Invacare Fox User manual

Edition: 1577880 Vers. 002 - 13.10.2014
Invacare
®
Fox
SERVICE MANUAL

SERVICE MANUAL
Invacare®- Fox
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

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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
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
@: [e-mail]
WWW: www.invacare.nl
Invacare Lda
Rua Estrada Velha, 949
P-4465-784 Leça do Balio
Portugal
(: [phone]
(: [phone]
Fax: [phone]
@: [e-mail]
WWW: www.invacare.pt

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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]
@: [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

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Contents
Chapter Page
1Introduction 8
1.1 General information ..................................................................................................................8
1.2 Notes on shipping .....................................................................................................................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
4Layout of components and componentry 15
4.1 Overview...................................................................................................................................15
4.2 Overview of the electronic modules......................................................................................16
5Service plan (1x annually) 17
6Operational faults 19
6.1 Drive fault diagnosis ...............................................................................................................19
6.2 Shark Error codes and diagnostic codes..............................................................................21
7Repair work 22
7.1 Covers.......................................................................................................................................22
7.1.1 Rear cover ....................................................................................................................22
7.1.2 Battery cover.................................................................................................................23
7.2Electronic modules..................................................................................................................25
7.2.1 Replacing the power module ........................................................................................25
7.2.2 Replace remote ............................................................................................................27
7.2.3 Drive program selection after component replacement................................................27
7.3 Updating the driving program................................................................................................28
7.4 Batteries ...................................................................................................................................29
7.4.1 Replacing batteries.......................................................................................................29
7.4.2 Installing/removing the battery boxes ...........................................................................32
7.4.3 Correct handling of damaged batteries.........................................................................33
7.5 Resetting circuit breaker.........................................................................................................34

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7.6 Checking the cables................................................................................................................34
7.7 Front wheels ............................................................................................................................35
7.7.1 Replacing front wheel ...................................................................................................35
7.7.2 Replacing/reversing the swinging axle..........................................................................36
7.7.3 Changing the wheelbase ..............................................................................................38
7.7.4 Replacing the steering head bearings on the steering wheels .....................................39
7.7.5 Installing the ball bearings ............................................................................................41
7.7.6 Replacing the rubber bumper .......................................................................................42
7.7.7 Replacing the caster locks............................................................................................43
7.8 Drive wheels.............................................................................................................................44
7.8.1 Replacing the drive wheels (wheel size 12½ x 2¼").....................................................44
7.8.2 Replacing the drive wheels (wheel size 12½ PS).........................................................46
7.9 Anti-tipper wheels....................................................................................................................47
7.10 Replacing the parking brake ..................................................................................................48
7.11 Drive unit..................................................................................................................................49
7.11.1 Replacing the motor/transmission unit Shark/VR2.......................................................49
7.12 Seat system..............................................................................................................................51
7.12.1 Moving the seat into the service position......................................................................51
7.12.2 Replacing the seat frame..............................................................................................53
7.12.3 Replacing the fabric seat (padded)...............................................................................55
7.12.4 Replacing the fabric seat (strechted)............................................................................56
7.12.5 Replacing the seat plate ...............................................................................................59
7.12.6 Replacing the safety latch.............................................................................................60
7.12.7 Adjusting the safety latch..............................................................................................60
7.13 Backrest unit............................................................................................................................61
7.13.1 Replacing the standard backrest..................................................................................61
7.13.2 Replacing a standard backrest with quick release........................................................62
7.14 Armrest.....................................................................................................................................64
7.14.1 Replacing the armrest...................................................................................................64
7.14.2 Replacing the holder.....................................................................................................65
7.15 Replacing the foot plate/heel strap of the legrest................................................................66
8Installing accessories 67
8.1 Replacing the holding strap...................................................................................................67
8.2 Curb climber.............................................................................................................................68
8.2.1 Replacing the positioning shoe.....................................................................................68
8.2.2 Replacing the curb climber ...........................................................................................69
8.3 Further accessories.................................................................................................................70

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9Adjusting the seating position 71
9.1 Adjusting the lower leg length and seat depth.....................................................................72
9.1.1 Adjusting the lower leg length.......................................................................................72
9.1.2 Adjusting the seat depth ...............................................................................................72
9.1.2.1 Adjusting the seat depth via the backrest unit (fabric seat padded)........................73
9.1.2.2 Adjusting the seat depth via the backrest unit (fabric seat strechted).....................74
9.2 Adjusting the seat height........................................................................................................75
9.2.1 Adjusting seat height above centre column..................................................................75
9.2.2 Adjusting seat height above seat support.....................................................................75
9.3 Adjusting the seat tilt..............................................................................................................76
9.4 Adjusting the center of gravity of the seat............................................................................76

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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 shipping
•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 jacking up, secure the vehicle by using chocks to block the wheels.
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!

