust the seat frame and the legrest fixation to the desired width according to the following
illustrations and tables:
Seat frame:
Screw position
Seat width
A
530 mm
B
480 mm
C
430 mm
D
380 mm
Leg supports connection:
Screw position
Seat width
A
380 mm
B
430 mm
C
480 mm
D
530 mm
Note
When switching from 430 mm to
480 mm and the other way around,
the fixation of the legrests must be
replaced.
· Reposition the screws and tighten them again.
· Install the seat plate or the sling seat.
· Reposition the seat cushion.
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Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
7.21.2 Adjusting the backrest width
The backrest width is adjusted by performing the following tasks:
·
Adjust the backrest tube.
·
Adjust the backrest:
- Sling backrest, as described in chapter 7.18.2.
- Flex3 backrest, as described in chapter 7.21.3.
·
Replace the backrest cushion (these are available in various widths).
When modifying the backrest width, the seat width must also be correspondingly adapted. Please
see chapter 7.21.1.
Requirements:
· 1x Allen key 3 mm
· 1x Allen key 5 mm
· 1x Open-ended spanner 13 mm
The screw position for the backrest width, refer to the table:
112
Screw position
Seat width
A
530 mm
B
480 mm
C
430 mm
D
380 mm
Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
·
Remove the backrest cushion.
·
Loosen the straps of the sling backrest or remove the Flex3 backrest.
·
Loosen and remove both screws (5) of the actuator fixation bracket.
·
Remove the cover of the actuator fixation bracket.
·
Loosen and remove the screws and nuts (2, 4) on the upper and lower actuator fixation
bracket on both sides.
·
Adjust the backrest fixation (6) for the new backrest width according to the table on page 112.
·
Insert the screws (2) through the cover of the actuator fixation bracket and the corresponding
holes of the backrest fixation to the actuator fixation.
·
Fasten these with the nuts (4).
·
Reposition the cover of the actuator fixation bracket.
·
Insert and tighten the screws (5) again.
·
Adjust the straps of the sling backrest to the new width or install the adjusted Flex 3 backrest.
·
Install the backrest cushion.
·
Perform a function check of the chair.
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SERVICE MANUAL
Invacare ® - Bora/Spectra XTR
7.21.3 Adjusting the Flex3 backrest
Requirements:
· Phillips screwdriver
· 5 mm Allen key
114
·
Remove the front lateral plates (2 and 4) from the backrest (1) by loosening and removing the
five hexagon socket head screws (3).
·
Remove both Phillips screws (A) on the middle plate.
·
Shift the position of the rear plate halves (three settings are possible using the drill holes).
- Before pulling the Flex3 backrest apart, a "1" will be visible in the
small, rectangular cut-out.
- After pulling the Flex3 backrest apart, a "2" will be visible in the
small, rectangular cut-out.
·
Re-insert the two screws (A) into the middle plate.
·
Fasten the front lateral plates (2 and 4) again.
Invacare ® - Bora/Spectra XTR
8
Installing accessories
8.1
Replacing the holding strap
8.1.1
Standard seat & Flex2
SERVICE MANUAL
Requirements:
· open-ended spanner, 13 mm
· 5 mm Allen key
Note
A nut is fixed between the two washers (2) and (4) as a spacer so that the belt mounting can
rotate freely.
·
Remove the plastic cap (5).
·
Loosen the bolt (3) and the associated nut (in
the figure this is covered by the plastic cap)
with a 5 mm Allen key and a 13 mm socket
spanner.
·
Remove the nut.
·
Remove the bolt including safety belt and flat
washers (2) and (4).
·
Remove the flat washers (4).
·
Replace the safety belt (1).
·
Refit the parts in the reverse order.
115
SERVICE MANUAL
8.1.2
Fixed seat unit
Requirements:
· open-ended spanner, 13 mm
· 13 mm jaw spanner
116
·
Loosen the bolt (1) with a 13 mm socket
spanner. Hold the nut using a 13 mm jaw
spanner to prevent rotation (not visible in
figure).
