Invacare Auriga User manual

Invacare® Auriga
Service Manual
6 / 10 km/h version

Invacare®Auriga Service Manual
How to get in touch with Invacare
If you have any questions or need support, please contact your authorised Invacare® Dealer first. He
has the necessary know-how and equipment plus the special knowledge concerning your Invacare®
product which enables him to offer you all-round satisfactory service. Should you wish to contact us
directly, you can reach us in Europe at the following:
Invacare® Deutschland GmbH
Dehmer Str. 66
D-32549 Bad Oeynhausen
Germany
! (Kundendienst): +49 - (0) 5731 - 754580
! (Technische Hotline): +49 - (0) 5731 - 754 570
Fax (Kundendienst): +49 - (0) 5731 - 754 216
Fax (Technische Hotline): +49 - (0) 5731 - 754 208
Invacare® Poirier
Les Roches
F-37230 Fondettes
France
! (Service Après-Vente): +33 - (0) 2 47 - 62 64 15
Fax (Service Après-Vente): +33 - (0) 2 47 - 62 64 64
Invacare® Ltd
South Road
Bridgend
Mid Glamorgan - CF31-3PY
United Kingdom
! (Customer Service): +44 - (0) 1656 - 647 327
Fax (Customer Service): +44 - (0) 1656 - 649 016
Invacare® A/S
Sdr. Ringvej 39
2605 Brøndby
Denmark
! (Kundeservice): +45 - (0) 3690 0000
Fax (Kundeservice): +45 - (0) 3690 0001
Invacare®, SA
c/ Areny, s/n
Poligon Industrial de Celrà
17460 Celrà (Girona)
Spain
! +34 - (0) 972 - 49 32 00
Fax: +34 - (0) 972 - 49 32 20
Mecc San S.R.L.
Via Dei Pini, 35
I - 36016 Thiene (VI)
Italy
! +39 - (0) 445-380059
Fax: +39 - (0) 445-380034
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Invacare®Auriga Service Manual
General Information
This Service Manual contains all the information necessary to service and repair the scooter.
•Please observe all safety instructions.
•Information about operation or general maintenance work can be found in the scooter Operating Manual.
•Information on ordering spare parts can be found in the spare parts catalogue.
•We reserve the right to make any alterations on the grounds of technical improvements.
•The Scooter may only be serviced and repaired by qualified personnel.
•- The minimum requirement for a maintenance technician is specialist training e.g. as bicycle or
orthopaedic mechanic, or suitable long experience.
- Experience and knowledge of electrical measuring devices (multimeters) is also required.
•Any alterations to the Scooter which occur as a result of incorrectly or improperly performed maintenance
work will lead to the exclusion of all liability on the part of INVACARE.
•If you have any problems or questions please contact INVACARE TECHNICAL SERVICES
Technical Services: Tel: [phone]
Fax: [phone]
Main Reception Tel: [phone]
Address: Invacare Limited
South Road
Bridgend Industrial Estate
Bridgend CF31 3PY
E-mail: [e-mail]
Page 3

Invacare®Auriga Service Manual
Notes on transport
•If the Scooter has to be shipped back to the manufacturer for major repairs, you should always use the
original packaging for transport.
•You should also include as accurate a fault description as possible. The following symbols are used in
this Service Manual:
Note:
This symbol indicates general information which highlights special points or simplifications in
dismantling / reassembly.
Caution:
It is imperative that you observe all safety instructions indicated by this symbol.
This symbol identifies service work and corresponding tools.
