Handicare 20 User manual

SERVICE MANUAL
PUMA 20/40

Puma 20/402 |
© 2011 Handicare
All rights reserved.
The information provided herein may not be reproduced and/or published in any form, by print, photo print, microfilm or any other
means whatsoever (electronically or mechanically) without the prior written authorisation of Handicare.
The information provided is based on general data concerning the constructions known at the time of the publication of this
manual. Handicare executes a policy of continuous improvement and reserves the right to changes and modifications.
The information provided is valid for the product in its standard version. Handicare cannot be held liable for possible damage
resulting from specifications of the product deviating from the standard configuration.
The available information has been prepared with all possible diligence, but Handicare cannot be held liable for possible errors in
the information or the consequences thereof.
Handicare accepts no liability for loss resulting from work executed by third parties.
Names, trade names, etc. used by Handicare may not, as per the legislation concerning the protection of trade names, be
considered as being available.

| 3Puma 20/40
1 Introduction Service manual Puma 20/40 ............................................................................................................5
1.1 This manual 5
1.2 Identification of the product 5
1.3 Symbols used in this manual 6
2 Safety...................................................................................................................................................................7
2.1 Maximum User weight reduction when Puma 20 options are installed on a Puma 40! 7
2.2 Personnel qualification 7
2.3 Cautions and warning statements 7
2.4 Used decals on the wheelchair 8
3 Tools, parts and components ...............................................................................................................................9
3.1 Tools 9
3.2 Tools electronics 9
4 Spare parts.........................................................................................................................................................10
4.1 Use of the parts lists 10
4.2 Carrier and seat adjustments 11
4.3 Wiring and modules Shark 22
4.4 Wiring and modules R-net 24
4.5 Wiring and modules DX2 26
4.6 Wiring and modules VR-2 28
5 Service instructions............................................................................................................................................30
5.1 Maintenance plan 30
5.2 Assembly, replacement and adjustment instructions 31
5.2.1 Puma 20 / Puma 40 Carrier 32
5.2.2 Driving wheels (Puma 20/40) 47
5.2.3 Castor wheels 54
5.2.4 Replacements 61
5.2.5 Seat adjustments 72
6 Trouble shooting.................................................................................................................................................83
6.1 Shark faultfinding table 83
6.2 R-net faultfinding table 84
6.3 DX2 faultfinding table 88
6.4 VR-2 faultfinding table 92
7 Technical product information.............................................................................................................................95
7.1 CE Declaration and standards 95
7.2 Technical information 95
7.3 Electrical diagram 97
8 Warranty...........................................................................................................................................................105
8.1 Provisions of warranty 105
8.2 Liability provisions 106

Puma 20/404 |

Introduction Service manual Puma 20/40 | 5Puma 20/40
1 Introduction Service manual Puma 20/40
1.1 This manual
This manual contains the instructions for repairs and general maintenance of the Puma 20/40 motor driven wheelchair.
Mechanics who do repairs on this wheelchair must be well trained and familiar with the repair methods and the maintenance of
the Puma 20/40 wheelchair.
Always make sure that the work is carried out safely, particularly with respect to procedures requiring the wheelchair to be lifted
up.
We advise that you contact our service department before doing repair work on a wheelchair that has been involved in an
accident.
The following specifications are important when ordering parts:
• Model
• Year of manufacture
• Colour
• Identification number
• Part number
• Name of the part concerned
This information is provided on the identification plate. See 'Identification of the product'.
Available documentation
The following technical documentation is available for this wheelchair:
• User manual
• Service manual
Service and technical support
For information concerning specific settings, maintenance or repair works please contact your supplier. He is always prepared to
help you.
Ensure you have at hand:
• Model
• Year of manufacture
• Identification number
This information is provided on the identification plate. See 'Identification of the product'.
1.2 Identification of the product
The identification plate contains the following data:
A. Model
B. Year of manufacture
C. Identification number
D. Use area indoors or outdoors
E. Maximum load in kg

Puma 20/406 | Introduction Service manual Puma 20/40
1.3 Symbols used in this manual
Warning symbol
Follow the instructions next to this symbol closely.
Not paying careful attention to these instructions could result in physical injury or damage to the wheelchair or the
environment.
ATTENTION! Suggestions and advice that help tasks or procedures involved to be carried out more easily.
Reference symbol
The symbol refers to a separate user manual. This reference will indicate the specific user manual and the section
to which is being referred.
Pull the charge cord out of the battery charging connection of the electric wheelchair before carrying out any maintenance on the
wheelchair.