·
Remove the bolt together with the flat washer
(3), the safety belt (4) and the spacer (2).
·
Replace the safety belt (1).
·
Refit the parts in the reverse order.
Invacare ® - Bora/Spectra XTR
Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
8.2
Replacing seat belts (Modulite seat)
8.2.1
Installation on the backrest mounting bracket (simple backrest)
Requirements:
· Socket spanner,13 mm
· 5 mm Allen key
·
The seat belts are attached via the drill hole (1) at the top right.
·
The installation of seat belts is described in chapter 8.1.1.
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SERVICE MANUAL
8.2.2
Invacare ® - Bora/Spectra XTR
Installation on the backrest mounting bracket (adjustable seat)
Requirements:
· 8 mm Allen key
118
·
Loosen the screw (1) with an 8 mm Allen key.
·
Remove the screw (1), the corresponding washer (2) and the seat belt and belt winder (3) from
the backrest mounting bracket (4).
·
Replace the safety belt.
·
Refit the parts in the reverse order.
Invacare ® - Bora/Spectra XTR
8.2.3
SERVICE MANUAL
Installation on the seat frame profile (adjustable seat)
Requirements:
· 8 mm Allen key
·
Loosen the screw (1) with an 8 mm Allen key.
·
Remove the screw (1), the washer (2), the seat belt, the sliding bushing (3) and the sliding
block (4) from the seat frame profile (5).
·
Replace the safety belt.
·
Refit the parts in the reverse order.
119
SERVICE MANUAL
8.3
Invacare ® - Bora/Spectra XTR
Luggage carrier
Requirements:
· 5 mm Allen wrench
· 10 mm open-ended wrench
120
·
Loosen and remove both hexagon socket head screws (4) together with the washer. The
screws are located on the wheelchair.
·
Install the luggage carrier fixation bracket (3).
·
Install both hexagon socket head screws (4) together with the washers, spacer sleeve, etc.
·
Repeat these work steps on the other side of the wheelchair.
·
Open the clamping levers (5) of the luggage carrier fixation bracket.
·
Push the brackets onto the luggage carrier (1).
·
Install the luggage carrier with the brackets. When tightening the screws (2), make sure that the
luggage carrier is correctly centered.
·
Close both of the clamping levers.
·
Make sure that the luggage carrier does not collide with the backrest or seat when adjusting the
backrest angle or seat tilt to any setting.
·
If collisions can occur:
- Open the clamping levers of the luggage carrier fixation bracket.
- Push the luggage carrier slightly towards the rear.
- Close the clamping levers of the luggage carrier fixation bracket.
Invacare ® - Bora/Spectra XTR
8.4
SERVICE MANUAL
Further accessories
Note
The installation instructions for additional accessories are available at your Invacare® specialist
supplier or directly from Invacare®.
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SERVICE MANUAL
9
Invacare ® - Bora/Spectra XTR
Adjusting the seating position
In order to adapt the mobility device optimally to the requirements of the user, we recommend that
you ask your authorised Invacare® the dealer toadjust the seat depth individually.
Adapting the seat to the user's seating position depends on which seat has been fitted, and should
be carried out in the following sequence.
1.
2.
3.
4.
5.
Adjusting the lower leg length and seat depth, see chapter 9.1.
Adjusting the center of gravity of the seat frame, see chapter 9.2.
Checking that the swivel castors can move freely.
Check that the wheelchair is stable and will not tip over, see chapter 9.3.
Repetition of steps 2 to 4, if necessary.
WARNING!
Danger of injury hazard after tilting of mobility caused by blocked steering wheels.
· Always check the seat depth settings for both forward and reverse movement.Make sure that
steering wheels can rotate freely and have not contact to any fixed mobility device
component.
CAUTION: Danger of tipping over!
Any change in the seating position can negatively influence the stability of the electric
wheelchair.
· Always make sure that the wheelchair is stable and will not tip over, after adjusting the seating
position.
WARNING!
Any changes to the drive program can affect the driving characteristics and the tipping
stability of the vehicle!
· Changes to the drive program may only be carried out by trained Invacare® specialist dealers!