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Invacare®Auriga Service Manual
Table of contents Page
1 Safety and assembly instructions 7
1.1 Before any inspection or repair work 7
1.2 During dismantling/reassembly 7
1.3 Before operation / after completion of work 8
2 Tool list 9
3 Layout of modules, components, displays and controls 10
5 Inspection plan 11
6 Operational faults 12
6.1 Diagnostics and troubleshooting 12
7 Error codes 13
8 Module combinations / variations 14
9 Maintenance and repair 15
9.1 Chassis 15
9.1.1 Front wheel frame (3-wheeler) 15
9.1.2 Front wheel frame (4-wheeler) 16
9.1.3 Rear frame assembly (3+4-wheelers) 17
9.2 Drive unit 18
9.2.1 Replacing the drive unit 19
9.2.2 Replacing the carbon brushes 19
9.3 Shroud 20
9.3.1 Front shroud (3-wheeler) 20
9.3.2 Front shroud (4-wheeler) 21
9.3.3 Rear shroud (3+4-wheelers) 22
9.3.4 Removing and re-fitting the front cover (3+4-wheelers) 23
9.3.5 Removing and re-fitting the rear cover (3+4-wheelers) 23
9.4 Wheels 24
9.4.1 Front wheel assembly (3-wheeler) 24
9.4.2 Front wheel assembly (4-wheeler) 25
9.4.3 Rear wheel assembly (3+4-wheelers) 25
9.5 Assembling / disassembling the front wheel (3-wheeler) 26
9.5.1 Assembling / disassembling the front fork (3-wheeler) 26
9.5.2 Replacing the bearings (3-wheeler) 26
9.6 Assembling / disassembling the front wheel (4-wheeler) 27
9.6.1 Assembling / disassembling the front suspension (4-wheeler) 27
9.6.2 Replacing the bearings (4-wheeler) 27
9.6.3 Assembling / disassembling the steering column tube (4-wheeler) 28
9.6.4 Assembling / disassembling the rear wheels (3+4-wheelers) 28
9.7 Electronic system 29
9.7.1 Batteries, electronic system, charger and connections 29
9.7.2 Replacing the charger 30
9.7.3 Replacing the batteries 30
9.7.4 Replacing the electronics 30
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Invacare®Auriga Service Manual
9.7.5 Replacing a fuse 31
9.7.6 Hand-held programmer 31
9.8 Tiller linking assembly / control panel 32
9.8.1 Steering column 32
9.8.2 Tiller 33
9.9 Replacing the keypad and the control panel 34
9.9.1 Assembling / disassembling the steering column shroud 34
9.9.2 Replacing the Bowden Cable 35
9.9.3 Replacing the throttle lever 35
9.9.4 Replacing the potentiometer 35
9.9.5 Replacing the light bulbs in the front 36
9.9.6 Replacing the light bulbs in the rear 36
9.9.7 Replacing the head light 36
10 Seating unit
10.1 Replacing the slide mechanism 38
10.1.1 Replacing the release lever 38
10.1.2 Replacing the upper seat support tube 39
10.1.3 Removing the armrests 39
10.1.4 Removing the armrest supports 39
10.1.5 Removing the headrest 39
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Invacare®Auriga Service Manual
1 Safety and assembly instructions
These safety instructions are intended to prevent accidents, and it is imperative that they are observed.
1.1 Before any inspection or repair work
•Read and observe this Service Manual and the associated operating manual.
•Observe the minimum qualification requirements for carrying out the work.
Caution:
•Please take into account the heavy weight of some components. This applies especially to
removal of drive units and batteries.
•The Scooter must be switched off before removal of voltage-carrying components. To do this
remove the batteries.
• When making measurements on voltage-carrying components, avoid short-circuiting the
contacts.
•Danger of fire!
•Use tools that are in good condition.
1.2 During dismantling / reassembly
•Mark all current settings for the Scooter (seat, armrests, backrest etc.), and the cable connecting plugs
associated, before any removals. This makes reassembly easier.
Caution:
•Support the Scooter when raised with suitable equipment before beginning removal or
reassembly.
•Never use “standard” nuts instead of self-locking nuts.
•Always use correctly dimensioned washers or spacers.
Note:
•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.
•Cable binders which have been cut off during disassembly should be replaced by new ones
during reassembly.
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Invacare®Auriga Service Manual
1.3. Before operation / after completion of work
Caution:
•Check all fixings for tight fit.
•Check all parts for correct interlocking.
