Invacare G40 User manual

SERVICE-MMANUAL
The manual contains:
Information on troubleshooting
Information on testing parts
Repair instructions
Edition: 12.2001
Invacare®
G40 with ACS-System

General information
This service manual contains all information necessary for maintenance and servicing of the “G40” wheelchair.
• Maintenance and servicing work is to be carried out in accordance with this service manual.
• Comply with all safety instructions
• Information on operation, general maintenance and servicing can be found in the operating manual of “G40”.
• Refer to the replacement parts catalog for information on ordering replacement parts.
• Maintenance and repair work on the “G40” may onla be performed by qualified personnel.
-Maintenance technicians should at least be trained in a relevant field, e.g. as a two-wheeled vehicle or
orthopaedics technician, or have an equivalent amount of professional experience.
-Personnel should also be familiar with electrical measurement equipment (multimeters).
• Should you encounter difficulties or have any questions, please contact INVACARE-SERVICE:
Switchboard: Tel. [phone]
Fax. [phone]
Service: Tel. [phone]-(70-80)
Fax. [phone]-(08-16)
Adress: Invacare Deutschland GmbH
Dehmer Str. 66
D-32549 Bad Oeynhausen
PO Box: Invacare Deutschland GmbH
Postfach 60 01 06
D-32 527 Bad Oeynhausen
• INVACARE can not be held liable for changes to the “G40” resulting from maintenance and servicing work
carried out incorrectly or not according to the relevant instructions.
Information concerning transportation
• If the wheelchair has to be sent away to the manufacturer for more serious repairs, always use the original
packaging for transportation.
• Please include a detailed account of the fault.
• We reserve the right to make changes in the interests of technical progress.
2
NOTE:
This symbol indicates general information concerning special features and helpful advice for installation.
ACAUTION:
Please pay special attention to this symbol. It indicates
>Safety instructions<.
You will notice the following symbols in this repair manual:

3
Contents
1.0 Safety and installation instructions . . . . . .4
2.0 List of tools . . . . . . . . . . . . . . . . . . . . . . . .5
3.0 Inspection plan . . . . . . . . . . . . . . . . . . . . .6
4.0 Operation troubles . . . . . . . . . . . . . . . . . . .8
4.1 General instructions . . . . . . . . . . . . . . . . . .8
4.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . .8
5.0 Error messages at remote . . . . . . . . . . . . .10
5.1 Error codes of remote . . . . . . . . . . . . . . .10
6.0 Arrangement of assembly groups, components
and operation elements . . . . . . . . . . . . . .12
7.0 Checks and repair work at seatsystem 14
7.1 Armrests and sides . . . . . . . . . . . . . . . . .14
7.2 Legrests . . . . . . . . . . . . . . . . . . . . . . . . .15
7.3 Backrest with frame, upholstery and hand
grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
7.4 Backrest adjusting . . . . . . . . . . . . . . . . . .18
7.5 Seatframe, seat shell and padding . . . . .19
8.0 Checks and repair work at chassis . . . . . .20
8.1 Chassis covering, grips and cover coating20
8.2 Wheels and tyres . . . . . . . . . . . . . . . . . . .21
8.3 Back-wheel suspension . . . . . . . . . . . . . .22
8.4 Front.wheel suspension . . . . . . . . . . . . . .23
8.5 Handbrake . . . . . . . . . . . . . . . . . . . . . . . .24
9.0 Checks and repair work at motor, gears,
servo and steering . . . . . . . . . . . . . . . . . .26
9.1 Driving motor and gears . . . . . . . . . . . . .26
9.2 Power-assisted steering unit . . . . . . . . . .28
10.0 Checks and repair work at
power supply
10.1 Batteries, battery box and check of . . . . . .
battery voltage . . . . . . . . . . . . . . . . . . . . .29
10.2 Battery charging . . . . . . . . . . . . . . . . . . .30
10.3 Battery charger unit . . . . . . . . . . . . . . . . .31
11.0 Checks and repair work at
lighting system . . . . . . . . . . . . . . . . . . . . .32
11.1 Front lighting system . . . . . . . . . . . . . . .32
11.2 Back lighting system . . . . . . . . . . . . . . . .33
12.0 Checks and repair work at
electronics . . . . . . . . . . . . . . . . . . . . . . . .34
12.1 Main module . . . . . . . . . . . . . . . . . . . . . .34
12.2 Remote . . . . . . . . . . . . . . . . . . . . . . . . . .35
12.3 Light servo module . . . . . . . . . . . . . . . . .36
12.4 Speedometer . . . . . . . . . . . . . . . . . . . . .37
13.0 Continuity check of cables . . . . . . . . . . . .38
14.0 Programming of wheelchair . . . . . . . . . . .39
15.0 Storing of wheelchair . . . . . . . . . . . . . . . .39

