Invacare TDX-SP N User manual

Edition: 01.02.2013
Invacare
®
TDX-SP / TDX-SP N
SERVICE MANUAL

SERVICE MANUAL Invacare®- TDX-SP / TDX-SP N
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
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®- TDX-SP / TDX-SP N SERVICE MANUAL
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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]
@: [e-mail]
@: [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
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]om
@: [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

SERVICE MANUAL Invacare®- TDX-SP / TDX-SP N
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Contents
Chapter Page
1Introduction 7
1.1 General information ..................................................................................................................7
1.2 Notes on transport ....................................................................................................................7
1.3 Definition and representation of information and safety information in this manual........8
1.4 Hazard symbols and symbols used.........................................................................................9
1.5 Images in this manual.............................................................................................................10
2Safety and fitting instructions 11
2.1 Before any inspection or repair work....................................................................................11
2.2 Personal safety equipment.....................................................................................................11
2.3 General safety information and information about fitting / removal..................................11
3Tightening torques 13
4Layout of components and componentry 14
4.1 Overview...................................................................................................................................14
4.2 Electronic modules..................................................................................................................16
4.2.1 ACS 2 electronic module ..............................................................................................18
4.2.2 ACS 2 PMA90L electronic module................................................................................18
4.2.3 Shark electronic module ...............................................................................................18
4.2.3.1 Shark with DCI 12-pole............................................................................................18
4.2.4 ACT actuator module....................................................................................................18
4.2.4.1 ACT 2 actuator module............................................................................................19
4.2.4.2 ACT 4 actuator module............................................................................................19
4.2.5 Lighting PCB.................................................................................................................19
5Service plan (1x annually) 20
6Operational faults 23
6.1 Drive fault diagnosis ...............................................................................................................24
6.2 REM remotes: Error codes and diagnostic codes ...............................................................28
6.3 Shark II remote: Error codes and diagnostic codes ............................................................30
6.4 Diagnosis of charging device faults......................................................................................31
7Test procedures 32
7.1 Testing the motor....................................................................................................................32
7.2 Testing the electro-mechanical parking brake.....................................................................33
8Repair work 35
8.1 Covers without lifter................................................................................................................35
8.1.1 Opening the front panel ................................................................................................35
8.1.2 Opening the rear cover panel .......................................................................................36
8.1.2.1 Rear cover without an operating hours counter.......................................................36
8.1.2.2 Rear cover with an operating hours counter............................................................37
8.1.3 Opening the top cover panel.........................................................................................38
8.1.4 Replacing the splash guard ..........................................................................................39
8.2 Electronic module....................................................................................................................40
8.2.1 Replacing the remote....................................................................................................40
8.2.2 Replacing the electronic module...................................................................................40
8.2.3 Replacing the G-Trac sensor........................................................................................44
8.2.4 Replacing the operating hours counter / connecting cable...........................................45
8.2.5 Drive program selection after component replacement................................................48
8.2.5.1 Profile selection with remote REM A or REM B.......................................................48
8.2.5.2 Profile selection with remote REM 550....................................................................49