· Invacare® supplies all mobility devices with a standard drive program ex-works. Invacare®
can only give a warranty for safe vehicle driving behaviour - especially the tipping stability - for
this standard drive program!
WARNING: Danger of crushing!
The seat is very heavy. Danger of injury to hands and feet.
· Pay attention to the hand and feet
· Use proper lifting techniques
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Invacare ® - Bora/Spectra XTR
9.1
Adjusting the lower leg length and seat depth
9.1.1
Adjusting the lower leg length
SERVICE MANUAL
Invacare® offers a range of legrests which can be adjusted individually.
See operation manual.
9.1.2
Adjusting the seat depth
A: Seat depth
B: Center of gravity of the seat/ seat position
Standard seat
The Seat depth is adjusted by moving the seat back.
The backrest holders (see Section 7.18) can be mounted in 3 different positions on the seat plate
(see Section 9.2.1).
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SERVICE MANUAL
Invacare ® - Bora/Spectra XTR
Flex2 seat
The Flex2 seat is fixed directly to the base frame.
·
Rear drillholes (1)
·
Front drillholes (2)
To adjust the seat depth, proceed as follows:
·
Loosen screws (3)
·
Push the front seat section forwards or
backwards
·
Retighten the screws (3)
Modulite seat
The seat depth is adjusted by shifting the position of the backrest.
See User Manual.
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Invacare ® - Bora/Spectra XTR
9.2
SERVICE MANUAL
Adjusting the center of gravity of the seat
The center of gravity of the seat can be adjusted by mounting the seat frame farther towards the
front or the rear on the seat.
CAUTION!
The seating system of the electric wheelchair is delivered ex works with an optimally
adjusted center of gravity. Any change in this adjustment setting can negatively influence
the stability of the electric wheelchair.
· You must perform an individual risk analysis every time you change the center of gravity of
the seating position, in order to ensure the safety and stability of the electric wheelchair.
A: Seat depth
B: Center of gravity of the seat/ seat position
125
SERVICE MANUAL
Invacare ® - Bora/Spectra XTR
Note
The user weight and seat depth have strong influences on the choice of the Center of gravity of
the seat. If the user is heavy and the seat depth is greater, the focus should be the farther back.
For best possible driving characteristics of rear-wheel drive wheelchairs, the weight to be
distributed: 30 – 40 % front and 60 - 70 % rear.
WARNING!
Danger of damage due to collisions of the legrests with other parts of the wheelchair!
· Set the legrests to the smallest angle before adjusting the seat center of gravity.
· Pay attention with adjusting the seat center of gravity that the legrests do not touch any other
parts of the wheelchair. This ensures that the legrests can not collide with other parts of the
wheelchair.
126
Invacare ® - Bora/Spectra XTR
9.2.1
SERVICE MANUAL
Standard seat
Requirements:
· 4 mm Allen wrench
· 5 mm Allen wrench
· 13 mm open-ended wrench
· Flat screwdriver
· Smal hammer
WARNING: Danger of crushing!
The seat is very heavy. Danger of injury to hands and feet!
· Pay attention to the hand and feet.
· Use proper lifting techniques.
The pictures show the standard seat without
seat covering from above (A) and below (B).
·
Rear bolts (1)
·
Front bolts (2)
·
Seat plate (3)
·
Seat frame (4)
The seat plate can be fixed in three different
positions on the seat frame.
·
Front fixing (V)
·
Centre fixing (M)
·
Rear fixing (H)
127
SERVICE MANUAL
The picture shows where the drillholes for fixing
the seat frame (3) are located on the base frame.
·
Rear drillholes (1)
·
Front bolts (2)
The seat frame can only be fixed in one position
on the base frame.
The picture shows the seat frame with the
drillholes for the standard seat.
128
·
Rear drillholes (1)
·
Front drillholes (2)
Invacare ® - Bora/Spectra XTR
Invacare ® - Bora/Spectra XTR
9.2.2
SERVICE MANUAL
Flex2 seat
Requirements:
· 4 mm Allen wrench
· 5 mm Allen wrench
· 13 mm open-ended wrench
· Flat screwdriver
· Smal hammer
WARNING: Danger of crushing!
