Invacare Kite User manual

Edition: 11.09.2013
Invacare
®
Kite
SERVICE MANUAL

SERVICE MANUAL
Invacare®- Kite
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 9
1.1 General information ..................................................................................................................9
1.2 Notes on shipping .....................................................................................................................9
1.3 Definition and representation of information and safety information in this manual ......10
1.4 Hazard symbols and symbols used.......................................................................................11
1.5 Images in this manual.............................................................................................................12
2Safety and fitting instructions 13
2.1 Before any inspection or repair work....................................................................................13
2.2 Personal safety equipment.....................................................................................................13
2.3 General safety information and information about fitting / removal..................................13
3Tightening torques 15
4Layout of components and componentry 16
4.1 Overview...................................................................................................................................16
4.2 Overview of the electronic modules (ACS 2 system)...........................................................17
4.2.1 ACS 2 70 / ACS 2 70L / ACS 2 90L electronic module.................................................19
4.2.2 ACS 2 90LG electronic module ....................................................................................19
4.2.3 ACT actuator module....................................................................................................19
4.2.3.1 ACT 2 actuator module............................................................................................19
4.2.3.2 ACT 4 actuator module............................................................................................20
4.2.4 Lighting PCB.................................................................................................................20
5Service plan (1x annually) 21
6Operational faults 23
6.1 Drive fault diagnosis ...............................................................................................................23
6.2 ACS2 remotes: Error codes and diagnostic codes..............................................................25
7Test procedures 26
7.1 Testing the motor....................................................................................................................26
7.2 Testing the electro-mechanical parking brake.....................................................................27
7.3 Checking an actuator..............................................................................................................29

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8Repair work 30
8.1 Covers.......................................................................................................................................30
8.1.1 Rear cover ....................................................................................................................30
8.1.2 Middle cover..................................................................................................................31
8.1.3 Side cover.....................................................................................................................32
8.1.4 Front cover....................................................................................................................33
8.1.5 Replacing a front splash guard.....................................................................................34
8.1.6 Replacing the splash guard ..........................................................................................35
8.2 Electronic modules..................................................................................................................36
8.2.1 Replacing the power module ........................................................................................36
8.2.2 Replacing the actuator module.....................................................................................38
8.2.3 Replacing the G-Trac sensor........................................................................................39
8.2.4 Replacing the lighting circuit board...............................................................................40
8.2.5 Replace remote ............................................................................................................41
8.2.6 Drive program selection after component replacement................................................42
8.2.6.1 Profile selection with remote REM A or REM B.......................................................42
8.2.6.2 Profile selection with remote REM 550....................................................................43
8.3 Updating the driving program................................................................................................44
8.4 Batteries ...................................................................................................................................45
8.4.1 Removing the batteries.................................................................................................45
8.4.2 Correct handling of damaged batteries.........................................................................48
8.5 Checking and replacing the main fuse..................................................................................49
8.6 Checking the cables................................................................................................................51
8.7 Lighting system.......................................................................................................................52
8.7.1 Replacing front headlight completely (LED lighting unit) ..............................................52
8.7.2 Replacing the front bulb holder (LED lighting unit) .......................................................54
8.7.3 Replacing the rear light completely (LED lighting unit).................................................55
8.7.4 Replacing light bulbs in the front (Conventional lighting system)..................................56
8.7.5 Replacing the head lamps completely (conventional lighting system)..........................57
8.7.6 Replacing the headlight bracket (conventional lighting system)...................................59
8.7.7 Replacing the rear bulb (conventional lighting unit)......................................................61
8.7.8 Replacing the complete tail light assembly (conventional lighting system)...................62
8.7.9 Replacing the tail light bracket (conventional lighting system)......................................63
8.8 Front wheels ............................................................................................................................64
8.8.1 Repairing a flat tire in the front......................................................................................64
8.8.2 Replacing the steering head bearings on the steering wheels .....................................64
8.8.3 Changing a front wheel (normal front wheel)................................................................67
8.8.4 Changing a front wheel (suspended front wheel) .........................................................69

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8.9 Drive wheels.............................................................................................................................70
8.9.1 Replacing the drive wheel.............................................................................................70
8.9.2 Replacing a tyre or inner tube.......................................................................................71
8.9.2.1 Replacing puncture-protected tyres.........................................................................71
8.9.2.2 Replacing puncture-proof tyres................................................................................73
8.9.3 Replacing the drive wheel hub......................................................................................74
8.10 Drive unit..................................................................................................................................75
8.10.1 Replacing the motor/transmission unit..........................................................................75
8.10.2 Replacing or rotating the motor / gearbox unit sealing ring ..........................................77
8.10.3 Replacing the motor / gearbox coupling.......................................................................78
8.10.4 Replacing the carbon brushes......................................................................................80
8.11 Replacing the rubber shock absorbers.................................................................................82
8.12 Replacing the tube frame........................................................................................................84
8.13 Replacing the double bearing of the Dual Swing Technology (D.S.T.)..............................86
8.14 Replacing the battery boxes...................................................................................................88
8.15 Seat system..............................................................................................................................89
8.15.1 Replacing the tilt actuator .............................................................................................89
8.15.2 Replacing the tilt module...............................................................................................91
8.15.3 Replacing the lifter / tilt module.....................................................................................93
8.16 Backrest unit............................................................................................................................97
8.16.1 Replacing the standard backrest..................................................................................97
8.16.2 Replacing a standard backrest with quick release........................................................99
8.16.3 Replacing a Flex2 backrest ........................................................................................100
8.16.4 Adjusting backrest former...........................................................................................101
8.17 Seat system Modulite............................................................................................................102
8.17.1 Replacing the tilt actuator ...........................................................................................102
8.17.2 Replacing the lifter actuator........................................................................................103
8.17.3 Replacing the lifter / seat angle adjustment module...................................................104
8.17.4 Replacing the backrest actuator.................................................................................107
8.18 Backrest Modulite..................................................................................................................108
8.18.1 Replacing the standard backrest................................................................................108
8.18.2 Replacing the backrest mounting bracket ..................................................................109
8.18.3 Replacing the backrest mounting bracket for SB 53 ..................................................110
8.19 Adjusting the seat width/ backrest width (Modulite) .........................................................111
8.19.1 Adjusting the seat width..............................................................................................111
8.19.2 Adjusting the backrest width.......................................................................................113
8.19.3 Adjusting the Flex3 backrest.......................................................................................115