4
1.0 Safety and installation instructions
The safety instructions are provided in the interests of working safety and must under all circumstances be
complied with.
Prior to all inspection and repair work:
• Read this service manual and the appertaining user manual.
• Ensure that minimum qualifications for performing relevant work are fulfilled (see chapter entitled “General
information”).
Caution:
• Note that some components are heavy. You should take this into account above all when removing
the batteries.
• The power supply for the wheelchair must be switched off before any conductive parts are removed.
Remove the batteries.
• When performing tests on conductive parts, ensure that the contacts are not short-circuited.
> Danger of fire and injury from burns <
• Only use tools which are in perfect working order and are not damaged.
During work and assembly:
• Mark the current settings of the wheelchair (seat, armrests, back etc.) and the combination of cable connec-
tions before carrying out disassembly work. This will make assembly an easier task afterwards.
ACHTUNG:
• Support the raised wheelchair with suitable supports before you begin assembly. Use the bottom tube
. frames of the chassis. Also see the illustration G40, bottom view, chapter 6.0.
• You should under no circumstances use “normal” nuts instead of self-locking nuts.
• Always use correctly-sized washers or separators.
Note:
• All plug connectors are fitted with mechanical clamps which prevent slipping when the wheelchair is in
operation.
• These clamps must be pressed in to release the connectors.
• When carrying out assembly work, ensure that the clamps are fitted properly.
• For checks and repair works you can fold up the seat system and arrest. This position is called
service position.
Prior to initial use / after repair work:
Caution:
• Check firm mounting of all fastening screws.
• Check that all parts are properly locked in place.
• Check regulation tyre pressure (2.5 bar) before starting the machine.
• Always perform a test-drive after repair work.

5
2.0 List of tools
A standard toolkit comprising the following minimum inventory is required:
Combination ring and open-end spanner SW 6, 7, 8, 10, 11, 12, 13, 17, 19
Allan key 2,5 mm, 3mm, 4mm, 5 mm, 6 mm, 8mm, 10mm
Torque wrench (commercially available)
Socket spanner set
Screwdrivers for slotted screws various
Crosstip screwdriver No.1, No.2
Side-cutting pliers
Flat pliers
Round pliers
Cable lug pliers
Wooden or plastic hammer
Tyre repair set (commercially available)
Air pressure gauge
Valve extraction tools
Special tool for removing wheel bearing
Multimeter with test points and various cable clips
Bridging cable
Soldering iron 30W
Assembly pliers for Starlock caps (commercially available)
Removing tools for font wheel hub (available by INVACARE-Service)
You will require the following for setting at the ACS control:
Programming unit Item no.
Software package, incl. interface cable and dongle Item no.