Safety | 7Puma 20/40
2 Safety
2.1 Maximum User weight reduction when Puma 20 options are installed on a Puma 40!
In case one of the following Puma 20 options is installed on a Puma 40 carrier, the maximum user weight is reduced to 136 kg:
• Sedeo Lite Seating System (or any Sedeo Lite component)
• Puma 20 motors
• Puma 20 Comfort suspension
• Puma 20 Electrical tilt adjustment (0 - 25º)
2.2 Personnel qualification
Service technicians:
Repairs may only be carried out by trained and authorised service technicians.
During the execution of their work, they are at all times fully responsible for the fulfilment of locally applicable safety guidelines
and standards.
Temporary employees and persons in training may only carry out repair and replacement work under the supervision of an
authorised service technician.
2.3 Cautions and warning statements
Safety
Safety information is indicated with the warning symbol.
• Follow the instructions carefully next to these warning symbols! Not paying careful attention to these instructions could result
in physical injury or damage to the wheelchair or the environment. Where ever possible, safety information is provided in the
relevant chapter.
Temperature
• Avoid physical contact with the wheelchair’s motors at all times. Motors are continuously in motion during use and can reach
high temperatures. After use, the motors will cool down slowly. Physical contact could cause burns.
• If you do not use the wheelchair, ensure that it is not exposed to direct sunlight for lengthy periods of time. Certain parts of the
wheelchair, such as the seat, the back and the armrests can become hot if they have been exposed to full sunlight for too long.
This may cause burns or allergic reactions to the skin.
Interference between carrier and tilt module at the lowest seat height
Optimizing the different functions in the wheelchair can lead to interference between certain parts. In this case the 45 deg tilt in
combination with the lowest seat height can limit the possible degree of tilt. This depends on the Centre of Gravity position of the
seating system and the seat depth.
The bigger the seat depth and/or the centre of gravity position going to the rear, the bigger the limit of the tilt angle.
We do not expect this to be a problem since people seated in the chair with the lowest seat height, have a small under leg length
and are therefore smaller people in general. The chance that they have a bigger seat depth or a rearward centre of gravity
position is limited.
If an interference should appear then this can be solved by:
• Decreasing the seat depth
• Positioning the centre of gravity forward
• Increase the seat height
Moving parts
• A wheelchair has moving and rotating parts. Contact with moving parts may result in serious
physical injury or damage to the wheelchair. Contact with the moving parts of the wheelchair
should be avoided.
• Wheels (turning and castor)
• Electric tilt in space adjustment
• Electric high/low option
• Electric backrest adjustment
• Electric elavating legrests

8 | Safety Puma 20/40
Electromagnetic radiation
The standard version of your electric wheelchair has been tested on the applicable requirements
with respect to electromagnetic radiation (EMC requirements) In spite of these tests:
• it cannot be excluded that electromagnetic radiation may have an influence on the wheelchair. For example:
• mobile telephony
• large-scale medical apparatus
• other sources of electromagnetic radiation
• it cannot be excluded that the wheelchair may interfere with electromagnetic fields.
For example:
• shop doors
• burglar alarm systems in shops
• garage door openers
In the unlikely event that such problems do occur, we request that you notify your supplier immediately.
Decals and instructions on the wheelchair
Decals and instructions on the wheelchair
• The signs, symbols and instructions affixed to the wheelchair comprise part of the safety facilities. They must never be covered
or removed. They must remain present and clearly legible throughout the entire lifespan of the wheelchair.
• Replace or repair all illegible or damaged signs, symbols and instructions immediately. Please contact your supplier for
assistance.
2.4 Used decals on the wheelchair
Check manual before using
Freewheel switch in ‘Drive’ mode
Freewheel switch in ‘Push’ mode.
Don’t put the freewheel switch in ‘Push’ mode on a slope
Battery charging connection
Attachment point of the tie-down system for transportation in a vehicle.
Danger of crushing!
Use caution when swinging the controller aside to avoid getting anything crushed.
Trap danger. Danger of getting fingers jammed.