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9Installing accessories 116
9.1 Replacing the holding strap.................................................................................................116
9.2 Replacing seat belts (Modulite seat) ...................................................................................117
9.2.1 Installation on the backrest mounting bracket (simple backrest)................................117
9.2.2 Installation on the backrest mounting bracket (adjustable seat).................................118
9.2.3 Installation on the seat frame profile (adjustable seat)...............................................119
9.3 Operating hours counter ......................................................................................................120
9.3.1 Replacing the operating hours counter.......................................................................120
9.3.2 Replacing the connecting cable of the operating hours counter.................................122
9.4 Luggage carrier......................................................................................................................124
9.5 Further accessories...............................................................................................................125
10 Adjusting the seating position 126
10.1 Adjusting the lower leg length and seat depth...................................................................127
10.1.1 Adjusting the lower leg length.....................................................................................127
10.1.2 Adjusting the seat depth .............................................................................................127
10.2 Adjusting the seat angle .......................................................................................................128
10.2.1 12° Adjusting the seat angle with Standard seat or Flex2 seat ..................................129
10.2.2 20° Adjusting the seat angle Flex2 seat or Modulite seat...........................................131
10.3 Adjusting the center of gravity of the seat..........................................................................133
10.3.1 Standard seat..............................................................................................................137
10.3.2 Flex2 seat ...................................................................................................................138
10.3.3 Modulite seat...............................................................................................................141
10.3.3.1 Adjustable seats ....................................................................................................143
10.3.3.2 Simple seat............................................................................................................144

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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) G-Trac sensor
2) Power module
3) Lighting PCB
4) Actuator module
The electronic modules used are
described in Chapter 4.2.
Electric seat tilting:
1) Actuator motor

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4.2 Overview of the electronic modules (ACS 2 system)
Different electronic modules can be fitted to the mobility aid.
1
2
3
4
5
6
7
8
9
Battery plug
Lighting cable
Contact bridge
Lighting circuit board
Lighting according to German
Road Traffic Act (StVZO).
LED lighting
Extension cable
Actuator cable lifter
Extension cable
10
11
12
13
14
15
16
End position switch "lower
position"
End position switch "upper
position"
Remotes
ACS attendant control,
switchable
Bus cables
Bus cables
ACT
17
18
19
A
B
C
D
E
F
G
G-Trac sensor
Bus cables
Power module
To the motor M1
To the motor M2
To the tilt actuator
To the lifter actuator
To the lifter actuator
Actuator left legrest
Actuator right legrest

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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 ACS 2
modules.
Electronicmodule Name Description
ACS 2 70
ACS 2 70L
ACS 2 90L
ACS 2 90L G
ACS 2 wiith ACT actuator module
See chapter 4.2.1
See chapter 4.2.1
See chapter 4.2.1
See chapter 4.2.2
See chapter 4.2.3
The actuator module is
optional.
Actuator module
ACT 2
ACT 4
See chapter 4.2.3.1
See chapter 4.2.3.2
The actuator module is
optional.
Lighting PCB See chapter 4.2.4
The lighting PCB is optional.
G-Trac sensor The G-Trac sensor is
optional.
Operation hour counter The operation hour counter
is optional.

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4.2.1 ACS 2 70 / ACS 2 70L / ACS 2 90L 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 (optional)
6) Motor M2
Rubber stoppers for free slots
2) & 3) Order number: 1552876
4.2.2 ACS 2 90LG electronic module
Connections
7) Battery 24V
8) Cable to G-Trac sensor (GYRO)
9) Bus cable (to remote or ACT)
10) Motor M1
11) Light
12) Motor M2
4.2.3 ACT actuator module
Different adjusting motors, also known as actuators, can be fitted to the mobility aid. These
actuators are either connected directly to the power module or to a separate actuator module. The
actuator module is connected to the power module via a bus cable.
4.2.3.1 ACT 2 actuator module
Connections
1) ACI*
2) Bus cable (ACT or power module)
3) Bus cable (ACT or power module)
4) Actuator - Channel 2
5) Actuator - Channel 1
Rubber stoppers for free slots
1) Order number: 1555701
2) & 3) Order number: 1552876
4) & 5) Order number: 1555700
* The ACI connection is used for actuator limitation or speed reduction.

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4.2.3.2 ACT 4 actuator module
Connections
1) ACI*
2) Bus cable (ACT or power module)
3) Bus cable (ACT or power module)
4) Actuator - Channel 4
5) Actuator - Channel 3
6) Actuator - Channel 2
7) Actuator - Channel 1
Rubber stoppers for free slots
1) Order number: 1555701
2) & 3) Order number: 1552876
4) to 7) Order number: 1555700
* The ACI connection is used for actuator limitation or speed reduction.
4.2.4 Lighting PCB
Connections
1) Driving light & l.h. indicator 1
2) Driving light & l.h. indicator 2
3) Power module
4) Driving light & r.h. indicator 1
5) Driving light & r.h. indicator 2
The lighting PCB connections are printed directly on the circuit board.