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8.3 Updating the driving program................................................................................................50
8.4 Batteries, cables & battery charger .......................................................................................51
8.4.1 Making the batteries accessible....................................................................................51
8.4.2 Replacing batteries (Standard TDX SP).......................................................................53
8.4.3 Replacing batteries / replacing battery cables (TDX-SP N)..........................................55
8.4.4 Correct handling of damaged batteries.........................................................................57
8.4.5 Checking and replacing the main fuse (Standard TDX-SP) .........................................58
8.4.6 Replacing the main fuse (TDX-SP N)...........................................................................59
8.4.7 Checking the cable .......................................................................................................60
8.4.8 Cable routing.................................................................................................................62
8.5 Battery carrier ..........................................................................................................................63
8.6 Replacing the battery case.....................................................................................................64
8.7 Lighting unit.............................................................................................................................65
8.7.1 Replacing the front bulb................................................................................................65
8.7.2 Replacing the front headlight complete ........................................................................66
8.7.3 Replacing the front bulbholder......................................................................................68
8.7.4 Replacing the rear bulb.................................................................................................69
8.7.5 Replacing the rear light complete .................................................................................70
8.7.6 Replacing the rear bulbholder.......................................................................................71
8.8 Wheel forks front/rear .............................................................................................................72
8.8.1 Replacing the wheel fork...............................................................................................72
8.8.2 Adjusting the wheel fork................................................................................................74
8.8.3 Replacing the wheels on double-sided wheel forks......................................................75
8.9 Drive wheels.............................................................................................................................76
8.9.1 Replacing the drive wheel.............................................................................................76
8.9.2 Replacing the tyre or inner tube....................................................................................77
8.9.2.1 Replacing pneumatic tyres ......................................................................................77
8.9.2.2 Replacing puncture-protected tyres.........................................................................79
8.9.2.3 Replacing puncture-proof tyres................................................................................81
8.9.3 Replacing the drive wheel hub (Standard motor)..........................................................82
8.9.4 Replacing the drive wheel hub (SSD motor).................................................................83
8.10 Rear wheel suspension...........................................................................................................84
8.10.1 Removing the rear wheel suspension...........................................................................84
8.10.2 Removing the rear wheel suspension – alternative method.........................................86
8.10.3 Refitting the rear wheel suspension..............................................................................88
8.10.4 Refitting the rear wheel suspension – alternative method............................................89
8.11 Rear springs.............................................................................................................................91
8.11.1 Removing the rear springs............................................................................................91
8.11.2 Refitting the rear springs...............................................................................................93
8.12 Bottom walking beam .............................................................................................................95
8.13 Top walking beam ...................................................................................................................96
8.13.1 Removing the top walking beam...................................................................................96
8.13.2 Refitting the top walking beam......................................................................................98
8.14 Drive unit................................................................................................................................100
8.14.1 Replacing the motor/transmission unit (Standard motor) ...........................................100
8.14.2 Replacing the motor/transmission unit (SSD motor) ..................................................102
8.14.3 Replacing or rotating the motor / gearbox unit sealing ring (SSD motor)...................104
8.14.4 Replacing the motor/transmission clutch (Standard Motor)........................................106
8.14.5 Replacing the motor/transmission clutch (SSD Motor)...............................................108
8.14.6 Replacing the carbon brushes (SSD motor)...............................................................110
8.14.7 Replacing the carbon brushes (Standard motor)........................................................112
8.15 Replacing the rubber bumper ..............................................................................................114
8.16 Castor housing front.............................................................................................................115
8.17 Replacing tilt module / lifter module....................................................................................116
8.17.1 Replacing the tilt module (max. > 30°) (without a lifter)..............................................116
8.17.1.1 Replacing the tilt module microswitch....................................................................118
8.17.1.2 Replacing the tilt module angular sensor...............................................................120
8.17.2 Replacing the tilt module (max. < 30°) (without a lifter)..............................................121
8.17.3 Replacing the lifter / tilt module...................................................................................124

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8.17.4 Replacing the tilt actuator ...........................................................................................128
8.17.5 Replacing the lifter actuator........................................................................................130
8.17.5.1 Method 1 - Removing the lifter actuator when the lifter is raised...........................130
8.17.5.2 Method 2 - Removing the lifter actuator when the lifter is lowered........................132
8.18 Seat support...........................................................................................................................136
8.19 Centre-mounted legrest (electric & manual).......................................................................138
8.19.1 Replacing the manually operated centre-mounted legrest .........................................138
8.19.2 Replacing the electrically operated centre-mounted legrest.......................................139
8.19.3 Replacing an electric legrest actuator.........................................................................141
8.19.4 Replacing the calf plate on the centre-mounted legrest (electric & manual) ..............143
8.19.5 Replacing the foot plate on the centre-mounted legrest (electric & manual)..............144
8.20 Anti-tip system.......................................................................................................................145
8.20.1 Removing the gas cylinder..........................................................................................145
8.20.2 Repairing the gas cylinder ..........................................................................................148
8.20.2.1 Replacing the guide block fixing or clamping support ...........................................148
8.20.2.2 Replacing the guide bush ......................................................................................149
8.20.2.3 Replacing the gas cylinder.....................................................................................149
8.20.3 Refitting the gas cylinder.............................................................................................150
8.20.4 Replacing the setting screw........................................................................................152
8.20.5 Adjusting the setting screw.........................................................................................155
9Installing accessories 156
9.1 Replacing the safety belt ......................................................................................................156
9.2 Further accessories...............................................................................................................156

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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.

