Invacare G50 Operating instructions

Invacare
®
G50
SERVICE INSTRUCTIONS
Edition: 20.03.11

SERVICE INSTRUCTIONS Invacare®- G50
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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

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(Kundtjänst): [phone]
Återförsäljare:
Invacare® AB
Fagerstagatan 9
S-163 91 Spånga
Sverige
Tillverkare:
Invacare® Deutschland GmbH
Kleiststraße 49
D-32457 Porta Westfalica
Deutschland
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

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Table of Contents
Chapter Page
TABLE OF CONTENTS 5
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
4ALLOCATION OF THE SUB-ASSEMBLIES AND COMPONENTS 15
5MAINTENANCE PLAN (ONCE A YEAR) 16
6OPERATIONAL FAULTS 19
6.1 Operational faults on wheelchair with ACS 19
6.1.1 Diagnosing drive faults 19
6.1.2 Diagnosing problems with electric actuators 21
6.1.3 Error Codes and Diagnostic Codes 22
7REPAIR WORK 26
7.1 General warning information on installation work 26
7.2 Replacing front cowling 27
7.2.1 Disassembly 27
7.2.2 Assembly 28
7.3 Replacing rear cowling / replacing rear lights 29
7.3.1 Disassembly 29
7.3.2 Assembly 30

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7.4 Replacing the side cowling 31
7.4.1 Placing seat in service position 31
7.4.2 Remove the rear cowling 32
7.4.3 Removing the side cowling 33
7.4.4 Assembly 36
7.5 Replacing the headlights 37
7.5.1 Placing seat in service position 37
7.5.2 Unmounting the headlights 39
7.5.3 Assembly 40
7.6 Replacing a motor 41
7.6.1 Disassembly 41
7.6.2 Assembly 46
7.7 Replacing the rear rocker / adjusting toe and camber 48
7.7.1 Disassembly 48
7.7.2 Assembly 51
7.7.3 Adjusting the camber 52
7.7.4 Adjusting the toe-in 52
7.8 Replacing the front shock absorbers 54
7.8.1 Disassembly 54
7.8.2 Assembly 58
7.9 Replacing the Bowden cable of the hand brake / adjusting the brake 59
7.9.1 Replacing the Bowden cable 59
7.9.2 Assembly 63
7.9.3 Adjusting the hand brake 63
7.10 Replacing the Bowden cable of the declutching mechanism 65
7.10.1 Replacing the Bowden cable 65
7.10.2 Assembly 69
7.11 Replacing the seat frame (EBAS) 70
7.11.1 Placing seat in service position 70
7.11.2 Disassembly 72
7.11.3 Assembly 76
7.12 Replacing electronics components 77
7.12.1 Replacing the power module 77
7.12.2 Replacing other electronic components 78
7.13 Changing the batteries 79
7.13.1 Tilting the seating system forward 80
7.13.2 Removing the batteries 81
7.13.3 Connecting the New Batteries 82
7.13.4 How to handle damaged batteries correctly 83
7.14 Checking and replacing the main fuse 84
7.14.1 Placing seat in service position 84
7.15 Checking the cables 87
7.15.1 Placing seat in service position 87
7.16 Replacing the ACS Remote 90
7.17 Updating the driving program 92

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7.18 Retrofitting the joystick left/right 93
7.18.1 Placing seat in service position 93
7.18.2 Retrofitting 95
7.19 Repairing a flat tyre 97
7.19.1 Repairing a flat tyre (type 4.00-8" pneumatic tyres) 97
7.19.2 Repairing a flat tyre (type 3.10/4.50-6 pneumatic tyres) 99
7.20 Replacing the safety belt 101
7.21 Testing an actuator motor 101
8REFURBISHMENT 102
8.1 Configuration table 102

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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.