Invacare FDX User manual

Edition: 26.03.2014
Invacare
®
FDX
SERVICE MANUAL

SERVICE MANUAL Invacare®- FDX
2
These instructions contain information about:
Testing work
Repair Instructions
This manual is part of the instructions for use.
Service addresses
Invacare Austria GmbH
Herzog Odilostrasse 101
A-5310 Mondsee
Austria
(: [phone]
Fax: [phone]
@: [e-mail]
WWW: www.invacare.at
Invacare n.v.
Autobaan 22
B-8210 Loppem (Brugge)
Belgium
(: [phone]
Fax: [phone]
@: [e-mail]
WWW: www.invacare.be
Invacare AG
Benkenstraße 260
CH-4108 Witterswil
Switzerland
(: [phone]
Fax: [phone]
@: [e-mail]
WWW: www.invacare.ch
Invacare Aquatec GmbH
Alemannenstraße 10
88316 Isny
Deutschland
([phone]
Fax [phone]
@: [e-mail]
WWW: www.invacare-aquatec.de
Invacare A/S
Sdr. Ringvej 37
DK-2605 Brøndby
Danmark
((Kundeservice): [phone]
Fax (Kundeservice): [phone]
@: [e-mail]
WWW: www.invacare.dk
Invacare® SA
c/ Areny s/n
Polígon Industrial de Celrà
E-17460 Celrà (Girona)
ESPAÑA
(: [phone]
Fax: [phone]
@: [e-mail]
WWW: www.invacare.es
Invacare® Poirier SAS
Route de St Roch
F-37230 Fondettes
France
(: [phone]
Fax: [phone]
@: [e-mail]
WWW: www.invacare.fr
Invacare® Ltd
Pencoed Technology Park
Pencoed
Bridgend CF35 5HZ
United Kingdom
((Customer services): [phone]
Fax (Customer services): [phone]
@: [e-mail]
WWW: www.invacare.co.uk
Invacare Mecc San s.r.l.
Via dei Pini, 62
I - 36016 Thiene (VI)
Italia
(: [phone]
Fax: [phone]
@: [e-mail]
WWW: www.invacare.it

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Invacare Ireland Ltd.
Unit 5 Seatown Business Campus
Seatown Rd, Swords
County Dublin
Ireland
(: [phone]
Fax: [phone]
@: [e-mail]
WWW: www.invacare.ie
Invacare® AS
Grensesvingen 9
Postboks 6230
Etterstad
N-0603 Oslo
Norge
((Kundeservice): [phone]
Fax (Kundeservice): [phone]
@: [email protected]
@: [e-mail]
WWW: www.invacare.no
Invacare® B.V.
Celsiusstraat 46
NL-6716 BZ Ede
Nederland
(: [phone]
Fax: [phone]
@: [email protected]om
@: [email protected]
WWW: www.invacare.nl
Invacare Lda
Rua Estrada Velha, 949
P-4465-784 Leça do Balio
Portugal
(: [phone]
(: [phone]
Fax: [phone]
@: [email protected]om
WWW: www.invacare.pt
Återförsäljare:
Invacare® AB
Fagerstagatan 9
S-163 91 Spånga
Sverige
Tillverkare:
Invacare® Deutschland GmbH
Kleiststraße 49
D-32457 Porta Westfalica
Deutschland
((Kundtjänst): [phone]
Fax (Kundtjänst): [phone]
@: [email protected]
@: [e-mail]
WWW: www.invacare.se
MÖLNDAL
(: [phone]
Fax: [phone]
@: [e-mail]
LANDSKRONA
(: [phone]
Fax: [phone]
@: [e-mail]
OSKARSHAMN
(: [phone]
Fax: [phone]
@: [e-mail]
Eastern
european
countries
European Distributor
Organisation (EDO)
Kleiststraße 49
D-32457 Porta Westfalica
Deutschland
([phone]
Fax [phone]
@: [email protected]om
WWW: www.invacare.de