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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 raising the vehicle, secure the wheels by blocking them with wedges!
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.
WARNING!
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
At rear underneath seat:
Electronic modules
The electronic modules are located
underneath the rear cover panel (1).
The electronic modules used are
described in Chapter 4.2.
In rear cover:
(1) – Operating hours counter (optional)

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At the front, underneath the seat:
(1) – actuator module (optional)
(2) – lifter actuator (optional)
(3) – tilt actuator (optional)

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4.2 Electronic modules
A variety of electronic modules can be fitted to the mobility aid.
Before you connect any mobility aid components such as adjusting motors/actuators or motors to
the electronic modules, you should first ensure that you know exactly which electronic module has
been fitted. Please refer to the following table for an overview.
Electronic module Designation Joystick boxes Notes
ACS 2
ACS 2 PMA90L
ACS 2 ACT
actuator module
REM 24
REM A
REM B
REM 550
The actuator module
is optional.
Shark
Shark with lighting
PCB
Shark II remote
The lighting PCB is
optional.
ACT actuator
module
The actuator module
is optional.
Lighting PCB
The lighting PCB is
optional.

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Electronic module Designation Joystick boxes Notes
G-Trac sensor
The G-Trac sensor is
optional
Operating hours
counter
The operating hours
counter is optional.

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4.2.1 ACS 2 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
6) Motor M2
Rubber stoppers for free slots
2) & 3) Order number: 1552876
4.2.2 ACS 2 PMA90L electronic module
Connections
1) Battery 24V
2) Cable to G-Trac sensor (GYRO)
3) Bus cable (to remote or ACT)
4) Motor M1
5) Light
6) Motor M2
4.2.3 Shark electronic module
4.2.3.1 Shark with DCI 12-pole
Connections
1) Cable to remote
2) DCI for actuators/lighting (12-pole)
3) Right-hand motor M1
4) Battery 24V
5) Left-hand motor M2
4.2.4 ACT actuator module
A range of adjusting motors, also known as actuators, can be fitted to the mobility aid. These
actuators are either connected directly to the electronic module or to a separate actuator module.
The actuator module is connected with the electronic module via a bus cable.

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4.2.4.1 ACT 2 actuator module
Connections
1) ACI*
2) Bus cable (to remote or ACT)
3) Bus cable (to remote or ACT)
4) Adjusting motor/actuator - Channel 2
5) Adjusting motor/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.
4.2.4.2 ACT 4 actuator module
Connections
1) ACI*
2) Bus cable (to remote or electronic
module)
3) Bus cable (to remote or electronic
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.
4.2.5 Lighting PCB
The lighting PCB connections are printed directly on the circuit board.

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5 Service plan (1x annually)
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.
Component Check Remedy Notes
ü
Safety belt Damage to safety belt Replace belt if
damaged. See chapter 9.1.
Belt lock function Replace belt if
damaged. See chapter 9.1
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 angle
adjustment Tight seating of SL
fuses Replace SL fuses if necessary
Power backrest
(if fitted) Damage to backrest
Seams
Fixing
Check cable
Check function
Replace parts if
damaged
Tighten screws
Replace cable motor
if necessary
Frames
(chassis) /
battery
mounting
Check fixings, welded
seams and battery
mounting
Tighten screws
Replace components
if necessary
Anti-tip system Check gas cylinder Repair or replace if
damaged
Replace gas cylinder
every 2 years!
See chapter 8.20
Check adjustment Speed See chapter 8.20.5.