6
3.0 Inspecton plan
Component
Armrests and sides
Action
> Tighten screws. Repla-
ce overlay.
> Tighten screws. Repla-
ce sides.
> Replace.
Check
• Damage to and attachment
of armrests
• Damage to and attach-
ment of side panels
• Mirrors
Seat > Tighten screws. Repla-
ce parts.
• Damage and screw
fastenings, stitching
Backrest with safety
belt > Adjust or replacebow-
den wire, gas spring.
> Tighten screws. Repla-
ce parts.
> Replace.
• Adjustment function
• Damage and screw
fastenings, stitching
• Belt and belt buckle
Latching mechanism
of seat in service
position
> Make moving
> Tighten screws.
Replace parts.
• Damage and secure lat-
ching into place
Legrests > Tighten, replace.
> Tighten, replace.
• Welded joint, lock, screw
attachment
• Footboard
Chassis with frame,
side grips and cover-
ing
> Tighten, replace.• Screw attachments, wel-
ded joints, damages
!
Wheel suspension and
wheels > Replace.
> Replace.
> Adjust, replace.
> Fit on new ones.
• Function and damage of
shock absorbers
• Wheel suspension
• Wheel bearing
• Tyre equipment
Hand brake > Adjust, replace.
> Tighten, adjust,
replace.
> Replace.
• Function
• Loose bowden wires, slee-
ves damaged
• Wear, damage of brake
discs and brake calipers
Drive and steering
asssembly > Adjust, replace.
> Adjust, replace.
• Check function in driving
and freewheel operation
• Check toggle link
Chapter
7.1
7.5
7.3
7.5
8.1
8.2
bis
8.4
8.5
9.0
7.2

7
Component
Batteries
Action
> Clean contacts, replace
battery or box
> Tighten, replace.
> Charge battery, replace.
Check
• Damage of battery and
box, corrosion on
contacts
• Check of contacts and
pole clips
• Check battery voltage
!
Light-servo module
and lighting system > Replace cable, connector or module.
> Replace lights.
> Replace light bulbs.
• Function servo- and light
module
• Damage of lights
• Function of light bulbs
Speedometer > Replace batteries, cable,
connector, speedometer or
sensor.
• Check function
Drive electronic and
main module > Replace module.
> Replace cable, connector
or module.
• Status display flashes
• Voltage supply
Drive electronic
Remote
> Tighten, replace.
> Replace.
> Replace remote.
> Replace cable, connector
or panel.
• Attachment
• Cables, plug connec-
tions
• Function joystick
• Voltage supply
Chapter
10.1
bis
10.2
12.3
und
11.0
12.1
12.2
12.4

8
4.0 Operation troubles
4.1 General instructions
Do the following if there are any troubles in driving mode, at lighting system or power supply:
• Analyze the in 4.2 described troubleshooting.
• Check the status display at remote and analyze the error codes like in chapter 5.1.
• Do the required checks / repair work. Note the cross references in the appertaining chapters in the manual or
in the appertaining documentation.
Drive motor / steering
servo motor disengaged
Battery defective
Battery deep
discharged
Power supply
interrupted
Engage motors
Replace battery
Pre-charge battery
check overload
protector
check voltage at
remote
check voltage at
main module
Status display at
remote off
Status display at
remote flashes
Microswitch defective
(nur TÜV-Version 10 km/h)
Motor defective
Incorrect program-
ming Check program- ming
Replace motor
Check microswitch
Error code 1 - 12 Check error code
Wheelchair doesn´t drive
Störungen
Drive motor runs in a jerky manner
Chapter 6.0
Chapter 10.1
Chapter 10.2
not correct
Chapter 12.2
Chapter 12.1
Chapter 5
not correct
Chapter 9.1
Manual for pro-
gramming unit or
PCD-software
4.2 Troubleshooting

9
Remote defective Replace remote
Switch remote off
and on
Joystick not in
neutral position
when switch on
Status display flashes, after 4 sec. the
driving mode display also flashes
Chapter 12.2
Chapter 12.2
Motor defective
Incorrect program-
ming Check program- ming
Replace motor
Steering servo motor reacts slowly /
irregularly
Chapter 9.1
Manual for pro-
gramming unit or
PCD-software
Light-/servo modu-
le defective Replace light- /servo module Chapter 12.3
Cable / connector
defective Check / replace cable / connector
Replace light bulb
Light bulb defec-
tive
Lighting system defective
Chapterl 11.1/11.2
Chapter 11.1/11.2
Light-/servo modu-
le defective Replace light- /servo module Chapter 12.3
Störungen
Charging unit
defective Replace charging unit
Replace battery
Battery defective
Charging batteries impossible
chapter 10.1
Chapter 10.3
Signal horn defective Replace remote Chapter 12.2
Speedometer defective Replace speedo-
meter Chapter 12.4

