Invacare PHOENIX PLUS User manual

PHOENIX PLUS
SERVICE GUIDE
PART NO: 1420254

INTRODUCTION
1) This manual provides basic details to enable the PHOENIX Wheelchair to be
maintained. It is not intended to be a comprehensive maintenance guide/policy, but is
intended for use by competent personnel to enable the chair to adequately maintained.
2) The manual includes detailing assemblies that are maintainable and the relevant
procedures.
3) The Wheelchair is manufactured by:
INVACARE Ltd
South Road
Bridgend Industrial Estate
Bridgend
Mid-Glamorgan
CF31 3PY
SALES TEL NO: 01656 647327 TECHNICAL SERVICE TEL NO: 01656 753337
FAX NO: 01656 649016 FAX NO: 01656 753299
4) For TECHNICAL ADVICE, repairs, servicing, contact Technical Services.
For SPARE PARTS orders contact Sales.
5) Quote the following details at all times:
5.1 Part Number
5.2 Description
5.3 Quantity required
5.4 Serial Number
5.5 Chair Type

POLICY
INVACARE Ltd repair is as follows:
Repairs to ANY component other than those detailed in this manual are not covered. Repairs
to ANY tube metal work is not generally permitted without express permission of INVACARE
Ltd. ALL fasteners i.e. bolts, Nyloc nuts, and any fastener showing damage MUST be
renewed.
In the event of repairing a crash damaged Vehicle we strongly advise you contact INVACARE
TECHNICAL SERVICES DEPARTMENT before proceeding with repairs.
Failure to comply with the above absolves INVACARE Ltd of liability.
Note: Certain components will require removal to carry out maintenance. With the exception
of fasteners, those components should be refitted.

CONTENTS
Page
- Armrests 1
- Upholstery and Back Seat Cloth 2
- Castor Wheel & Fork 3
- Rear Wheel & Tyres 6
- Footrest 8
- Mechanical Brake 9
- Batteries & Charger 10
- Motor Assembly 13
- Gearbox Assembly 15
- Controller with Integral Joystick Remote (DL. 40) 17
- What to do in the event of a fault 18
- Troubleshooting 19
- Diagnostics 19
- Frame & Chassis 22

TOOLS REQUIRED
THE FOLLOWING LIST DETAILS THE BASIC TOOLS REQUIRED TO CARRY OUT THE
MAINTENANCE GIVEN IN THE FOLLOWING CHAPTERS.
2 - Open End Spanner (13mm)
1 - Open End Spanner (11mm)
2 - Open End Spanner (10mm)
1 - Open End Spanner (8mm)
1 - 1/4" BSW Open End Spanner
1 - Combination Spanner (19mm)
1 - Socket / Wrench (Shallow) (19mm)
1 - Phillips Screwdriver (No 1)
1 - Flat Bladed Screwdriver (No 1)
1 - Nylon Mallet
1 - Torque Wrench
1 - Allen Key - (6mm)
1 - Allen Key - (5mm)
1 - Allen Key - (3mm)
1 - Allen Key - (4mm)
1 - Knife
1 - Pressure Gauge
2 - Tyre Levers
1 - Pump
1 - Drift
1 - Vice
1 - Talcum Powder
1 - Valve Remover
1 - Multi-Meter
1 - Soldering Iron
1 - Pin Hammer
1 - Punch
1 - Pair Pliers
1 - Battery Discharge Tester
1 - HHP - ProgrammerNOTE: THE ABOVE LIST IS NOT EXHAUSTIVE

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ARM REST
PARTS:
1. Armrest Pad Bracket
2. Hand Knob
3. Armrest Bracket
4. Arm Upright Assembly
5. Washer
6. Cap
7. Screw
8. Skirt Guard
9. Screw (Allen)
10. Armpad Fixing Screws
11. Armrest Pad
Tools Required:
No1 Phillips Screwdriver
Flat Headed Screwdriver
6mm Allen Key
INTRODUCTION
STEP 1
Check that the skirtguard is fixed and not physically damaged. If the panel is loose re-
tighten the fixing screw, install a new panel if necessary.
