Huka Skwirrel II User manual

1
service manual
Skwirrel II
06-2009

2
introduction
Welcome to the first edition of the service manual for Skwirrel II. This manual is meant to be a guideline for
repairing and servicing the wheelchair in the most efficient way. Good preventive maintenance and fast
service provides optimal mobility for our wheelchair users. As Huka we think this is the key factor for happy
wheelchair drivers. They should rely on our products and enjoy the freedom these products can give.
Remember we are providing not a wheelchair, we are providing mobility and freedom of movement.
You as a local supplier are playing a very important role in this process. If the service is good, the customer
will be happy with the product and of course their supplier. If the user has to wait long for repair, this will
damage our product, but also your reputation as a local supplier.
Our common goal is to make sure the wheelchair is and stays in perfect condition. Should there be a
problem (which will always happen) the quality of the mobility provided by us and you is related to the
response of the local supplier. If the supplier can fix the problem is a fast and proper way, it will have great
positive influence on the user.
In this manual we try to explain step by step how to replace parts of the wheelchair. When it comes to
adjusting after installing, this will also be mentioned and explained. We try to support you with as much
information as possible. However, should you find passages which are not clear to you or information
missing about certain issues, please do not hesitate to inform us. Only this way we can make this manual
even better.
you can reach us at: e.vanol[email protected]

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Index
chapter
page
1
taking the covers off.
4
1.1
taking the top cover off
4
1.2
taking the side panel covers off
5
2
2.1
placing or replacing the batteries
6
2.2
replacing the main fuse
9
3
replacing the wheels and tyres
10
3.1
replacing the front tyres
10
3.2
replacing the rear tyres
14
4
re-adjusting the parking brake
17
5
Adjusting the front suspension
19
6
replacing electronic components
20
6.1
replacing the side steering joystick module
20
6.2
replacing the desktop steering joystick module
21
6.3
replacing the ISM module
22
6.4
replacing the PM module
23
7
replacing cables
24
7.1
replacing the cable from joystick to the ISM
24
7.2
replacing the cable from the ISM to the PM
28
7.3
replacing the lighting cable of the chassis
29
8
replacing the drive motors
30
9
replacing the actuators
35
9.1
replacing the seat lift up actuator
35
9.2
replacing the seat lift down actuator
37
9.3
replacing the seat tilt actuator
39
9.4
replacing the seat tilt switch
42
10
Lights and indicators
44
10.1
replacing the head light bulb
44
10.2
replacing the indicator bulb
45
10.3
replacing the rear light bulb
45
11
The electronic system
47
11.1
the joystick module
47
11.2
the intelligent seating module
47
11.3
the power module
48
12
safety inhibits of the wheelchair
49
12.1
inhibits input
49
12.2
Skwirrel II inhibits
50
13
system errors
51
14
programming
52
14.1
setting up the programming
52
14.2
programming the driving profiles
53
14.3
setting the speeds parameters
57
15
system tests
61
15.1
PM status
62
15.2
ISM status
63
15.3
JSM status
64
15.4
Joystick status
65
15.5
system logs
66
16
Drawings
69

4
1. Taking the covers off.
1.1 taking the top cover off
step 1.
Loosen the knob at the back end of the top cover.
step 2.
Loosen up both knobs at the front of the top cover.
step 3.
Lift up the rear end of the top cover so the thread pin comes
out of the frame tube.
step 4.
Carefully pull the front end of the top cover a little forward so
the mounting hole is clear of the pin.
step 5.
Now you can lift up the top cover and take it away from the chassis.
NOTE:
The mounting of the covers will take place in reverse order.

5
1.2taking the side covers off
step 1.
Loosen up the bolt in on the front side.
step 2.
loosen up the screw on the rear end.
step 3.
take away slowly and carefully the side cover.
NOTE:
The mounting of the covers will take place in reverse order.