10
5.0 Error messages at remote
5.1 Error codes of remote
The following error codes refer to the G40 standard model with remote, main module and servo-/light module.
Do the follwing check before analyzing the error codes:
• Switch on and off the remote several times.
Wait five sec. before switching on again.
This check determines whether the error can automatically be corrected by the electronic system in which case
the flashing of status display is automatically deactivated.
If this is not the case, localize the error with the flash code.
2 x flashes
Flash codes on remote status display:
1 x flash Elektronic module defective
Steering servo disengaged
5 x flashes Motor connection loose/defective
Drive motor defective Check/replace motor
Check/replace cable/connector
6 x flashes
Brake error at motor Check motor brake
Motor connection loose/defective Check/replace cable/connector
4 x flashes Motor connection loose/defective Check/replace cable/connector
Drive motor defective Check/replace motor
3 x flashes Drive motor disengaged* Engage motor (Driving mode)
* Flash code can only be activated when you move the joystick in freewheel operation.
Check / replace status display of
modules
Cable/connector loose, defective
Servo-/light module defective
Back turn signal bulb defective **
Short circuit in Lighting system
Engage servo (Driving mode)
Check/replace connector/cable
Replace servo-/light module
Replace turn signal bulb
Check lighting system
Steering servo motor defective Check/replace servo motor
Check/replace motor
Chapter 12.0
Chapter 9.2
Chapter 13.0
Chapter 12.3
Chapter 9.2
Chapter 11.2
Chapter 11.0
Chapter 9.1
Chapter 19.0
Chapter 9.1
Chapter 13.0
Chapter 9.1
Chapter 9.1
Chapter 9.1
Chapter 9.1
** Flash code can only be activated when the turn signal is also switched on.
The flash codes can be generally deactivated by switching off and on at remote.

11
7 x flashes Battery deep discharged
9 x flashes Incorrect data transfer bet-
ween the modules
10 x flashes
11 x flashes Power-assisted steering- or
drive motor overloaded Switch off and on the remote
12 x flashes Compatibilityproblems bet-
ween the modules
8 x flashes Battery voltage too high
Chapter 10.2
Charge batteries
Chapter 10.3
Check charging unit
Check modules and Programming,
inform INVACARE-service Chapter 14.0
Repair by INVACARE-service
necessary

12
6.0 Arrangement of assemblies, components and features
G40, front view
G40, side view
1 Leg rests complete, appertaining to seat
system
2 Chassiscovering
3 Seat shell, appertaining to seat system
4 Seat padding, appertaining to seat system
5 Back padding, appertaining to seat system
6 Mirror
7 Front lighting system, integrated in
seat shell
8 Front wheels, powered
9 Back wheel, steerable
10 Frame with back shell 11 and grip
grip 12
13 Sides complete with arm rests
14 Side grip
15 Covering
16 Remote with speedometer
17 Hand brake complete with brake
disc 18
19 Back rest adjusting, complete
20 Walking stick holder
21 Walking stick loop
The following illustrations show the arrangement of the main assemblies, components and features for right-
handed people. The terms are the same as the component terms in the replacement parts catalog.
3
4
56
1
1
77
2
8
8
9
28
9
11 13
14
15
16
17
18
19
20
12
10
21

13
1 Chassis (Tube frame back, bottom)
2 Seat frame, appertaining to seat system
3 Seat shell with indentations for electronic
modules
4 Locking mechanism of seat support for
service
5 Locking mechanism of seat in closed
position
6 Gas spring for back rest adjusting
7 Batteries in battery box
8 Battery box
9 Cable form for drive motor
G40, service view
22
33
4
5
7
6
7
9
11
10
G40, back view
10 Disengaging lever for drive motor
11 Cable form for servo-/light module
12 Lighting system back, integrated in chassis
13 Shock absorbers, back
14 Steering rod, appertaining to power-assisted
steering
1
12 12
13 13
14 14
15 G40, bottom view
16
17
8
18
19
1
1
20 20
15 Disengaging lever for servo motor
16 Gear box with front axle
17 Drive motor, flange mounted to gear box
18 Main module of drive electronics
19 Servo steering with motor
20 Wheel suspension, back
8

