Invacare Comet User manual

Edition: 28.03.12
Invacare
®
Comet
SERVICE MANUAL

SERVICE MANUAL Invacare®- Comet
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]
@: [email protected]
WWW: www.invacare.at
Invacare n.v.
Autobaan 22
B-8210 Loppem (Brugge)
Belgium
(: [phone]
Fax: [phone]
@: [email protected]
WWW: www.invacare.be
Invacare AG
Benkenstraße 260
CH-4108 Witterswil
Switzerland
(: [phone]
Fax: [phone]
@: [email protected]
WWW: www.invacare.ch
Invacare Aquatec GmbH
Alemannenstraße 10
88316 Isny
Deutschland
([phone]
Fax [phone]
@: [email protected]
WWW: www.invacare-aquatec.de
Invacare A/S
Sdr. Ringvej 37
DK-2605 Brøndby
Danmark
((Kundeservice): [phone]
Fax (Kundeservice): [phone]
@: [email protected]
WWW: www.invacare.dk
Invacare® SA
c/ Areny s/n
Polígon Industrial de Celrà
E-17460 Celrà (Girona)
ESPAÑA
(: [phone]
Fax: [phone]
@: [email protected]
WWW: www.invacare.es
Invacare® Poirier SAS
Route de St Roch
F-37230 Fondettes
France
(: [phone]
Fax: [phone]
@: [email protected]
WWW: www.invacare.fr

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Invacare® Ltd
Pencoed Technology Park
Pencoed
Bridgend CF35 5HZ
United Kingdom
((Customer services): [phone]
Fax (Customer services): [phone]
@: [email protected]
WWW: www.invacare.co.uk
Invacare Mecc San s.r.l.
Via dei Pini, 62
I - 36016 Thiene (VI)
Italia
(: [phone]
Fax: [phone]
@: [email protected]
WWW: www.invacare.it
Invacare Ireland Ltd.
Unit 5 Seatown Business Campus
Seatown Rd, Swords
County Dublin
Ireland
(: [phone]
Fax: [phone]
@: [email protected]
WWW: www.invacare.ie
Invacare® AS
Grensesvingen 9
Postboks 6230
Etterstad
N-0603 Oslo
Norge
((Kundeservice): [phone]
Fax (Kundeservice): [phone]
@: [email protected]
@: [email protected]
WWW: www.invacare.no
Invacare® B.V.
Celsiusstraat 46
NL-6716 BZ Ede
Nederland
(: [phone]
Fax: [phone]
@: [email protected]
@: [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]
WWW: www.invacare.pt

SERVICE MANUAL Invacare®- Comet
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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]
@: [email protected]
WWW: www.invacare.se
MÖLNDAL
(┐[phone]
Fax: [phone]
@: [email protected]
LANDSKRONA
(: [phone]
Fax: [phone]
@: [email protected]
OSKARSHAMN
(: [phone]
Fax: [phone]
@: [email protected]
Eastern
european
countries
European Distributor
Organisation (EDO)
Kleiststraße 49
D-32457 Porta Westfalica
Deutschland
([phone]
Fax [phone]
@: [email protected]
WWW: www.invacare.de

Invacare®- Comet SERVICE MANUAL
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Table of Contents
Chapter Page
1INTRODUCTION 7
1.1 General information 7
1.2 Notes on transport 7
1.3 Definition and representation of information and safety information in this manual 8
1.4 Hazard symbols and symbols used 9
1.5 Images in this manual 10
2SAFETY AND FITTING INSTRUCTIONS 11
2.1 Before any inspection or repair work 11
2.2 Personal safety equipment 11
2.3 General safety information and information about fitting / removal 11
3TIGHTENING TORQUES 13
4OVERVIEW ELECTRONIC MODULES 14
5SERVICE PLAN (1X ANNUALLY) 15
6OPERATIONAL FAULTS 17
6.1 Operational faults 17
6.1.1 Drive fault diagnosis 17
6.2 Error Codes and Diagnostic Codes 18
7REPAIR WORK 20
7.1 General warning information on installation work 20
7.2 Replacing the drive motor 20
7.3 Replacing wheel suspension 24
7.4 Replacing shock absorber 26
7.5 Replacing front axle 28
7.6 Replacing steering column/fork 3-wheel 30
7.7 Replacing brakes 34

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7.8 Replacing brake cable 37
7.9 Replacing lifter/lifter electronic 38
7.10 Replacing steering linkage/steering rod 40
7.11 Replacing the seat suspension / spring 42
7.12 Replacing operating console 44
7.13 Replacing bend speed reducer 46
7.14 Replacing the potentiometer 48
7.15 Replacing front headlight (lamp) 51
7.16 Replacing the front direction indicators 53
7.17 Replacing centre brake light 54
7.18 Replacing rear lights/direction indicators 56
7.19 Replacing the electronic module 58
7.20 Updating software 62
8ACCESSORIES 63
8.1 Installing the windshield 63

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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.