•Only operate Scooter with correct tyre pressure (2.5 bar).
•Check electrical components for correct functioning.
As a last check always perform a test drive.
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Invacare®Auriga Service Manual
2 Tool list
You will need a standard tool set with at least the following:
•Set of open and ring spanners
•Set of Allen-keys
•Torque wrench
•Socket spanner set
•Set of screwdrivers
•Oblique pliers
•Flat-nosed pliers
•Circlip pliers
•Pointed pliers
•Cable lug pliers
•Wooden or plastic hammer
•Tyre repair kit (commercial)
•Tyre pressure indicator
•Valve removal tool
•Wheel bearing puller
•Multimeter with probes and various cable clips
•Soldering iron 30W
•Front wheel hub puller
•Pop riveting tool
•Stepped mandril
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Invacare®Auriga Service Manual
3 Layout of modules, components, displays and controls
The following figures show the layout of scooter modules. Removal and reassembly of spare parts is
described in Chapter 9.
1) De-clutching lever
2) Release lever for swivelling and
removing seat (under the seat
on the right)
3) Release lever for seat sliding rail
adjustment (under the seat on
the right in the front)
4) Primary Charging Socket
5) Key switch (ON/OFF)
6) Throttle
7) Control panel
8) Lever for adjusting the angle
of the steering column
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Invacare®Auriga Service Manual
5 Inspection plan
Component
Wheel suspension
and wheels
Lighting System
Drive Unit
Chassis
Batteries
Control Panel
Check
- Check drive wheels for tight fit and
side play
- Check steering wheels for tight fit,
float and side play
Check castor fork bearings
- Check tyres
- Check cabling
- Check function
- Check functions in drive and push
modes
- Check fixings, welded seams
- Damage to batteries and case,
contact corrosion
- Check contacts, terminals
- Check battery voltage
- Status display flashing
- Cable, connecting plug
Chapter
9.6.4
9.5
9.5.2
9.6.2
9.9.5
9.2.1
9.1
9.7.3
9.9
Remedy
# Adjust, replace wheels
# Replace wheels, wheel fork or
wheel bearings
# Replace
# Fit new
# Replace cables if necessary
# Replace cable or bulbs if
necessary
# Replace motor if necessary /
replace brushes
# Tighten screws and nuts, adjust
or replace components
# Clean contacts, replace
batteries or case
# Tighten, clean, replace if
necessary
# Charge batteries / replace
# Replace cable, connector plug
or control panel
# Tighten, replace
$
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Invacare®Auriga Service Manual
6 Operational faults
6.1 Diagnostics and troubleshooting
The electronic system provides diagnostic information to help service personnel to locate and correct faults in
the system. When a fault occurs the status display will flash in bursts, followed by a pause, then flash again.
The type of fault that has occurred is indicated by the number of flashes, which also called a flash code.
Depending on the severity of the fault, and its effect on the safety of the user, the electronic system can react
in several different ways. For example it can:
•simply display the flash code as a warning, and allow normal operation to continue
•display the flash code, and immobilise the scooter until the system is turned off and back on again
•display the flash code, immobilise the scooter, and prevent further operation of the scooter until the
fault is corrected.
If an error occurs, please proceed as follows:
•Check the troubleshooting guide in chapter 7.
•Check the status display on the control panel, and compare any flash codes with the troubleshooting
guide in chapter 7.
•Perform any checks and repairs that are necessary.
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Invacare®Auriga Service Manual
7 Error codes
Before assessing the error codes, carry out the following test:
• Turn the remote on and off several times. Before you switch on wait approx. 5 seconds.
The test checks whether the error can be automatically rectified by the electronics, and if necessary
deactivates the flashing status display on the control panel. If this is not the case, you can locate the fault
using the flash codes as follows:
•Turn the control panel on and off.
•Check which flash code is showing.
•Wait for the flash code pause (approx. 2-3 seconds).
•Re-count the code.
