Invacare FDX User manual

Invacare® FDX
SERVICE MANUAL
These instructions contain information about:
testing work
repair work
Edition:14.07.10

Mobitec Mobilitätshilfen GmbH
Herzog Odilostrasse 101
A-5310 Mondsee
Austria
+43 - 6232 - 55 35 0
Fax: +43 - 6232 - 55 35 4
@: [email protected]
@: [email protected]
WWW: www.mobitec-austria.com
Invacare® n.v.
Autobaan 22
B-8210 Loppem (Brugge)
Belgium
+32 - (0)50 - 83 10 10
Fax: +32 - (0) 50 - 83 10 11
@: [email protected]
WWW: www.invacare.be
Mobitec Rehab AG
Benkenstraße 260
CH-4108 Witterswil
Switzerland
+41 - (0)61 - 48 77 08 0
Fax: +41 - (0)61 - 48 77 08 1
@: [email protected]
@: [email protected]
WWW: www.mobitec-rehab.ch
Invacare Aquatec
Alemannenstraße 10
88316 Isny
Deutschland
0 75 62 / 7 00 - 251
Fax 08 00 / 6 73 81 72
@: [email protected]
WWW: www.invacare-aquatec.de
Invacare® A/S
Sdr. Ringvej 37
DK-2605 Brøndby
Danmark
(Kundeservice): +45 - (0)36 - 90 00 00
Fax (Kundeservice): +45 - (0)36 - 90 00 01
@: [email protected]
WWW: www.invacare.dk
Invacare® SA
c/ Areny, s/n
Poligon Industrial de Celrà
17460 Celrà (Girona)
ESPAÑA
: +34 - (0)972 - 49 32 00
Fax: +34 - (0) 972 - 49 32 20
@: [email protected]
WWW: www.invacare.es
Invacare® Poirier SAS
Route de St Roch
F-37230 Fondettes
France
: +33 - (0)247 - 62 64 66
Fax: +33 - (0)247 - 42 12 24
@: [email protected]
WWW: www.invacare.fr
Invacare® Ltd
Pencoed Technology Park
Pencoed
Bridgend CF35 5HZ
United Kingdom
(Customer Service): +44 - (0)1656 - 776 222
Fax (Customer Service): +44 - (0)1656 - 776 220
@: [email protected]
@: [email protected]
WWW: www.invacare.co.uk
2

Invacare Mecc San s.r.l.
Via Dei Pini, 62
I - 36016 Thiene (VI)
ITALIA
+39 - 0445 - 38 00 59
Fax: +39 - 0445 - 38 00 34
@: [email protected]
WWW: www.invacare.it
Invacare Ireland Ltd.
Unit 5 Seatown Business Campus
Seatown Rd, Swords
County Dublin
Ireland
+353 - 18 10 70 84
Fax: +353 - 18 10 70 85
@: [email protected]
Invacare® AS
Grensesvingen 9
Postboks 6230
N-0603 Oslo
Norge
(Kundeservice): +47 - (0) 22 57 95 10
Fax (Kundeservice): +47 - (0)22 57 95 01
@: [email protected]
WWW: www.invacare.no
Invacare® B.V.
Celsiusstraat 46
NL-6716 BZ Ede
The Netherlands
: +31 - (0)318 - 69 57 57
Fax: +31 - (0) 318 - 69 57 58
@: [email protected]
WWW: www.invacare.nl
Invacare® PORTUGAL Lda
Rua Senhora de Campanhã 105
P-4369-001 Porto
PORTUGAL
: [phone]
Fax: [phone]
@: [email protected]
WWW: www.invacare.pt
3