14
7.0 Checks and repair work at seat system
7.1 Arm rests and sides
• Arm rest damaged?
• Screws of arm rest loose?
• Bag damaged?
• Side covering damaged?
• Arm rest tube frame damaged?
• Side mount damaged?
• Clip lever damaged?
• Mirror damaged?
> Replace arm rest.
> Tighten screws.
> Replace bag.
> Replace side covering.
> Replace arm rest tube frame.
> Replace side mount.
> Replace clip lever.
> Replace mirror.
Check Action
Right side, complete Left side, complete
1
3
1
22
5
56
6
7
8
13
10
12, 11 12, 11
9
1 Arm rest tube frame 2 Arm rest
3 Side covering 4 Bag (not illustrated)
5 Side mount 6 Clip lever M8x60
7 Mirror 8 Wing screw M6x10
9 Hexagon head screw M6x16 10 Nut M8, self locking with cap
11 Hexagon head screw M5x35 12 Disc 5,4
13 Nut M8
Complete disassembly
• Bring seat system in service position and arrest.
• Release wing screw (8) and draw off sides with arm rest sideways away from chassis.
• Release clip lever and draw off side mount downwards.
• Release bag (4) from side covering (3) (velcro fastener).
• Release screws (11) with discs (12) at side covering and draw off arm rest (2).
• Release plastic rivets at bottom of side covering with a screw driver and draw off side covering (3)
from arm rest tube frame.
• Remove cap, release nut (10) and draw off mirror (7) out of arm rest tube frame (1).
Assembly
• The assembly is carried out in reverse order.
NOTE:
If there´s an arm rest with integrated remote:
Switch off wheelchair, take plug out of remote, release remote and take it out of arm rest.

15
7.2 Legrests
Legrests compl. Legrest
Parts
1 Legrest, top 2 Insertion tube 3 Footplate mount
4 Footplate 5 Calfsupport holder 6 Calfsupport
7 Calf pad mount 8 Calfsupport pivot 9 2 Plastic discs 17x6,5
10 Clamping lever M6x10 11 Hexagon head screw M6x10 12 Fillister-head screw M6x16
13 Countersunk screw M5x25 14 Nut M5 (self locking) 15 Screw M6x45
16 Nut M6 17 Nut M8 18 Disc 8,4
19 Fillister-head self-tapping screw 20 Hat nut M6 21 Slide SL 18
22 Slide F30x15 23 Clamping sleeve 5x20 (Not shown, belongs to 7 and 8.)
2
2
1
2
3
4
4
4
5
66
6
1
2
7
8
9
22
11
20
15,16 21
19
12
17
18
13
14
10
• Screws loose?
• Calfsupport damaged?
• Footplate damaged?
• Footplate mount damaged?
• Welded joints or insertion tube defective?
• Welded joints or top legrest defective?
• Calfsupport pivot goes heavily, defective?
• Slides missing or damaged?
> Tighten screws.
> Replace calfsupport.
> Replace footplate.
> Replace footplate mount.
> Replace insertion tube.
> Replace top of legrest.
> Make pivot moving or replace.
> Replace slide.
Check Action
Complete disassembly:
• Bring seat system in service position and arrest.
• Release clamping lever (10) and draw off legrest from chassis.
• Release hexagon head screw und draw off top of legrest from insertion tube.
• Release fillister-head screwand draw off calfsupport.
• Release countersunk screws (13 and nuts (14) and remove calf pad mount(7).
• Remove nut (17) and disc (18)and remove calfsupport holder (5) from pivot (8).
• Remove clamping sleeve (23) and remove calfsupport pivot (8) from clip part (7).
• Remove tin screws (19) and draw off footplate (4) from footplate mount.
• Remove screw (15) with hatnut (20) and discs (9) and draw off footplate mount from insertion tube.
• Release slide (21/22) from footplate mount/top of legrest with a screwdriver.
Assembly
• Assembly is carried out in reverse order.
NOTE:
• The screw (15) with nut (16) serves for adjusting of footplate.
• Don´t tighten the screw (15) with hatnut (20) and nut (17) too strong.