STEP 2
Check for armpad wear or damage. Replace if necessary.
STEP 3
Check for corrosion or paint damage to the bracketry and replace affected parts where
necessary.
DISMANTLING
STEP 1
Remove the handknob by rotating it anti-clockwise. Pull out the arm assembly.
STEP 2
Remove the two armpad fixing screws under the armpad and remove the armpad.
STEP 3
Remove the allen screw and pull out the armpad bracket.
STEP 4
Carefully remove the 2 caps with a flat headed screwdriver, remove the 2 phillips screws and
remove the skirtguard. Take care not to loosen the washers.
To re-assemble reverse step 4 to 1 taking care not to over tighten the fixing screws as this
could cause burrs and split the plastic washer.
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UPHOLSTERY AND BACK/SEAT CLOTH
PARTS:
1. One Piece Backrest Complete
2. One Piece Backpost
3. Taptite Screw
4. Upholstery Washer
5. Seat Upholstery
6. 40cm High Back Upholstery
Tools Required:
No1 Phillips Screwdriver
INTRODUCTION
STEP 1
Check that the upholstery does not sag and is not unevenly stretched, torn or excessively
worn, paying attention to the adjustment features within the tension adjustable back
upholstery.
STEP 2
Check that all stitches are in good condition.
STEP 3
Check that all screws and washers are tight and free of sharp edges and burrs.
DISMANTLING
STEP 1
Remove all fixing screws and detach upholstery from tubework.
To re-assemble reverse above procedure ensuring that the fixing holes in the upholstery and
tubes are properly aligned.
NOTE:
TAKE CARE NOT TO OVER TIGHTEN SCREWS AS THIS MIGHT CAUSE BURRS.
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CASTOR WHEEL AND FORK
PARTS:
1. Castor fork
2. Washer
3. Nyloc Nut
4. Axle Bolt
5. Nyloc Nut
6. Pneumatic Castor
7. Bearing
8. Tyre
9. Inner Tube
10. Hub Centre
11. Castor Wheel
12. Fork Stem
13. Bearings
Tools Required:
19mm Socket Spanner x 2
Flat Bladed Screwdriver
Mallet
Pressure Gauge
Tyre Levers
Pump
Drift
INTRODUCTION
STEP 1
Check castor wheels are not buckled or physically damaged. Replace if required.
STEP 2
Check that the wheel bearings run freely without excessive play.
STEP 3
Check that the castor wheel and fork nuts are tight.
STEP 4
Check that the castor forks are bent or damaged.
STEP 5
Check the crown/castor fork bearings for wear and correct adjustment.
STEP 6
Check tyres for wear and correct inflation. Both wheels should show the same degree of wear
(see side of tyre pressure rating). For tyre fitment see rear tyre section.
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CASTOR WHEEL AND FORK
DISMANTLING
STEP 1
Remove castor socket cap with flat bladed screw driver, hold the lower fork stem nut secure
with 19mm spanner and remove the upper fork stem nut.
STEP 2
Gently tap the threaded end to the fork stem with a mallet taking care not to damage the
threads. Remove the castor fork assemblies
STEP 3
Lever out the top fork bearings carefully, using the fork stem as a lever. Take care not to
damage the threads.
STEP 4
Remove the castor fork bearings using a drift and a mallet, tapping gently to avoid damaging
the castor socket and bearing.
STEP 5
To remove the castor wheels undo the axle nut with a 13mm spanner using a second
spanner at the other end of the axle to lock against rotation. Remove the axle bolt and
remove the wheel from the fork.
STEP 6
Remove the bearings by hand.
To reassemble reverse step 6 & 7, but adjust tightness of nut until the wheel runs freely to a
gradual halt.
a) If the wheel stops abruptly, loosen the castor axle nut.
b) If the wheel wobbles (sideplay), tighten the castor axle nut enough to allow free spinning
without sideplay.
