Invacare Tornado User manual

Invacare® Tornado
SERVICE MANUAL
This manual contains information on:
Troubleshooting
Maintenance
Repair
Version: 20.07.06

2
Mobitec Mobilitätshilfen GmbH
Herzog Odilostrasse 101
A-5310 Mondsee
Austria
+43 - 6232 - 55 35 0
Fax: +43 - 6232 - 55 35 4
@: [email protected]
@: [email protected]
WWW: www.mobitec-austria.com
Invacare® n.v.
Autobaan 22
B-8210 Loppem (Brugge)
Belgium
+32 - (0)50 - 83 10 10
Fax: +32 - (0)50 - 83 10 11
@: [email protected]
WWW: www.invacare.be
Mobitec Rehab AG
Benkenstraße 260
CH-4108 Witterswil
Switzerland
+41 - (0)61 - 48 77 08 0
Fax: +41 - (0)61 - 48 77 08 1
@: [email protected]
@: [email protected]
WWW: www.mobitec-rehab.ch
Invacare® Deutschland GmbH
Kleiststraße 49
32457 Porta Westfalica
Deutschland
(Technische Hotline): 0180 - 5 26 22 64
Fax (Technische Hotline): 0180 - 5 26 22 75
@: [email protected]
WWW: www.invacare.de
Invacare® A/S
Sdr. Ringvej 39
DK-2605 Brøndby
Danmark
(Kundeservice): +45 - (0)36 - 90 00 00
Fax (Kundeservice): +45 - (0)36 - 90 00 01
@: [email protected]
WWW: www.invacare.dk
Invacare® SA
c/ Areny, s/n
Poligon Industrial de Celrà
17460 Celrà (Girona)
ESPAÑA
: +34 - (0)972 - 49 32 00
Fax: +34 - (0)972 - 49 32 20
@: [email protected]
WWW: www.invacare.es
Invacare® Poirier SAS
Route de St Roch
F-37230 Fondettes
France
: +33 - (0)247 - 62 64 66
Fax : +33 - (0)247 - 42 12 24
@: [email protected]
WWW: www.invacare.fr
Invacare® Ltd
South Road
Bridgend Industrial Estate
Mid Glamorgan - CF31-3PY
United Kingdom
(Customer Service): +44 - (0)1656 - 664 321
Fax (Customer Service): +44 - (0)1656 - 667 532
@: [email protected]
@: [email protected]
WWW: www.invacare.co.uk

3
Invacare Mecc San s.r.l.
Via Dei Pini, 62
I - 36016 Thiene (VI)
ITALIA
+39 - 0445 - 38 00 59
Fax: +39 - 0445 - 38 00 34
@: [email protected]
WWW: www.invacare.it
Invacare® AS
Grensesvingen 9
Postboks 6230
N-0603 Oslo
Norge
(Kundeservice): +47 - (0)22 57 95 10
Fax (Kundeservice): +47 - (0)22 57 95 01
@: [email protected]
WWW: www.invacare.no
Invacare® B.V.
Celsiusstraat 46
NL-6716 BZ Ede
The Netherlands
: +31 - (0)318 - 69 57 57
Fax: +31 - (0)318 - 69 57 58
@: [email protected]
@: [email protected]
WWW: www.invacare.nl
Invacare® PORTUGAL Lda
Rua Senhora de Campanhã 105
P-4369-001 Porto
PORTUGAL
: [phone]
Fax: [phone]
@: [email protected]
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): +46 - (0) 8 761 70 90
Fax (Kundtjänst): +46 - (0) 8 761 81 08
@: [email protected]
@: [email protected]
WWW: www.invacare.se
MÖLNDAL
+46 - (0) 31 – 86 36 00
Fax: +46 - (0) 31 – 86 36 06
@: [email protected]
LANDSKRONA
+46 - (0) 418 – 285 40
Fax: +46 - (0) 418 – 180 89
@: [email protected]
OSKARSHAMN
+46 - (0) 491 – 101 40
Fax: +46 - (0) 491 – 101 80
@: [email protected]

4
Table of Contents
Chapter Page
1INTRODUCTION 6
1.1 General information 6
1.2 Notes on transport 6
1.3 Important symbols in this manual 6
2SAFETY AND ASSEMBLY INSTRUCTIONS 8
2.1 Before any inspection or repair work 8
2.2 General safety information and notes on assembly / disassembly 8
3TIGHTENING TORQUES 10
4LAYOUT OF COMPONENTS AND MODULES 11
5SERVICE PLAN (1X ANNUALLY) 13
6OPERATIONAL FAULTS 15
6.1 Troubleshooting the Tornado with ACS 15
6.1.1 Diagnosing driving faults 15
6.1.2 Diagnosing problems with electric actuators 18
6.1.3 REM24 Error Codes and Diagnostic Codes 19
6.2 Operational faults on a wheelchair fitted with Shark electronics 21
6.2.1 Diagnosis of actuation disorders 21
6.2.2 Shark error codes and diagnostic codes 23
7REPAIR WORK 25
7.1 General warning information on installation work 25
7.2 Replacing the drive motors 25
7.3 Replacing components of the ACS or Shark electronics 28
7.4 Replacing batteries 30
7.5 Replacing the main fuse 35
7.6 Checking the cables 37