16
7.3 Backrest with frame, padding and grip
Backrest, front view, without padding Backrest, back view
1
1
2
15 15
14 10
11, 12
13
7, 8
3, 4, 5, 16
10
1 Back shell 2 Backframe
3 Backmount socket 4 Starlock caps 16,0
5 Disc 17,0 6 Backpadding (not shown)
7 Clutch part for gas spring 8 Wing screw M6x10
9 Safety belt (not shown) 10 Mounting plate for safety belt
11 Hexagon head screw M6x20 12 Disc 6,4
13 Threaded bolt M6x6 14 Walking stick loop
15 Grip 16 Chassis
2
• Backpadding damaged?
• Screws at backframe loose?
Backshell damaged?
• Backframe damaged, welded joints
defective?
• Grip damaged?
• Walking stick loop damaged?
• Safety belt damaged?
• Backframe does not go easily?
> Replace backpadding.
> Tighten screws.
> Replace back shell.
> Replace backframe.
> Replace grip.
> Replace walking stick holder.
> Replace safety belt.
> Make moving or replace backmount socket.
Check Action
Complete disassembly:
• Draw off backpadding from seat shell (velcro fasteners).
• Release crosstip screw and remove walking stick loop (14).
• Release threaded bolts (13) and pull out grip (15).
• Release wing screw (8) and pull out clutch part from backframe (2) downwards.
• Release hexagon head screws (11) with discs (12) and remove safety belt (9) with mounting plate (10).
• Pull out backshell (1) from backframe (2) downwards.
• Note position of discs (5).
• Release starlock caps (4) with a flat screwdriver and remove backmount socket (3) with discs (5).
• Remove backframe (2) from chassis.

17
Assembly
• Assembly is carried out in reverse order.
For assembly of backframe at chassis do the following:
• Positon chassis, back- and side frame so, that you can insert backmount socket (3) with discs.
• Put in the starlock caps into the pliers as you can see below.
• Position pliers with caps (4) on both sides on the backmount socket and tighten.
• Tighten pliers with a ring spanner until the caps are completely pressed on.
• Release starlock pliers and take off.
• Complete assembly of backrest.
NOTE:
• Use new starlock caps (4) for assembly.
• During assembly of backframe (2) take care, that the discs (5) are pushed into the backmount socket
in right order.
Starlock pliers with caps Insertion of caps
4

18
7.4 Backrestadjusting
Check gas spring and bowden wire!
• Bowden wire defective?
• Bowden wire sleeve defective?
• Gas spring defective?
• Trip lever does not move easily or is defective?
• Fork defective?
• Hanger assembly of gas spring does not move
easily?
• Clutch defective?
• Adjusting defective?
> Readjust bowden wire.
> Replace bowden wire.
> Replace bowden wire sleeve.
> Replace gas spring.
> Make moving or replace trip lever
> Replace fork.
> Make moving hanger assembly or replace
screwing.
> Replace clutch.
> Replace adjusting lever.
Check Action
Complete disassembly
• Release wing screw (10) and draw off clutch (9) from backframe (8).
• Bring seat system in service position and arrest.
• Release hexagon head screw with nut and discs and take off fork (2) from seat frame.
• Turn gas spring (1)out of fork (2).
• Release screw (11) with nut (13) and discs (12) and take off clutch (9) from gas spring (1).
• Release clamping screws (5) and nuts and screw out adjusting screws (4).
• Pinch off caps (15) from bowden wire (6) and take off bowden wire sleeve (7).
• Release screw and nut and take off trip lever(3) from fork (2).
Assembly
• Assembly is carried out in reverse order.
NOTE:
• Mark or note the position of adjusting screws beforedisassembly.
• Screw in gas spring at assembly until stop into fork.
• Adjust bowden wire so, that at screwed in gas spring??????????????????
• After drawing in a new bowden wire, caps must be squeezed on.
• The adjusting lever is stored in seat frame and arrested with a starlock cap. For disassembly you first
have to remove the seat shell. See chapter 7.5.
Gas spring and bow-
den wire compl.
1
2
3
46, 7
4
6, 7
9
10
8
11, 12, 13
1 Gas spring
2 Fork M10x1
3 Trip lever for gas spring
4 Adjustment screw
5 Clamping screw
6 Bowden wire
7 Bowden wire sleeve
8 Backframe
9 Clutch
10 Wing screw M6x10
11 Hexagon head screw
M10x35
12 2 discs 10,5
13 Nut M10
14 Adjusting lever for backrest
15 Cap for bowden wire
5
14
15