The seat is very heavy. Danger of injury to hands and feet!
· Pay attention to the hand and feet.
· Use proper lifting techniques.
The illustration shows the Flex2 seat from above
without seat covering.
·
Loosen the fixation screws at the
appropriate positions (2).
·
Slide the Flex2 seat forward or rearward
until the fixation screws can be inserted into
the corresponding variation holes:
1 – Rear
2 – Middle
3 – Front
·
Replace the fixation screws and tighten.
·
Re-install all seat components.
·
Check all functions during a test-drive.
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SERVICE MANUAL
9.2.3
Invacare ® - Bora/Spectra XTR
Modulite seat
The Modulite seat is available in two versions:
· Adjustable seats (plate and strap):
Adjustment of the center of gravity via the lateral profiles, as described in chapter 9.2.3.1.
· Simple seat:
Adjustment of the center of gravity via the oblong holes of the seat adaptor, as described in
chapter 9.2.3.2.
CAUTION!
Increased danger of tipping over, if the center of gravity is shifted too far towards the rear.
There must ALWAYS be at least 80 mm clearance between the backrest and the rear axle.
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Invacare ® - Bora/Spectra XTR
SERVICE MANUAL
Note
The front edge of the seat frame profile should be located 38 to 40 mm in front of the steering
heads of the castors.
If you decrease this value, make sure that
· you decrease the seat depth by the same value and
· there are no collisions between the legrests and the castors.
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SERVICE MANUAL
9.2.3.1
Invacare ® - Bora/Spectra XTR
Adjustable seats
Requirements:
· 8 mm Allen key
· Remove the seat plate or sling seat (1), see chapter 7.21.1.
· Loosen the socket head screws (2) in the front and rear, left and right – DO NOT remove.
· Shift the position of the seat.
· Re-tighten the screws.
· Install the seat plate or the sling seat again.
132
Invacare ® - Bora/Spectra XTR
9.2.3.2
SERVICE MANUAL
Simple seat
Requirements:
· 8 mm Allen key
· Remove the seat plate (1) or the sling seat, see chapter 7.21.1.
· Loosen the socket head screws (2) in the front and rear, left and right – DO NOT remove.
· Shift the position of the seat frame.
· Re-tighten the screws.
· Install the seat plate again.
133
SERVICE MANUAL
9.3
Invacare ® - Bora/Spectra XTR
Check the tipping stability
Any change in the seating position can negatively influence the tipping stability of the electric
wheelchair. For this reason, after adjusting the seating position, you should always verify the
tipping stability of the wheelchair.
WARNING!
Any changes to the drive program can affect the driving characteristics and the tipping
stability of the vehicle!
· Changes to the drive program may only be carried out by trained Invacare® specialist
dealers!
· Invacare® supplies all mobility devices with a standard drive program ex-works. Invacare®
can only give a warranty for safe vehicle driving behaviour - especially the tipping stability for this standard drive program!
Tipping stability check
·
Set the following angle on the wheelchair:
- Backrest
30 °
- Seat tilt
max.
·
Allow the user to down in the wheelchair in a sitting position that is typical for them.
·
Drive the front wheels of the wheelchair onto a step about 100 mm high.
This can be done using a ramp, for example (illustration B).
·
Make sure that the front wheels are pointed backwards compared to the direction of travel.
·
Attach a reference weight of 8 kg to the push bar (illustration B).
·
Verify that the wheelchair is at most in a balanced or "floating" condition in this position.
This means that the front wheels can slightly lose contact with the ground, but the chair must
not tip back onto its anti-tipper wheels.
If the wheelchair does not fall back onto its anti-tipper wheels, then the tipping stability is OK.
If the wheelchair falls back onto its anti-tipper wheels, then you must either:
shift the center of gravity far enough forward that the chair does not fall onto the anti-tipper
wheels or
install the adaptor again.
You must repeat the steps described above after each modification to verify the tipping stability.
134
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