Flash
Code
1 x
2 x
3 x
4 x
5 x
Fault
Battery needs to be
charged
Battery voltage too
low
Seat lifter is raised
Battery voltage too
high.
Current time-out
Brake Fault
Remarks
• Battery charge is running low. Charge the
batteries as soon as possible.
• The batteries are depleted. Charge the batteries.
• If the scooter is left turned off for a time, then the
batteries may recuperate enough to allow it to be
driven for a very short period again.
• Lower the seat lifter completely.
• Battery voltage is too high. If a charger is
connected, disconnect it.
• The electronic system charges the batteries
when driving downhill and when braking. This
fault is caused by the battery being over-charged
because of this. Turn the scooter off and back
on again.
• The scooter has drawn too much current for too
long, possibly because the motor has been over-
worked, jammed or stalled. Turn the scooter
power off, leave it off for a few minutes, and then
turn the power back on again.
• The controller has detected a short-circuited
motor. Check the cable harness for short
and check the motor: Contact your authorised
Invacare® Dealer.
• Check that the de-clutching lever is in the
engaged position.
Impact on
Scooter
No impact
Drive inhibited
Reduced
driving speed
Drive inhibited
Drive inhibited
Drive inhibited
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Invacare®Auriga Service Manual
8 Module combinations / variations
The Auriga can be supplied in the following options from start of production:
Colour:
• Ruby Red
• Saphire Blue
Batteries :
• 30 Ah (Standard)
• 40 Ah
Accessories :
• Basket, rear
• Rear view mirror (right or left)
• Cane holder
Flash
Code
6 x
7 x
8 x
9 x
Fault
Out Of Neutral At
Power Up
Speed Pot Error
Motor Volts Error
Other Internal
Errors
Notes:
• The park brake coil or wiring is faulty. Check the
park brake and wiring for open or short circuits.
Contact your authorised Invacare® Dealer.
• Throttle is not in neutral position when turning
key switch on. Return throttle to neutral, turn
power off, and back on again.
• Throttle may need to be re-calibrated. Contact
your authorised Invacare® Dealer.
• The throttle or its wiring may be faulty
or incorrectly set up. Contact your authorised
Invacare® Dealer.
• The motor or its wiring is faulty. Contact your
authorised Invacare® Dealer.
• Contact your authorised Invacare® Dealer.
Impact on
Scooter
Drive inhibited
Drive inhibited
Drive inhibited
Drive inhibited
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Invacare®Auriga Service Manual
9 Maintenance and repair
9.1. Chassis
9.1.1 Front wheel frame (3-wheeler)
Note:
When servicing the chassis, if deformations or faulty welding seams are found, then the complete chassis
should be replaced.
Page 15
Pos
1,1
1,01
1,2
1,23
1,30
1,32
1,35
1,37
1,38
1,39
1,41
1,45
Qty
1
1
1
1
1
2
1
1
1
1
2
1
Part Description
FRONT FRAME ASSY., (3 WHEELER)
FRONT FRAME, (3 WHEELER)
FRONT BUMPER ASS’Y.,3W
FORK BEARING SET, 8 PCS/SET
SUPPORTING BRACKET, REAR SHROUD
SPACER, FRONT FRAME AND REAR FRAME ASSEMBLY
ASSEMBLY HOOK, FRAME, 3W/4W
ASSEMBLY LEVER, FRAME
BLACK TIP
PIN WITH TIE, RD. 8x50L
BATTERY STRAP, 50x660L
MAIN LOOM, FRAME, 3W/4W
Part-No.