TO RE-ASSEMBLE
STEP 1
Insert the fork stem bearings using a mallet and drift across the bearing to prevent damage.
STEP 2
Start at the bottom and place the threaded end of the fork stem through both bearings and in
the castor fork socket.
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CASTOR WHEEL AND FORK
TO RE-ASSEMBLE
STEP 3
Locate fork stem nut on the threaded end of the stem and tighten with a 19mm spanner just
enough to allow the fork to swivel freely.
STEP 4
To check for correct tightness, preform the following test:
a) Tip chair backwards and rest the push handles on the floor (remove the battery boxes
first).
b) Raise castor wheel towards ceiling, then gently push downward to either side. The wheel
and fork should freely rotate down and hang straight towards the floor after a pendulum -
type swing.
NOTE:
IF THE WHEEL STOPS ANGLED TO ONE SIDE, LOOSEN THE FORK STEM NUT
SLIGHTLY. IF THE WHEEL CONTINUES TO SWING TO BOTH SIDES ( LIKE A
PENDULUM), TIGHTEN THE FORK STEM NUT SLIGHTLY. CHECK BEARINGS FOR
EXCESSIVE PLAY BY GENTLY ROCKING THE FORK ASSEMBLY.
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REAR WHEEL AND TYRES
PARTS:
1. Tyre
2. Inner Tube
3. Outer Rim
Inner Rim
4. Socket Head Cap Screw
5. Washer
6. Wheel Bolts
7. Wheel Hub
8. Key
Tools Required:
Allen Key 6mm
Spanner 13mm
Mallet
Tyre Levers
Pressure Gauge
Pump
Vice
Talcum Powder
Valve Remover
Flat Bladed Screwdriver
DISMANTLING
ALLOY TYPE WHEELS
INSPECTION
STEP 1
Check wheel is not buckled or physically damaged. Replace if required.
STEP2
Check tyres for wear and correct inflation, both wheels should allow the same degree of wear
(see side of tyre for pressure rating).
DISMANTLING
STEP 1
Jack up one of the gearboxes to lift one wheel off the floor.
STEP 2
Remove the 5 M8 Wheel Bolts securing the Wheel to the Wheel Hub. Remove the Wheel.
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STEP 3
Deflate the tyre, locate, loosen and remove Socket Head Cap Screw securing the two halves of
the Wheel Rims together. Important note: Ensure the tyre is fully deflated before attempting
to separate to the two halves of the Wheel Rims.
STEP 4
Remove the tyre and tube.
STEP 5
To remove the Wheel Hub from the Axle Shaft locate loosen and remove the Wheel Hub Bolt
securing the Wheel Hub to the Axle Shaft.
STEP 6
Gently tap the wheel centre with a mallet and pull the wheel off the gear box shaft (take care not
to loose the key located in the gearbox shaft).
TO RE-ASSEMBLE
STEP 1
Re-fit the Wheel Hub to the gearbox shaft ensuring alignment of the keyway of the wheel centre
to the key fitted to gearbox shaft. Gently tap the wheel centre with a mallet until the threads can
be seen inside the shaft.
STEP 2
Fit the wheel bolt, ensuring that the washer has been fitted, to the gearbox shaft. Torque
rating of rear wheel bolt = 35 - 40Mm.
STEP 3
Locate tyre and tube to the face of the inside Rim that has the hole for the valve to seat in,
slightly inflate the tube.
STEP 4
Locate the other half of the Wheel Rim in position, insert Socket Cap Screws in position and pro-
ceed to tighten the screws. Ensure the inner tube is not trapped between the Wheel Rim halves.
Tighten securely Socket Head Cap Screws.
STEP 5
Inflate to the correct pressure as indicated on the Tyre Side Wall.
STEP 6
Position Wheel on Wheel Hub, locate and tighten Wheel Bolts securely.