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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.

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2 Safety and fitting instructions
These safety instructions are intended to prevent accidents at work, and it is imperative that they
are observed.
2.1 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)!
2.2 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!
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!

SERVICE MANUAL Invacare®- Comet
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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 electronic.
•Always carry out a trial run at the end of your work.
Note
Mark all current settings for the mobility aid (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 aids with a standard drive program ex-works. Invacare® can
only give a warranty for safe vehicle driving behaviour - especially tipping stability - for this
standard drive program!

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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 M4 M5 M6 M8 M10 M12 M14 M16
Tightening torque
in Nm ±10% 3 Nm 6 Nm 10 Nm 25 Nm 49 Nm 80 Nm 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.

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4 Overview electronic modules
Different electronic modules can be installed in the scooter. These are listed below:
Electronic modules Designation Notes
Rhino1
DS112KB02
DS162KD01
max. current:
110 A
160 A
Rhino2
DS120
max. current:
120 A
Rhino2
DS160
max. current:
160 A

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5 Service plan (1x annually)
Component Check Remedy Notes
ü
Seat:
•Welded seams,
fixings and
upholstery
•Tighten screws,
replace parts if
damaged
•Seat suspension
•Grease the spring
generously,
replace parts if
damaged
See "Replacing
the seat
suspension /
spring" on page
42
Frames
(chassis) /
battery
mounting
•Check fixings,
welded seams and
battery mounting
•Check battery fixing
straps
•Tighten screws,
replace parts if
damaged
Wheel
suspension and
wheels
•Check drive wheels
for tight fit
•Tighten hub nuts,
replace if
necessary
•Check steering
wheels for tight fit,
float and side play
•Adjust / replace
•Pneumatic tyre
•Repair or replace
if damaged See operating
manual
•Check tracking and
steering linkage.
•Tighten screws
•Check tracking
and steering
Brake
•Test brake function
in pushing mode
•Adjust or replace
brake
Shock absorber
•Check shock
absorber
•Adjust or replace
shock absorber
Drive units,
coupling
mechanism
•Check functions in
drive and push
modes
•Check clutch
mechanism
•Replace motor if
necessary
•Tighten screws /
nuts, adjust or
replace
Lighting
•Check function
•Check cable/plug
connections
•Replace lightbulbs
or cable
Batteries
•Check batteries for
damage
•Replace batteries
See operating
manual
•Check battery
voltage
•charge batteries
See operating
manual
•Check contacts and
terminals
•Clean contacts
and terminals

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Component Check Remedy Notes
ü
Drive electronic
•Status display
flashing
•Fixing
•Cable, connecting
plug
•Drive lever function
•Power supply
•Evaluate blinking
code
•Tighten or replace
fixing.
•Replace cable,
connecting plug.
•Replace drive
lever
•Replace cable,
connecting plug or
console
Drive program
•Check drive
electronic program
version Newer
version available?
•Update software
Speed
reduction in
bends
•Check cable and
connecting plug
•Check function
•Adjust or replace
sensor on relay.

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6 Operational Faults
6.1 Operational faults
Please proceed as follows if you have any problems:
•First assess the possible cause of the problem using the following table.
•Check the drive console status display. Evaluate the blink error code.
•Carry out the necessary checks and repairs as recommended in the following table.
6.1.1 Drive fault diagnosis
PROBLEM
OTHER
SYMPTOMS POSSIBLE CAUSE SOLUTION Documentation
Scooter will
not start Status display
on operating
console does
not illuminate
batteries
defective
•Replace
batteries See operating manual
completely
discharge battery
•Pre-charge
batteries
Power supply to
operating console
possibly
interrupted
•Check master
fuse See operating
i
nstructions for main fuse
position
•Check cable
between
modules for
loose
connections or
damage
See "Replacing the
electronic module" on
page 58
Operating
console defective
•Replace
operating
console
See "Replacing
operating console" on
page 44
Operating unit
status display
blinking
Various causes
•Assess error
code See "Error Codes and
Diagnostic Codes" on
page 18