1421011
1421012
1421013
1421014
1421015
1421016
1421017
1421019
1421020
1421024
1421027
1421029
1.23
1.2
1.1
1.23
1.38
1.41
1.45
1.01
1.35
1.37
1.32
1.30
1.39

Invacare®Auriga Service Manual
Pos
1,1
1,01
1,2
1,03
1,04
1,09
1,10
1,3
1,4
1,23
1,25
1,26
1,30
1,32
1,35
1,37
1,38
1,39
1,41
1,43
1,45
Qty
1
1
1
2
4
1
1
1
1
1
2
1
1
2
1
1
1
1
2
1
1
Part Description
FRONT FRAME ASS’Y.,(4 WHEELER)
FRONT FRAME ONLY, 4W
FRONT SUSPENSION SYSTEM, 4W
BUFFER, RUBBER BUSHING
BALL BEARING, STEM
FRONT AXLE SET, LH
FRONT AXLE SET, RH
CONNECTING ROD SET, LONG RD. 10 X 350 L
CONNECTING ROD SET, RD. 10 X 150 L, SHORT
FORK BEARING SET, 8 PCS/SET
BUFFER, RUBBER BLOCK, M10 X 30 L
FRONT BUMPER, 4W
SUPPORTING BRACKET, REAR SHROUD
SPACER, FRONT FRAME AND REAR FRAME ASSY
ASSEMBLY HOOK, FRAME, 3W/4W
ASSEMBLY LEVER, FRAME
BLACK TIP
PIN WITH TIE, RD. 8 X 50 L
BATTERY STRAP, 50 X 660 L
STEERING PEDESTAL ASS’Y.
MAIN LOOM, FRAME, 3W/4W
Part-No.
1421031
1421030
1421032
1421033
1421034
1421035
1421036
1421037
1421038
1421014
1421040
1421241
1421015
1421016
1421017
1421019
1421020
1421024
1421027
1421249
1421029
9.1.2 Front wheel frame (4-wheeler)
1.30
1.45
1.32
1.10
1.03
1.35
1.1
1.37
1.39 1.38
1.2
1.01
1.23
1.25
1.23
1.41
1.09
1.04
1.3
1.43
1.4
1.26
1.2
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Invacare®Auriga Service Manual
9.1.3 Rear frame assembly (3+4-wheelers)
Pos
1,48
1,49
1,53
1,5
1,6
1,66
Qty
1
1
1
2
1
1
Part Description
REAR FRAME ONLY, 3W/4W
SHOCK ABSORBERS
MOUNTING CLAMP, TRANSAXLE
ANTI-TIPPER WHEEL ASS’Y
RELEASE LEVER ASS’Y., TRANSAXLE, 3W/4W
MOUNTING BASE
Part-No.
1421251
1426314
1421253
1421254
1421255
1421256
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Invacare®Auriga Service Manual
Page 18
9.2 Drive Unit
6.02
6.01
Pos
6,01
6,02
Qty
1
2
Part Description
TRANSAXLE ASS’Y., M33D
CARBON BRUSH
Part-No.
1416109
1421275

Invacare®Auriga Service Manual
9.2.1 Replacing the drive unit
• Remove the seat and the rear shroud (see chapter 9.3.5).
• Pull the de-clutching lever and jack up the vehicle.
•Remove the screw that connects the release lever
to the drive unit.
• Loosen the bolts that hold the wheels and
remove them, if necessary using a special tool to
remove wheels (see notes on page 24).
•Release the clamps that hold the drive unit.
•Disconnect the cable that connects the drive unit
and the electronic system, and remove the drive unit.
Reassembly is done in reverse order.
9.2.2 Replacing the carbon brushes
• Remove the seat and the rear shroud (see chapter 9.3.5).
•Remove the spray guard of the charger.
•Remove all four screws on the charger
and remove the charger.
•Remove both plastic screws from the drive unit
and replace the brushes.
Reassembly is done in reverse order.
Page 19
6.02
6.01

Invacare®Auriga Service Manual
Page 20
9.3 Shroud
9.3.1 Front shroud (3-wheeler)
Pos
2,1
2,1
2,03
2,05
Qty
1
1
2
1
Part Description
FRONT SHROUD ASS’Y., RUBY RED, 3W
FRONT SHROUD ASS’Y., SAPPHIRE BLUE, 3W
SIDE TRIM, 16 X 640 L
CARPET, GREY, 3W
Part-No.
1421257
1421258
1421259
1421260
2.1
2.05
2.03