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FOOT REST
PARTS:
1. Hanger assembly 8. Angle Footrest Assembly
2. Extension assembly 9. Tube Sub-Assembly
3. Footplate
4. Screw
5. Extension tube
6. Extension adjustment screw
7. Tube end plug
TOOLS REQUIRED
No1 Philips screwdriver
Spanner 13mm
Flat bladed screwdriver
Mallet
INSPECTION
STEP 1
Check that the Footplate fits securely
and operates correctly.
STEP 2
Check the operation of the Footplate extension, clamping and adjustment bolt.
STEP 3
Check the footrest for damage
STEP 4
Check for damage and distortion to the footrest hanger paying particular attention to the
securing tabs that clamp the extension (welds, flanges etc).
DISMANTLING
STEP 1
Operate the quick release mechanism and detach the footrest assembly.
STEP 2
Remove the extension clamping screw with a 13mm spanner and detach the footrest
extension from its hanger.
STEP 3
Remove the bumper rubber screw and pull out the bumper rubber.
STEP 4
With a mallet, gently tap the footplate of the extension
To re-assemble reverse steps 1 to 4.
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MECHANICAL HAND BRAKE
PARTS:
1. Brake Assembly Complete
2. Brake Shoe
3. Brake clamp bracket
4. Brake fixing nut
5. Rubber tip
6. Brake lever mechanism
Tools Required:
Spanner 10mm
No1 Philips screwdriver
INSPECTION
STEP 1
Check that the brake mechanism has no excessive looseness, is not worn or damaged.
STEP 2
Check that the brake shoe is positioned correctly to provide maximum surface area contact
on the tyre tread, and gives the positive brake hold (apx 10-11 gap between tyre and brake
shoe).
DISMANTLING
STEP 1
Loosen and remove the brake fixing bolt with an 10mm spanner.
STEP 2
Remove the brake from the sideframe, slide off the rubber tip.
STEP 3
Use a 10mm spanner to dismantle lever mechanism if necessary.
STEP 4
Use No1 Philips screw driver to remove brake block fixing screw.
To re-assemble reverse steps 1 to 4.
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BATTERIES AND CHARGER
PARTS:
1. Rear Battery Box (Battery not shown)
2. Front Battery (Battery not shown)
3. Battery Cradle
4. Power Lead (not shown)
5. Battery Box Lid - Front Moulding
6. Battery Box Lid - Rear Moulding
7. Connector Plug
8. Plug Cover
9. 40 Amp Circuit Breaker
10. 40 Ah Sonnenschien Battery (Not shown)
11. Power Socket (not shown)
12. Power Lead Plug (not shown)
13. Battery Terminal Cover RH - (Not Shown)
14. Battery Terminal Cover LH - (Not Shown)
15. Battery Chargers
Tools Required:
Pliers /Flat Bladed Screwdriver/10mm Spanner/No 1 Phillips Screwdriver/Multi Meter
Astratech Battery Discharger
INSPECTION - BATTERIES
STEP 1
Check that the battery box case, leads, sockets, and batteries are not damaged.
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STEP 2
Measure the battery voltages, the values must be the same +/- 0.2v. If not replace the
batteries.
STEP 3
For the battery charger operate, the battery voltage must be shown above 8v each. If not the
batteries must be removed and charged with an unregulated charger until the voltage
reaches 9v. Re-connect the batteries and charge through a complete charge cycle (this may
or may not recover the batteries, if not replace the batteries).
STEP 4
On completion of charge the battery voltage must read 14.20v (+/-) at 20°C or combined
28.4v.

BATTERIES AND CHARGER
DISMANTLING - BATTERIES
STEP 1
Unplug the battery lead, disconnect the battery box from the connecting plug, lift off the
battery cradle and remove the battery cradle from the mounting bars.
STEP 2
Remove the battery boxes/battery box from cradle.
STEP 3
Unclip the battery box lids, with a 10mm spanner, undo the battery terminals and remove the
batteries from the cases.
To re-assemble, reverse steps 1 to 3 and charge the battery fully.
INSPECTION - CHARGER
STEP 1
Check the charger case for physical damage.