Tools, parts and components | 9Puma 20/40
3 Tools, parts and components
3.1 Tools
The tools below are needed for various mechanical settings and maintenance:
Quantity Description Size (mm)
1 Screwdriver, medium 5
1 Hammer (plastic) -
1 Chaser -
1 Pair of wire cutters -
1 Circlip pliers -
1 Water pump pliers -
2 Open ended spanner 10, 13
2 Ring spanner 10, 13
1 Torque wrench, socket 10, 13
1 Torx key T30
1 Allen key 4, 6, 8
1 Loctite 243 -
# Tie wraps
Remark Size: the EU key width (of the relevant tool).
Use only high-quality tools for the adjustment(s) described.
Make sure that the hexagon of the spanner is attached securely to the hexagon of the fastening article. This prevents the 'rotation'
of hexagons of fastening articles and spanners that may affect proper adjustment.
3.2 Tools electronics
The following tools are needed for various electronic settings:
Article
numbers Description
DX2 DX Shark Rnet Pilot+ VR-2 PC Hand
Brand
1001893 Shark Programming adaptor (DK-ADAPT) X X Dynamic
00355.0440 Hand Held Programmer (DX-HHP-GDW) X X X X Dynamic
1009567 Programming adaptor for DX2, Shark, A-series and R-series
(DWIZ-ADAPT) X X X* X X Dynamic
00355.0469 Wizard programming cable (GSM61171) X X X X Dynamic
1003236 Dynamic Wizard USB set (DWIZ-KIT + DWD-OEM-U) X X X X Dynamic
9006857 R-net Diagnostic Test Tool (D50996) X X PGDrivesTechnology
9006858 R-net Programming cable for R-net DTT (SA79174) X X PGDrivesTechnology
PR0111 Pilot+ Hand Held Programmer PP1B (D49511) X X X PGDrivesTechnology
9006859 VR-2 Programming cable for R-net DTT (SA79176) X X PGDrivesTechnology
PR0200 Pilot+ PC Programmer A(D50144) X X X PGDrivesTechnology
PR0210 PG Pilot+ PC Programmer B (D50145) X X X PGDrivesTechnology
9003295 R-net PC Programmer OEM (D50611) X X PGDrivesTechnology
9003296 R-net PC programmer Dongle OEM X X PGDrivesTechnology
X* = except the Hand Help Programmer

10 | Spare parts Puma 20/40
4 Spare parts
4.1 Use of the parts lists
This document is meant as a reference book to be used to order parts for the wheelchair that is shown on the front cover.
How to order:
When ordering parts, please specify:
• Serial number (see the identification plate)
• Group (to which the relevant part belongs)
• Article number
• Number of parts required
• Description (in the relevant language)
• Dimensions (if applicable)
Remark:
• If a part does not have a position number, it means that the part concerned cannot be purchased separately. The part concerned is
part of the assembly shown. This assembly must be ordered as one piece. It has to be replaced in its entirety.
• Boxed position numbers refer to the relevant drawing.
Order address:
Please mail or fax your orders to your supplier.
Service technicians:
Repairs may only be carried out by trained and authorised service technicians.
During the execution of their work they are at all times fully responsible for the fulfilment of locally applicable safety guidelines and
standards.
Temporary employees and persons in training may only carry out repair and replacement work under the supervision of an authorised
service technician.

Puma 20/40 Spare parts | 11
4.2 Carrier and seat adjustments
01 Battery tray and chair interface Puma 20/40 5
02 Suspension arm and motors Puma 20 6
03 Suspension arm and motors Puma 40 7
04 Castor forks and wheels Puma 20 8
05 Castor forks and wheels Puma 40 9
06 Covers Puma 20 10
07 Covers Puma 40 11
08 Tilt and lift modules Puma 20 12
09 Tilt and lift modules Puma 40 13
10 Kerb climber Puma 20/40 14
Pos Description Page

Pos Qty Article number Description
12 | Spare parts Puma 20/40
01 Carrier and seat adjustments / Battery tray and suspension and chair interface Puma 20/40
1-3 1 9005935 Chair Interface set
4,5a 2 9002758 Battery MK M40-12 Gel (40Ah C20)
4,5b 2 9006051 Battery MK M50 AGM (50Ah C20)
4,5c 2 9002759 Battery MK M34-12 Gel (60Ah C20)
4,5d 2 1001453 Battery MK M24-12 Gel (74Ah C20)
6a,6b,6c,6d,7 4 9005956 Battery spacer set universal
6a,6b,7 4 9005957 Battery spacer set MK (40/50A)
6c,6d,7 4 9005958 Battery spacer set MK (60/74A)
6,7* 1 9005959 Battery spacer set Sonnenschein
*= spacers needed if equiped with Sonnenschein Batteries (not a standard
Handicare item)
8,9 1 9005931 Battery straps
8-13 1 9005930 Battery box
14a 2 1007080 Socket head screw DX2
14b 2 9006237 Socket head screw Shark
14c 2 00000.4042 Socket head screw R-net 120
14d 2 00000.4035 Socket head screw R-net 90 / VR2