6
2.1 Placing or replacing the batteries
step 1.
Put the seat in its highest position, so it is easier to reach
the batteries. Should this be not possible, leave the seat in the position.
step 2.
Take the top cover of as explained in chapter 1, page 4.
loosen the two knobs in the front and the one in the rear
and lift the top cover of the chassis.
step 3.
Disconnect the cables from the batteries.
step 4.
if the seat is still in the lowest position, connect the new and
charged batteries to the chair. Place the batteries close to
the wheelchair and connect them. Now you can put the seat
lift in its highest position.
WARNING:
Make sure you isolate the contact of the cables to
prevent short circuit errors.

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step 5.
Lift the used batteries out of their boxes using the grip
handle on the battery.
step 6.
If you lift the battery, some rubber buffers will come off.
Collect them, because they are needed to secure the new
batteries.
step 7.
now put the new battery carefully into the battery box. Make
sure no cable gets stuck between the battery and the battery
box. slowly lower the battery until it sits on the bottom of the
battery box. Make sure the connections of the battery are on
the inside of the chassis (see arrows)
step 8.
place the rubber buffers between the battery box and the
battery. Place two on each long side of the battery. This way
the batteries are secured and don’t move around whilst
driving on bumpy roads.

8
step 9.
Connect the cables back on to the battery.
The information about connecting the batteries is shown on the battery box sticker.
step 10.
Place the cover back on to the chassis and secure it with the three knobs.
WARNING:
Make sure you connect the rights poles in to the right
cables. Wrong connections lead to short circuit!

9
2.2 replacing the main fuse
step 1.
take the main covers off
step 2.
open up the fuse holder which is positioned on each of the
batteries.
step 3.
Is the fuse broken, check first if there is any damage on
the battery cables or if there has been an extreme driving
load on the system (extreme up hill driving for a long period).
step 4.
Loosen the two nuts which hold the fuse and replace the fuse.
step 5.
Test the wheelchair before putting the covers back ion to it.
WARNING:
If the main fuse is broken, it means there is a serious
short circuit or overload of the electronic system.
Check the system before replacing the main fuse.

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3. Replacing the wheels and tyres
3.1 replacing the front tyres
step 1.
First, lift the wheelchair chassis up and place a block
underneath the chassis. This way the front wheels
are lifted and free from the ground. Make sure the parking
brake is still on.
step 2.
Remove the centre bolt which holds the wheel cover.
step3.
Lift the wheel cover out of the rim by using a flat screw driver.
Lift the cover carefully so you don’t get scratches.
step 4.
loosen up the five M8 nuts. the wheel is now loose on the
motor hub.

11
step 5.
Take the wheel of the wheel hub.
step 6.
Remove the plastic bolt covers of the bolts.
step 7.
Mark the bolts on the rim. This is important when assembling
the rim again. If these bolts are mounted on to the wrong hole,
the wheel covers will not fit.
step 8.
Release the air from the tyre by pushing the valve open.

12
step 9.
Loosen the five bolts which keep the two rim parts together.
step 10.
Split the rim and remove the tyre and tube.
step 11.
Put the new tyre and tube on to the rim and bolt the rim
back together again. Do not tighten the bolts yet!
step 12.
Put the rim back on to the wheel hub. This will put all holes
in line so the wheel will fit on to the wheel hub easily. No,
tighten two of the five bolts to fixate the rim parts.
WARNING:
Make sure you put the bolts back in to the marked
holes. Otherwise the wheel cover will not fit.

13
step 13.
Tighten all five bolts now.
step 14.
Fill the tyre with air up to 2,5 Bar pressure.
step 15.
Put the plastic bolt covers on to the five bolts. These
bolt covers fixate the plastic wheel cover and prevent it from
vibrating during driving.
step 16.
Bolt the wheel now back on to the wheel hub.

14
step 17.
Place the wheel cover over the plastic bolt covers.
step 18.
Tighten the central wheel cover bolt.
3.2 replacing the rear tyres
step 1.
Lift the rear end of the wheelchair and put a support under
the rear axle so the rear wheels are free of the ground.
step 2.
Lift off the central nut cover with a flat screw driver.