STEP 2
Check the input and output leads and plugs for damage, cuts and wear.
STEP 3
Check that the charging, charge complete and power on lamps are operating correctly.
STEP 4
With an ammeter or a multimeter set to amp (range 10A) test the charging current.
NOTE :
AMMETERS MUST BE CONNECTED IN SERIES WITH THE BATTERY CIRCUIT.
STEP 5
The current reading should read approximately 7amp at charge start and 0.2 amp at
complete charge.
STEP 6
With a voltmeter or a multimeter, set to volts (range 30v) test the charging voltage at the
battery supply (red + blue - ve wires). The reading should increase to 28.4v during charging.
NOTE:
NO DISMANTLING IS NECESSARY FOR CHARGERS (INSPECTION OF PLUGS ONLY).
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MOTOR ASSEMBLY
PARTS:
1. Electro-Magnetic Brake
2. Brush
3. Motor Plug
4. Motor Complete
5. Commutator
6. Motor End Cap
Tools Required:
No1 Phillips Screwdriver
Flat Headed Screwdriver
Soldering Iron
Multi Meter
3mm Allen Key
INSPECTION
STEP 1
Check motor assembly for damage.
STEP 2
Set multimeter to continuity test.
STEP 3
Test continuity of motor leads and electro-magnetic brake leads (motor - lead shows in
diagram). Brake resistance should read 50ohms - 80 ohms.
STEP 4
Check all joints for bad connection, cracked or dry solder joints and oxidation.
STEP 5
Check that all the brushes can move freely in the brush guides with no obstruction (this can
be easily done by pulling on the free brush feeder wire).
STEP 6
Check that all the brushes are not chipped, cracked or worn.
STEP 7
Check that the brush spring is positioned to the centre of the brush body to apply even force.
Also check the brush spring tensions.
STEP 8
Check the condition of the brush feeder wire and check that the termination screws are
secure.
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MOTOR ASSEMBLY
STEP 9
Visually inspect the commutator for carbon deposits and remove with a soft brush.
NOTE:
ENSURE ALL THE SEGMENTS OF THE COMMUTATOR ARE NOT BRIDGED WITH
CONDUCTIVE MATERIALS (I.E. CARBON OR COPPER).
DISMANTLING
STEP 1
Remove the motor end via the two phillips screws.
STEP 2
Remove the two/three electro magnetic brake fixing screws and remove the brake.
STEP 3
Remove the brush feeder wire termination screws, release the brush springs and remove the
brushes.
To reassemble reverse the steps 1 to 4, taking care not to damage the brushes and ensuring
correct alignment of the electro-magnetic brake.
Should there be fitting, scoring or wear then replace the Motor Unit.
NOTE:
WHEN REFITTING MOTORS, PLEASE ENSURE THAT BOTH SUPPLY WIRES ARE
FASTENED TO THE CONTROLLER IN SUCH A WAY THAT THE RIGHT HAND MOTOR
CANNOT BE ACCIDENTLY CONNECTED TO THE LEFT AND VISA VERSA

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GEARBOX ASSEMBLY
PARTS:
1. Motor Gearbox Clamp Nut
2. Gearbox Gasket
3. Declutching Lever Lower
4. Declutching Lever Upper
5. Gearbox Lid Screw
6. Motor Gearbox Clamp Screw
7. Lid to Gearbox Screw
8. Clamp
9. Key
Tools Required:
5mm Allen Key
Pin Hammer
Punch
3mm Allen Key
Pliers
Vice
Spanner
8mm Spanner
INSPECTION
STEP 1
Check casing for cracks or damage or leakages.
STEP 2
Check Gearbox for noises (gears and bearings).
STEP 3
Check the declutching lever and mechanism engages and disengages correctly.
STEP 4
Check that the output shaft of the gearbox is not damaged or bent. Remove the rear wheel
and inspect the key and keyway for wear and correct fitting.
DISMANTLING
STEP 1
Remove the rear wheel from the gearbox (see page 6).
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