19
7.5 Seatframe, seat shell and padding
Complete disassembly
• Remove backframe and backshell. See chapter 7.3.
• Secure frame (1) with sockets and remove padding (3) from seat shell (2) (velcro fasteners).
• Release plug from light-/servomodule and take module out of seat shell (2).
• Bring seat in service position and fix it.
• Take off gas spring from seat frame and release bowden wire from gas spring.
• Remove plastic rivets with a screw driver and take off the front lighting carefully out of seat shell down-
wards.
• Draw off plug from connector row (6), remove cable connector, disengage lighting cable carefully and
remove lamps completely.
• Release screws from seat support and remove both parts of support from seatframe (1).
• Remove securing socket again and take off frame (1) with seat shell (2) from chassis.
• Press seat shell (2) at front and sides carefully outwards and take off from frame (1).
Assembly
• Assembly is carried out in reverse order.
• Padding damaged?
• Seat shell damaged?
• Seatframe warped or
welded joints defective?
• Screwed connections of lat-
ching mechanism loose?
• Latching mechanism warped
or defective?
> Replace padding.
> Replace seat shell.
> Straighten frame.
> Replace frame.
> Tighten screws.
> Straighten or replace.
Check Action
NOTE:
• Take care during disassembly / assembly that the cable forms to the front lighting,
to light-/servomodule and to remote run freely and aren´t damaged.
• Before disassembly of seatframe and seat shell you first have to remove backframe and backshell.
After that secure seatframe with fitting sockets at chassis.
Seatframe Seat shell
1 Seatframe 2 Seat shell
3 Padding (not shown) 4 Latching mechanism
5 Front lighting equipment, compl. 6 Connector row for lighting system
2
2
1
1
4
5
Light-/servo module
6

20
8.0 Checks and repair work at chassis
8.1 Chassiscovering, grips and cover coating
Disassembly side grip
• Bring seat system in service position and arrest.
• Remove caps (9), remove hexagon head screws (10) with discs (11) and take off grip (2) with rosettes
(4).
Assembly
• Assembly is carried out in reverse order.
• Cover coating loose or damaged?
• Side grip or rosette damaged?
• Chassiscovering damaged?
• Stick holder damaged?
> Stick or replace coating.
> Replace side grip or rosette.
> Replace chassiscovering.
> Replace stick holder.
Check Action
Chassiscovering Side grip
1
2
3
24
6
7
8
59, 10, 11
9, 10, 11
disassembly chassiscovering
• Remove hexagon head screws with nuts and take off stick holder (5).
• Release wing screw (8) and take off brake lever (7).
• Remove side grips (2) with rosettes (4).
• Remove the eight plastic rivets (6), two at sides, two at front, two at back.
For doing that you first must draw off the pins (in covering) with pliers out of the rivets.Then remove the
rivets from outside with a screwdriver.
• Take off chassiscovering from chassis upwards.
Assembly
• Assembly is carried out in reverse order.
1 Chassiscovering 2 Side grip 3 Cover coating
4 Rosettes 5 Stick holderr 6 Plastic rivet
7 Brake lever 8 Wing screw M6x10 9 Cap SKS 8
10 Hexagon head screw 11 Securing disc Schnorr M8
NOTE:
Before thedisassembly of chassiscovering you first must disassemble the seat system completely.
See chapter 7.1 to 7.5.