SERVICE MANUAL Invacare®- FDX
4
Table of contents
Chapter Page
1INTRODUCTION 8
1.1 General information 8
1.2 Notes on transport 8
1.3 Definition and representation of information and safety information in this manual 9
1.4 Hazard symbols and symbols used 10
1.5 Images in this manual 11
2SAFETY AND FITTING INSTRUCTIONS 12
2.1 Before any inspection or repair work 12
2.2 Personal safety equipment 12
2.3 General safety information and information about fitting / removal 12
3TIGHTENING TORQUES 14
4ARRANGEMENT OF SUB-ASSEMBLIES AND COMPONENTS 15
4.1 Overview 15
4.2 Electronic modules 16
4.2.1 ACS 2 PMB70 / ACS 2 PMB70L electronic module 17
4.2.2 ACS 2 PMA90L electronic module 17
4.2.3 Actuator module ACT 17
4.2.3.1 Actuator module ACT2 17
4.2.3.2 Actuator module ACT 4 18
4.2.4 Lighting circuit board 18
4.3 Remotes 19
5MAINTENANCE PLAN (ONCE A YEAR) 21
6OPERATIONAL FAULTS 24
6.1 Drive fault diagnosis 25
6.2 REM remotes: Error codes and diagnostic codes 29
6.3 Diagnosis of charging device faults 31

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7TEST PROCEDURES 32
7.1 Testing the motor 32
7.2 Testing the electro-mechanical parking brake 33
8REPAIR WORK 35
8.1 Covers 35
8.1.1 Open front cover 35
8.1.2 Opening the rear cover 36
8.1.3 Opening the lateral cover 37
8.1.4 Opening the cover of the rear wheel cantilever arm 40
8.2 Electronic modules 41
8.2.1 Replacing remotes 41
8.2.2 Replacing electronic modules 41
8.2.3 Replacing the G-Trac sensor 44
8.2.4 Drive program selection after component replacement 46
8.2.4.1 Profile selection with G90A remote 46
8.2.4.2 Profile selection with remote REM A or REM B 47
8.2.4.3 Profile selection with remote REM 550 48
8.3 Updating the driving program 49
8.4 Batteries, cables & battery chargers 50
8.4.1 Removing the batteries 50
8.4.2 Replacing batteries / replacing battery cables 53
8.4.3 How to handle damaged batteries correctly 55
8.4.4 Replacing the main fuse 55
8.4.5 Checking the cables 56
8.5 Replacing the battery boxes 58
8.6 Lighting system 59
8.6.1 Replacing light bulbs in the front (conventional lighting system) 59
8.6.2 Replacing the LEDs in the front (LED lighting system) 59
8.6.3 Replacing the complete head lamp assembly (conventional lighting system until 03/12) 60
8.6.4 Replacing headlamps completely (conventional lighting system starting 03/2012) 62
8.6.5 Replacing the head lamps completely (LED lighting system until 03/2012) 64
8.6.6 Replacing headlamps completely (LED lighting system starting 03/2012) 66
8.6.7 Replacing the head lamp bracket (conventional lighting system until 03/0212) 68
8.6.8 Replacing headlamp brackets (conventional lighting system starting 03/2012) 69
8.6.9 Replacing the front bulb holder (LED lighting system until 03/2012) 70
8.6.10 Replacing a light bulb in the rear (conventional lighting system) 71
8.6.11 Replacing the LEDs in the rear (LED lighting system) 71
8.6.12 Replacing the complete tail lamp assembly (conventional lighting system) 72
8.6.13 Replacing the tail lamp bracket (conventional lighting system) 74
8.6.14 Replacing the tail lamps completely (LED lighting system) 75
8.7 Rear wheels 76
8.7.1 Replacing a rear wheel 76
8.7.2 Replacing a rear wheel fork 77
8.7.3 Adjusting the wheel fork 79
8.8 Drive wheels 81
8.8.1 Replacing a drive wheel 81
8.8.2 Replacing a tyre 82
8.8.3 Replacing a drive wheel hub 83