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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 electronics.
•Always carry out a trial run at the end of your work.
CAUTION!
Danger of injury and damage to property, if the maximum speed reduction on a
wheelchair with a lifter does not function correctly!
The wheelchair’s control unit must reduce the maximum possible speed as soon as the
lifter is raised.
•Test the maximum speed reduction for correct function after any maintenance work or
modifications to the wheelchair.
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.
CAUTION!
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 Layout of components and componentry
4.1 Overview
Under the rear cover:
1) Power module
2) Drive unit
The electronic modules used are
described in chapter 4.2.
Under the seat:
1) Parking brake
2) Battery boxes
3) Saferty latches for the seat
Special features:
1) Scissor system, please refer to user
manual.
2) Swinging axle, please refer to
chapter 7.7.2.

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4.2 Overview of the electronic modules
Different electronic modules can be fitted to the mobility aid.
Before you connect mobility aid components such as actuators or motors, please begin by
ascertaining which module is installed. Please refer to the following table for an overview of the
modules.
Power modules Designation Joystick boxes Notes
ACS
Shark DK-PMB01
Shark II remote Battery cable
Shark / DX2
VR2
R-Net EL PM90
R-Net remote Battery cable VR2
LiNX
UniShark
Shark II remote Battery cable
Shark / DX

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5 Service plan (1x annually)
Component Check Remedy Notes
ü
Armrests •Damage to armrests •Replace covering
if damaged
•Armrest fixings •Tighten screws
Side panels •Damage to side
panels
•Replace side
panels if damaged
•Side panel fixings •Tighten screws
Seat lock •Seat lock defective •Replace seat lock
Seat angle
adjustment •Tight seating of SL
fuses •Replace SL fuses if necessary
Frames
(chassis) /
battery
mounting
•Check fixings,
welded seams and
battery mounting
•Tighten screws
•Replace
components if
necessary
Wheel
suspension and
wheels
•Check drive wheels
for tight fit and side
play
See chapter 7.8.
•Check steering
wheels for tight fit,
float and side play
•Replace wheels,
wheel fork or
wheel bearings
See chapter 7.7
Swinging axle •Check caster locks •Replace caster
locks See chapter 7.7.4
•Check swinging axle
for damage •Replace swinging axle See chapter 7.7.2
Drive units,
coupling
mechanism
•Check functions in
drive and push
modes
•Check coupling
mechanism
•Replace motor if
necessary.
•Tighten
screws/nuts,
adjust or replace if
necessary
Legrests •Check welded
seams, interlocking,
screws, footplates
•Tighten, replace if
necessary
Batteries •Check batteries for
damage •Replace batteries if necessary See chapter 7.4.
•Check battery
voltage •Charge batteries See operating
manual
•Check contacts and
terminals •Clean contacts and terminals Please refer to the
safety information
in chapter 7.4 for
handling batteries

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Component Check Remedy Notes
ü
Remote /
electronic
module
•Remote, status
display blinking •Evaluate error/blink code
•Fixings •Tighten fixings,
replace if
necessary
•Cables and
connecting plugs •Tighten cables and connecting
plugs, replace if
necessary
•Drive lever function •Replace drive
lever if necessary
•Replace remote if
necessary
•Power supply •Tighten cables
and connecting
plugs, replace if
necessary
Drive program •Check drive
electronics program
version
•Update software if
newer version
available.
See chapter 7.3.

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6 Operational faults
Different power modules can be installed in the mobility aid in connection with different remotes.
The rectification of operational faults depends on the installed power module in each case.
The power modules used are described in 4.2.
Note
The tables for rectification of operational faults listed in the following chapters are only an excerpt
from the original manufacturer's manuals.
You can obtain the original manuals from Invacare®.
If you have problems with the mobility aid, please proceed as follows:
•First assess the possible cause of the problem using the following table.
•Check the remote status display. Evaluate the error code.
•Carry out the necessary checks and repairs as recommended in the following table.
6.1 Drive fault diagnosis
PROBLEM OTHER
SYMPTOMS POSSIBLE CAUSE SOLUTION DOCUMENTATION
Mobility
device will
not start
The remote
status display
illuminates
normally and
does not show
an error code.
Drive motors
disengaged Engage drive motors
See operating manual
Remote status
display does
not illuminate
Batteries
defective Replace batteries See chapter 7.4.
Completely
discharge
battery
Pre-charge
batteries See operating manual
Power supply
to remote
interrupted
Reset circuit
breaker See chapter 7.5.
Check cables
between the
modules for loose
connections and
damage
See chapter 7.6.
Remote
defective Replace remote See chapter 7.2.2.
Remote status
display blinking Various causes Assess error code See chapter 6.2.

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PROBLEM OTHER
SYMPTOMS POSSIBLE CAUSE SOLUTION DOCUMENTATION
Mobility
device
judders in
drive mode
None
Batteries
defective
(unstable
voltage)
Replace batteries See chapter 7.4.
Drive motor(s)
defective Replace motor(s) See chapter 7.11.1.
Batteries
not being
charged
None Batteries
defective Replace batteries See chapter 7.4.
LEDs blinking
on charging
unit
Charging unit
defective Replace charging unit See charging unit user manual
Mobility
device runs
too slowly
None Remote
defective Replace remote See chapter 7.2.2.
Batteries
defective Replace batteries See chapter 7.4.