Återförsäljare:
Invacare® AB
Fagerstagatan 9
S-163 91 Spånga
Sverige
Tillverkare:
Invacare Deutschland GmbH
Kleiststraße 49
D-32457 Porta Westfalica
Deutschland
(Kundtjänst): +46 - (0) 8 761 70 90
Fax (Kundtjänst): +46 - (0) 8 761 81 08
@: [email protected]
@: [email protected]
WWW: www.invacare.se
MÖLNDAL
+46 - (0) 31 – 86 36 00
Fax: +46 - (0) 31 – 86 36 06
@: [email protected]
LANDSKRONA
+46 - (0) 418 – 285 40
Fax: +46 - (0) 418 – 180 89
@: [email protected]
OSKARSHAMN
+46 - (0) 491 – 101 40
Fax: +46 - (0) 491 – 101 80
@: [email protected]
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 17
4.2.1 ACS II PMB70 / ACS II PMB70L electronic module 18
4.2.2 ACS II PMA90L electronic module 18
4.2.3 Actuator module ACT 18
4.2.3.1 Actuator module ACT2 18
4.2.3.2 Actuator module ACT 4 19
4.2.4 Lighting circuit board 19
4.3 Remotes 20
5MAINTENANCE PLAN (ONCE A YEAR) 22
6OPERATIONAL FAULTS 24
6.1 Drive fault diagnosis 25
6.2 Diagnosis of charging device faults 29
5

7TEST PROCEDURES 30
7.1 Testing the motor 30
7.2 Testing the electro-mechanical parking brake 31
8REPAIR WORK 33
8.1 Covers 33
8.1.1 Open front cover 33
8.1.2 Opening the rear cover 34
8.1.3 Opening the lateral cover 35
8.1.4 Opening the cover of the rear wheel cantilever arm 38
8.2 Electronic modules 39
8.2.1 Replacing remotes 39
8.2.2 Replacing electronic modules 39
8.2.3 Replacing the G-Trac module 42
8.2.4 Drive program selection after component replacement 44
8.2.4.1 Profile selection with G90A remote 44
8.2.4.2 Profile selection with remote REM A or REM B 45
8.2.4.3 Profile selection with remote REM 550 46
8.3 Updating the driving program 47
8.4 Batteries, cables & battery chargers 48
8.4.1 Removing the batteries 48
8.4.2 Replacing batteries / replacing battery cables 51
8.4.3 How to handle damaged batteries correctly 53
8.4.4 Replacing the main fuse 54
8.4.5 Checking the cables 55
8.5 Lighting system 57
8.5.1 Replacing light bulbs in the front (conventional lighting system) 57
8.5.2 Replacing the LEDs in the front (LED lighting system) 57
8.5.3 Replacing the complete head lamp assembly (conventional lighting system) 58
8.5.4 Replacing the head lamps completely (LED lighting system) 60
8.5.5 Replacing the head lamp bracket (conventional lighting system) 62
8.5.6 Replacing a light bulb in the rear (conventional lighting system) 63
8.5.7 Replacing the LEDs in the rear (LED lighting system) 63
8.5.8 Replacing the complete tail lamp assembly (conventional lighting system) 64
8.5.9 Replacing the tail lamp bracket (conventional lighting system) 66
8.5.10 Replacing the tail lamps completely (LED lighting system) 67
8.6 Seat / seat frame (without lifter) 68
8.7 Replacing the tilt module / lifter module 71
8.7.1 Replacing the tilt module (without lifter) 71
8.7.2 Replacing the lifter / tilt module 74
8.7.3 Replacing the tilt actuator 78
8.7.4 Replacing the lifter actuator 80
8.7.4.1 Method 1 - uninstalling the lifter actuator with the lifter raised 80
8.7.4.2 Method 2 - uninstalling the lifter actuator with the lifter lowered 82
6

8.8 Centre-mounted legrest (electric & manual) 86
8.8.1 Replacing the manually operated centre-mounted legrest 86
8.8.2 Replacing the electrically operated centre-mounted legrest 88
8.8.3 Replacing an electric legrest actuator 90
8.8.4 Replacing the calf plate on the centre-mounted legrest (electric & manual) 92
8.8.5 Replacing the foot plate on the centre-mounted legrest (electric & manual) 93
8.9 Replacing the restraining belt 94
8.10 Replacing the anti-tipper wheels 95
8.11 Rear wheels 96
8.11.1 Replacing a rear wheel 96
8.11.2 Replacing a rear wheel fork 97
8.11.3 Adjusting the wheel fork 99
8.12 Drive wheels 101
8.12.1 Replacing a drive wheel 101
8.12.2 Replacing a tyre 102
8.12.3 Replacing a drive wheel hub 103
8.13 Drive unit 105
8.13.1 Replacing the motor / gearbox unit 105
8.13.2 Replacing or rotating the motor / gearbox unit sealing ring 107
8.13.3 Replacing the motor / gearbox coupling 108
8.13.4 Replacing the carbon brushes 110
8.13.5 Running the motor in 112
8.14 Replacing the motor / gearbox fixation and rear wheel cantilever arm 113
8.15 Replacing the spring in the rear 115
8.16 Fixation rings 117
8.16.1 Replacing a front fixation ring 117
8.16.2 Replacing a rear fixation ring 118
8.17 Replacing the battery boxes 119
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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.
9