15
step 3.
Loosen the M8 central wheel bolt.
step 4.
Pull the wheel of the rear axle.
step 5.
Loosen all five bolts of the rim.
step 6.
Carefully split the two rim half parts by splitting it with a flat
screw driver.

16
step 7.
Replace the tyre and tube (or the solid tyre).
step 8.
Place both rim parts back on to the tyre. Make sure you line
out the valve opening of the rim.
step 9.
Tighten the five bolts on the rim. After doing this pump up the
tyre up to 2,5 Bar pressure. If the tyre is solid you only need
to tighten the five bolts.
step 10.
Place the wheel back on to the rear axle. Before doing this,
put al little grease on to the axle to prevent it from corrosion.
Tighten the M8 nut.
WARNING:
Don’t tighten the nut to hard. If it tightened to hard the
ball bearings might get damaged. Make sure the
wheel rotates easily

17
step 11.
Put the central wheel cover bat in to the hole of the rim.
4. Re-adjusting the parking brake
brake lever switched on parking brake released
position adjustment tubes close up adjustment tube
The parking is using two Bowden cables running from each drive motor to the parking brake lever at the
rear end of the chassis. The Bowden cable hardly brakes, but it can stretch a little bit after a while. This will
result in a wheelchair which is not easy to push when in freewheel position. If the Bowden cable in to thight
it might result in a noisy drive motor. The kind of noise is a fast clicking sound and a kind of coughing noise
is coming from the drive motor. This means the parking brake has to be re-adjusted.

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step 1.
Make sure the Bowden cable is tightened well at the parking
brake lever.
step 2.
Adjust each adjustment tube separately. First loosen the
fixation nut of the adjustment tube. Turn the adjustment
tube clockwise to decrease the tension of the Bowden cable.
Turn the adjustment tube counter clockwise to increase the
tension of the Bowden cable.
step 3.
if the parking brake lever is in to release setting the wheelchair
should be easy to push. When the wheelchair is switched on,
the display of the joystick module should show a warning text
telling “M1 brake error”. If it tells “M2 brake error” it means
the left motor (M1) hasn’t been adjusted tight enough.
NOTE:
A parking brake which is adjusted without any tension doesn’t influence the driving of the wheelchair.
It only influences the free wheel mode of the wheelchair. It results in a wheelchair which is very heavy
to push in free wheel mode.

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5. Adjusting the front suspension.
The front suspension is by default adjusted to the maximum user weight of 50 kg. Should it be required to
change the setting of the suspension take notice of the following steps:
step 1.
Each spring damper unit has a nut underneath the spring.
This nut needs to be moved to change the spring load.
step 2.
softer suspension.
Use a wrench to move the nut down to reduce the tension
on the spring. Now the suspension is softer.
step 3.
stiffer suspension.
Use a wrench to move the nut up to increase the tension
on the spring. Now the suspension is stiffer.
NOTE:
Make sure both sides are adjusted equally. Check after adjusting the length of the spring on both
sides. If the length is the same, the adjustment is the same.
NOTE:
The suspension setting is a balance between grip and driving comfort. A very stiff suspension means
good mechanical grip, but very little driving comfort. To soft suspension means high driving comfort
but very little mechanical grip. This results in very poor driving handling of the wheelchair. Make sure
you always have a good balance between these two parameters.

20
6. Replacing electronic components of the wheelchair.
6.1 replacing the side steering joystick module.
step 1.
Switch off the wheelchair and disconnect the cable of the
joystick module.
step 2.
loosen the two bolts underneath the mounting plate.
step 3.
Replace the unit by a new one.
step 4.
tighten the two mounting bolts again.
step 5.
connect the cable and start the wheelchair. It will run a handshake protocol. After this protocol, switch off
and on again. The wheelchair is now ready for use.