Pos Qty Article number Description
Puma 20/40 Spare parts | 13
02 Carrier and seat adjustments / Suspension arm and motors Puma 20
1-9 2 9005963 Anti-Tip complete FWD
1,3,4,6 2 9002896 Anti tipper wiel FWD
10-18 2 9005962 Anti-Tip complete RWD
10,12,13,15 2 9002897 Anti tipper wiel RWD
19-23 1 9005964 Rubber suspension set
24a,25-29 1 9005939 Motor bracket right
24b-29 1 9005938 Motor bracket left
28-33a,37,38 1 9005940 Motor right 6 Km/h DX
28-32,33b,37,38 1 9005941 Motor left 6 Km/h DX
28-32,34a,37,38 1 9005942 Motor right 6 Km/h PG
28-32,34b,37,38 1 9005943 Motor left 6 Km/h PG
28-32,35a,37,38 1 9005944 Motor right 10 Km/h DX
28-32,35b,37,38 1 9005945 Motor left 10 Km/h DX
28-32,36a,37,38 1 9005946 Motor right 10 Km/h PG
28-32,36b,37,38 1 9005947 Motor left 10 Km/h PG
30-31 2 9005644 Freewheel lever
32 2 9002784 Brake Release Sticker
37 2 9006360 2 set Puma 20 Motor Brushes 4pc service
38 2 9006452 Puma 20 Motor Brake Cover service

Pos Qty Article number Description
14 | Spare parts Puma 20/40
03 Carrier and seat adjustments / Suspension arm and motors Puma 40
1-12 1 9005965 Rubber suspension + bridge
8-12 1 9005966 Rubber suspension set
13-21 2 9005963 Anti-tip complete FWD
13,15,16,18 2 9002896 Anti tipper wiel FWD
22-30 2 9005962 Anti-tip complete RWD
22,24,25,27 2 9002897 Anti tipper wiel RWD
31a,32-36 1 9005939 Motor bracket right
31b-36 1 9005938 Motor bracket left
31c 1 9006782 Motor bracket 4 pole Alpine, right
31d 1 9006781 Motor bracket 4 pole Alpine, left
35-40a, 44a 1 9005949 Motor 6 Km/h DX, right
35-39,40b, 44a 1 9005948 Motor 6 Km/h DX, left
35-39, 40c, 44b 1 9006783 Motor 4-pole Alpine 6 Km/h DX, left
35-39, 40d, 44b 1 9006784 Motor 4-pole Alpine 6 Km/h DX, right
35-39,41a, 44a 1 9005951 Motor 6 Km/h PG, right
35-39,41b, 44a 1 9005950 Motor 6 Km/h PG, left
35-39, 41c, 44b 1 9006785 Motor 4-pole Alpine 6 km/h PG, left
35-39, 41d, 44b 1 9006786 Motor 4-pole Alpine 6 km/h PG, right
35-39,42a, 44a 1 9005952 Motor 10 Km/h DX, right
35-39,42b, 44a 1 9005953 Motor 10 Km/h DX, left
35-39, 42c, 44b 1 9006787 Motor 4-pole Alpine 10 km/h DX, left
35-39, 42d, 44b 1 9006788 Motor 4-pole Alpine 10 km/h DX, right
35-39,43a, 44a 1 9005954 Motor 10 Km/h PG, right
35-39,43b, 44a 1 9005955 Motor 10 Km/h PG, left
35-39, 43c, 44b 1 9006789 Motor 4-pole Alpine 10 km/h PG, left
35-39, 43d, 44b 1 9006790 Motor 4-pole Alpine 10 km/h PG, right
37-38 2 9005644 Freewheel lever
39 2 9002784 Brake Release Sticker
44a 2 9006361 2 set P40 motor brushes service
44b 2 9005107 4 set HT motor brushes service

Pos Qty Article number Description
Puma 20/40 Spare parts | 15
04 Carrier and seat adjustments / Castor forks and wheels Puma 20
1-6 2 9005934 Anti shimmy + bearings set
7-10 2 9005932 Castor fork
8-12a 2 9005986 Castor wheel indoor 2.80/2.50-4, air
8-11,12b 2 9005989 Castor wheel indoor 2.80/2.50-4, punctureproof
8-11,12c 2 9005987 Castor wheel outdoor right 3.00-4, grey air
8-11,12d 2 9006820 Castor wheel outdoor left 3.00-4, grey air
8-11,12e 2 9005990 Castor wheel outdoor 3.00-4, grey punctureproof
13, 14, 15, 16a 2 9005992 Drive wheel Indoor 12 1/2 x 2 1/4, air
13, 14, 15, 16b 2 9005995 Drive wheel Indoor 12 1/2 x 2 1/4, punctureproof
13, 14, 15, 16c 2 9005993 Drive wheel outdoor 3.00-8, grey air
13, 14, 15, 16d 2 9005996 Drive wheel outdoor 3.00-8, grey punctureproof