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8.9 Replacing the spring in the rear 85
8.10 Replacing the anti-tipper wheels 87
8.11 Drive unit 88
8.11.1 Replacing the motor / gearbox unit 88
8.11.2 Replacing or rotating the motor / gearbox unit sealing ring 90
8.11.3 Replacing the motor / gearbox coupling 91
8.11.4 Replacing the carbon brushes 93
8.11.5 Running the motor in 95
8.12 Replacing the motor / gearbox fixation and rear wheel cantilever arm 96
8.13 Seat adjustment standard 98
8.13.1 Seat / seat frame (without lifter) 98
8.13.2 Replacing the tilt module / lifter module 101
8.13.2.1 Replacing the tilt module (without lifter) 101
8.13.2.2 Replacing the lifter / tilt module 104
8.13.2.3 Replacing the tilt actuator 108
8.13.2.4 Replacing the lifter actuator 110
8.13.3 Seat frame 116
8.13.3.1 Adjusting the seat width 116
8.13.3.2 Adjusting the seat depth 118
8.14 Centre-mounted legrest (electric & manual) 122
8.14.1 Replacing the manually operated centre-mounted legrest 122
8.14.2 Replacing the electrically operated centre-mounted legrest 123
8.14.3 Replacing the electrically operated centre-mounted legrest LNX (Modulite seat) 125
8.14.4 Replacing an electric legrest actuator 126
8.14.5 Replacing the calf plate on the centre-mounted legrest (electric & manual) 128
8.14.6 Replacing the foot plate on the centre-mounted legrest (electric & manual) 129
8.15 Back unit 130
8.15.1 Replacing the standard back 130
8.15.2 Adjusting the belt back 131
8.15.3 Replacing the EasyAdapt back 132
8.15.4 Replacing / adjusting the universal backrest frame for the EasyAdapt backrest 133
8.16 Back unit with ergonomic length adjustment 136
8.16.1 Adjusting the width 136
8.16.2 Replacing the planetary gear 137
8.16.3 Replacing the servo motor 139
8.16.4 Replacing the microswitch 140
8.16.5 Fitting back plates to the base support of the back with ergonomic length adjustment 141
8.16.6 Fitting the handlebar 142
8.16.7 Replacing the travelling armrest 143
8.16.8 Replacing the arm support on the travelling armrest 144
8.16.9 Retrofitting a travelling armrest 145
8.17 Seat adjustment Modulite 146
8.17.1 Seat / seat frame Modulite (without lifter) 146
8.17.2 Replacing the tilt actuator 149
8.17.3 Replacing the lifter actuator 150
8.17.4 Replacing the lifter / seat angle adjustment module 151
8.17.5 Replacing the backrest actuator 154
8.18 Backrest Modulite 155
8.18.1 Replacing the standard backrest 155
8.18.2 Replacing the backrest mounting bracket 156
8.18.3 Replacing the backrest mounting bracket for SB 53 157

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8.18.4 Adjusting the seat width/ backrest width 158
8.18.4.1 Adjusting the seat width 158
8.18.4.2 Adjusting the seat width (legrest LNX) 160
8.18.4.3 Adjusting the backrest width 162
8.18.4.4 Adjusting the Flex3 backrest 164
8.19 Fixation rings 165
8.19.1 Replacing a front fixation ring 165
8.19.2 Replacing a rear fixation ring 166
9INSTALLING ACCESSORIES 167
9.1 Replacing the restraining belt 167
9.2 Replacing the harness belt 168
9.3 Replacing seat belts (Modulite seat) 170
9.3.1 Installation on the backrest mounting bracket (simple backrest) 170
9.3.2 Installation on the backrest mounting bracket (adjustable seat) 171
9.3.3 Installation on the seat frame profile (adjustable seat) 172
9.3.4 Replacing the harness belt (adjustable seat) 173
9.3.5 Replacing the harness belt (simple seat) 175
9.4 DAHL Docking Station 177
9.5 Fitting the stick holder 180
9.6 Further accessories 181

SERVICE MANUAL Invacare®- FDX
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1 Introduction
1.1 General information
●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 aid
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 aid 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 aid 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.
1.2 Notes on transport
●If the mobility aid has to be shipped back to the manufacturer for major repairs, you should
always use the original packaging for transport.
●Please attach a precise description of the fault.

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1.3 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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1.4 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.
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.