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.
10

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.
11

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!
12

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 electronics.
●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!
13

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.
14

4 Arrangement of sub-assemblies and components
4.1 Overview
In the rear under the seat:
Electronic modules
The electronic modules are located
under the rear cover:
(1) – Electronic module
(2) – Actuator module (optional)
(3) – Lighting circuit board (optional & not
shown in the illustration)
The electronic modules that are installed
are described in chapter 4.2.
In the front under the seat:
(1) – Actuator module (optional)
(2) – Lifter actuator (optional)
(3) – Tilt actuator (optional)
15

On the right, next to the spring seat:
(1) – G-Trac module (optional)
16

4.2 Electronic modules
Various different types of electronic modules can be installed in the wheelchair.
Before you connect components of the wheelchair such as adjustment motors or actuators to the
electronic module, make sure you know exactly which electronic module is installed. The following
table provides an overview.
Electronic modules Designations Remotes Remarks
ACS II PMB70
ACS II PMB70L
ACS II PMA90LG
ACS II with actuator
module ACT
G90A
REM A
REM B
REM 550
REM24
The actuator module
is optional.
Actuator module
ACT The actuator module is optional.
Lighting circuit
board The lighting circuit board is optional.
G-Trac module The G-Trac module is
optional
17

4.2.1 ACS II PMB70 / ACS II PMB70L electronic module
Connections
1) Battery 24V
2) Bus cable (to remote or ACT)
3) Bus cable (to remote or ACT)
4) Motor M1
5) Light
6) Motor M2
4.2.2 ACS II PMA90L electronic module
Connections
1) Battery 24V
2) Cable to G-Trac module (GYRO)
3) Bus cable (to remote or ACT)
4) Motor M1
5) Light
6) Motor M2
4.2.3 Actuator module ACT
Various types of adjustment motors, also called actuators, can be installed on the wheelchair.
These actuators are either connected directly to the electronic module or to a separate actuator
module. The actuator module is connected to the electronic module via a bus cable.
4.2.3.1 Actuator module ACT2
Connections
1) ACI*
2) Bus cable (to remote or ACT)
3) Bus cable (to remote or ACT)
4) Adjustment motor/actuator - channel
2
5) Adjustment motor/actuator - channel
1
* The ACI connection serves to limit the movement of an actuator or to reduce velocity.
18

4.2.3.2 Actuator module ACT 4
Connections
1) ACI*
2) Bus cable (to remote or electronic
module)
3) Bus cable (to remote or electronic
module)
4) Actuator - channel 4
5) Actuator - channel 3
6) Actuator - channel 2
7) Actuator - channel 1
* The ACI connection serves to limit the movement of an actuator or to reduce velocity.
4.2.4 Lighting circuit board
The connections of the lighting circuit board are located directly on the board.
19

4.3 Remotes
Various types of remotes can be installed on the wheelchair.
Before you connect components of the wheelchair such as adjustment motors or actuators, make
sure you know exactly which remote is installed. The following table provides an overview.
Remotes Designations Remarks
REM G90A Can be connected to
- ACS II PMB70
- ACS II PMB70L
- ACS PMA90LG
power modules.
REM A Can be connected to
- ACS II PMB70
- ACS II PMB70L
- ACS PMA90LG
power modules.
REM B Can be connected to
- ACS II PMB70
- ACS II PMB70L
- ACS PMA90LG
power modules.
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