Pos Qty Article number Description
16 | Spare parts Puma 20/40
05 Carrier and seat adjustments / Castor forks and wheels Puma 40
1-6 2 9005934 Anti shimmy + bearings set
7-10 2 9005932 Castor fork
8-11 2 9005998 Castor wheel Indoor 2.80/2.50-4, air
8-10,12 2 9006003 Castor wheel indoor 2.80/2.50-4, punctureproof
8-10,13a 2 9006000 Castor wheel outdoor right 3.00-4, grey air
8-10,13b 2 9005999 Castor wheel outdoor left 3.00-4, grey air
8-10,14a 2 9006005 Castor wheel outdoor right 3.00-4, grey punctureproof
8-10,14b 2 9006004 Castor wheel outdoor left 3.00-4, grey punctureproof
8-10,15a 2 9006002 Castor wheel outdoor 3.00-4, right black air
8-10,15b 2 9006001 Castor wheel outdoor 3.00-4, left black air
8-10,16a 2 9006007 Castor wheel outdoor 3.00-4, right black punctureproof
8-10,16b 2 9006006 Castor wheel outdoor 3.00-4, left black punctureproof
17-22 2 9006009 Drive wheel indoor 12 1/2 x 2 1/4, air
17-21,23 2 9006012 Drive wheel indoor 12 1/2 x 2 1/4, punctureproof
17-21,24 2 9006010 Drive wheel outdoor 3.00-8, grey air
17-21,25 2 9006013 Drive wheel outdoor 3.00-8, grey punctureproof
17-21,26 2 9006011 Drive wheel outdoor 3.00-8, black air
17-21,27 2 9006014 Drive wheel outdoor 3.00-8, black punctureproof

Pos Qty Article number Description
Puma 20/40 Spare parts | 17
06 Carrier and seat adjustments / Covers Puma 20
1-4 1 9005971 Battery cover black
3-4 1 9005972 Battery cover clips set
5 1 9004517 Battery access cover
6-7 1 9005973 Tube end covers dark grey set
8 1 9005970 Handicare logo Service
9-10 1 9005981 Ballhead covers dark grey set
11-12 1 9005969 Tube bottom cover set
13 1 9004515 Power module cover

Pos Qty Article number Description
18 | Spare parts Puma 20/40
07 Carrier and seat adjustments / Covers Puma 40
1-4 1 9005971 Battery cover black
3-4 1 9005972 Battery cover clips set
5 1 9005970 Logo Handicare
6,7 1 9005974 Suspension bridge cover dark grey
8a,16a,18a,19a 1 9005982 Deco covers green
8b,16b,18b,19b 1 9005983 Deco covers blue
8c,16c,18c,19c 1 9005984 Deco covers orange
8d,16d,18d,19d 1 9005985 Deco covers silver
9 1 9004517 Battery access cover
10,13 2 9005978 Drive wheel fender black with bracket
14,15a,15b 1 9005975 Motor arm covers dark grey set
17,20 1 9005969 Tube bottom cover set
21-22 2 9005976 Castor wheel fender black
23 1 9004515 Power module cover

Pos Qty Article number Description
Puma 20/40 Spare parts | 19
08 Carrier and seat adjustments / Tilt modules Puma 20
1-7 1 9006017 Electrical tilt 25º
4-6 1 9006025 Til actuator mounting set
4-7 1 9006199 Tilt actuator
8-14 1 9006018 Electrical tilt 25º Add-on
15-17 1 9006016 Mechanical tilt

Pos Qty Article number Description
20 | Spare parts Puma 20/40
09 Carrier and seat adjustments / Tilt and lift modules Puma 40
1-3, 4-7, 8-11 1 9006020 Electrical lift with electrical tilt 45º
4-6 1 9006025 Til actuator mounting set
4-7 1 9006023 Tilt actuator
8-10 1 9006024 Lift actuator mounting set
8-11 1 9006022 Lift actuator
12-18, 4-7 1 9006019 Electrical lift with fixed tilt
19-25, 8-11 1 9006021 Electrical tilt 45º