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Scooter
judders in
drive mode
None Drive motor
defective
•Replace
motor(s) See "Replacing the
drive motor" on page
20
Drive lever
potentiometer
defective
•
Replacing the
potentiometer See "Replacing the
potentiometer
" on page
48
Batteries
not being
charged
None batteries
defective
•Replace
batteries See operating manual
LEDs blinking
on charging unit
Charging unit
defective
•Replace
charging unit See charging unit
operating manual
Scooter
runs too
slowly
None Operating
console defective
•Replace
operating
console
See "Replacing
operating console" on
page 44
batteries
defective
•Replace
batteries
See operating manual
Scooter
does not
reduce
speed on
bends.
None
Speed reducer for
bend travel not
adjusted.
•Adjust speed
reducer
Speed reducer
defective
•Replace speed
reducer See "Replacing bend
speed reducer
" on page
46
6.2 Error Codes and Diagnostic Codes
Blink
code Fault Consequence for the Scooter Comments
1 Battery must be
charged Continues to drive •The batteries are discharged. Charge the
battery as soon as possible.
2 Battery voltage too
low Stops driving •The batteries are depleted. Charge
batteries.
•If you switch the Scooter off for a few
minutes, the battery can often recuperate
to such a stage that a short journey is
still possible.
3 Battery voltage too
high Stops driving •The battery voltage is too high. If the
battery charger is connected, disconnect
it from the Scooter.
•The electronic system charges the
batteries when running downhill and
when braking. This fault is caused when
the battery voltage becomes too high
during this process. Switch the Scooter
off and on again.

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Blink
code Fault Consequence for the Scooter Comments
4 Power time
exceeded
Stops driving •The maximum current was exceeded
over too long a period, probably because
the motor was overloaded or has been
working against an immovable
resistance. Switch the scooter off, wait a
few minutes and then switch on again.
•The electronic system has determined a
motor short-circuit. Check the wiring
harness for short-circuit and check the
motor.
•Contact your Invacare® dealer.
5 Brake failure Stops driving •Ensure that the disconnection lever is
pressed in.
•There is a defect in the braking coil or in
the cabling. Check the magnetic brake
and cabling for open or short-circuited
circuitry. Contact your Invacare® dealer.
6 No neutral position
when switching
Scooter on.
Stops driving •Drive lever is not in neutral when the
keyswitch was turned. Put the drive lever
in neutral, turn the power off and then
turn on again.
•It may be necessary to recalibrate the
drive lever. Contact your Invacare®
dealer.
7 Fault in speed
potentiometer Stops driving •The drive lever electronic could be faulty
or incorrectly connected. Check the
cabling for open or short-circuited
circuitry.
•Potentiometer is not correctly adjusted.
Put the potentiometer into the centre
position.
8 Motor voltage error Stops driving •The motor or its cabling is defective
Check the cabling for open or short-
circuited circuitry.
9 Miscellaneous
internal fault Stops driving •Contact your Invacare® dealer.
10 Push/freewheel
mode error Stops driving •The Scooter has exceeded the
permissible maximum speed during
pushing or freewheeling. Switch the
electronic system off and on again.

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7 Repair Work
7.1 General warning information on installation work
CAUTION!
Risk of damage to the vehicle! Collisions can be caused if shim rings are removed from
the drive wheels during installation work!
Shim rings are frequently placed between the drive shaft and the wheel hub to compensate
tolerances. Collisions can be caused if these shim rings are removed and not re-installed!
•Install all shim rings in exactly the same positions they were in before dismantling.
7.2 Replacing the drive motor
ATTENTION! Risk of accident.
When parking the scooter on the scooters support wheels it is no longer slowed by the
engine brake. The scooter can roll away out of control.
•Place the scooter rear frame on a supporting wooden block before you remove the wheels.
ATTENTION! Risk of accident.
Accidental rolling can lead to accidents.
•Secure the scooter against rolling away.
NOTE:
When disassembling, note the position of small parts such as screws and washers. Put small
parts down so that they can be reassembled in the right sequence.
NOTE:
The plugs on the electronic module cannot be wrongly connected because all plugs have a
different size and only fit in one socket.
Requirements:
•Open spanner, 10 mm.
•Open spanner, 17 mm.
•oblique pliers
•Rubber hammer
•Phillips screwdriver
•Supporting wooden block