5
7.7 Replacing the remote 39
7.8 Testing an actuator motor 40
7.9 Adjusting and replacing the speed reduction switch 41
7.10 Replacing the steering head bearings on the front or rear castor wheels 42
7.10.1 Front Castor Wheels 42
7.10.2 Rear Castor Wheels 44
7.11 Replacing the Anti-Dive Spring and/or its plastic guides 46
7.12 Repairing a flat tyre 49
7.13 Replacing a drive wheel 51

6
1 Introduction
1.1 General information
These repair instructions contain all the information necessary for maintenance and overhaul of the
wheelchair.
• All maintenance and overhaul work must be carried out in accordance with these repair
instructions.
• Please observe all safety instructions.
• Information about operation or about general maintenance and care work should be taken
from the wheelchair Operating Manual.
• You can find information about ordering spare parts in the spare parts catalogue.
• Use only genuine Invacare® spare parts. Using parts from any other source will void the
warranty!
• We reserve the right to make any alterations on the grounds of technical improvements.
• The wheelchair may only be maintained and overhauled by qualified personnel.
• The minimum requirement for service technicians is relevant training, such as in the cycle or
orthopaedic mechanics fields, or suitably long-term job experience.
- Experience and knowledge of electrical measuring devices (Multimeter)
is also a requirement.
- Special Invacare training sessions are recommended.
• Alterations to the wheelchair, which occur as a result of incorrectly or improperly executed
maintenance or overhaul work lead to the exclusion of all liability on the part of INVACARE.
• If you have any problems or questions please contact INVACARE SERVICE.
1.2 Notes on transport
• If the wheelchair has to be shipped back to the manufacturer for major repairs, you should
always use the original packaging for transport.
• You should also include as accurate a fault description as possible.
1.3 Important symbols in this manual
WARNING!
This symbol warns you of danger!
• 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!
BURN HAZARD!
This symbol warns you of burns due, for example, to leaking battery acid!
• Always follow the instructions to avoid injury to the user or damage to the product!

7
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.

8
2 Safety and assembly instructions
These safety instructions are intended to prevent accidents during 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 General safety information and notes on assembly / disassembly
Danger of injury by crushing!
• Please note the heavy weight of some components. This applies especially to removal of
drive units and batteries!
• Prop up the lifted wheelchair with appropriate supports before starting the disassembly or
assembly!
Danger of fire and burns due to electrical short-circuit!
• The wheelchair must be switched off before removal of voltage-carrying components! To do
this, disconnect the batteries or remove them!
• When making measurements on voltage-carrying components, avoid short-circuiting the
contacts. Danger of fire and combustion!
Danger of injury and damage to the vehicle can result from incorrect or incomplete
maintenance!
• Only ever use tools which are undamaged in good condition!
• Some moving parts have Teflon bushings! These parts must never be lubricated with grease!
• Never use standard nuts instead of self-locking nuts!
• Always use correctly dimensioned washers or spacers!
• Cable binders which have been cut off during disassembly should be replaced with new ones
during reassembly!
• After completing maintenance work and before operating the vehicle, make sure all fixations
are correctly secured! Check all parts for correct interlocking1
• Only operate wheelchair with correct tyre pressure (see Technical Specifications)!
• Check electrical components for correct functioning, incorrect polarity of cables can result in
damage to the electronics!
• As a last check, always carry out a test-drive!
Notes
Mark all current settings for the wheelchair (seat, armrests, backrest etc.), and the cable
connecting plugs associated, before any removals. 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.

9
WARNING: Any alteration to the drive programme can influence vehicle handling and the
tipping stability of the wheelchair!
• Alterations to the drive programme may only be carried out by trained Invacare®-dealers!
• Invacare® supplies all wheelchairs from the factory with a standard drive programme.
Invacare® can only assume a warranty for the safe vehicle handling of the wheelchair – in
particular tipping stability - for this standard drive programme!

10
3 Tightening torques
The tightening torques stated in the following table are dependent on the thread diameters for the
nuts and bolts for which no special values are determined. All values apply to dry and grease-free
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: All other nuts or plastic connectors not noted here must be tightened
FINGERTIGHT!

11
4 Layout of components and modules
The following image shows the Tornado from above rear, with the seat lifter raised and the rear
cowling removed.
1 Seat tilt actuator
2 Seat-frame / rear
cowling anti-collision
switch
3 Speed-reduction switch
4 Power module
5 CLAM (Combined Light
and Actuator Module)
The following image shows the Tornado from above, with the lifter raised and the seat removed
1 Cable loom connectors
2 Seat lifter and tilt
actuator end-position
switch
3 Speed-reduction switch
4 Seat-frame / rear
cowling anti-collision
switch

12
The following image shows the Tornado from the front right, with the lifter raised
1 Lifter actuator

13
5 Service plan (1x annually)
Component Check Action Notes 9
Armrests and
side panels
• Armrest damage and
fastening
• Side panel damage and
fixing
⇒Tighten screws, replace
padding if damaged
⇒Tighten screws, replace
side panels if damaged
Seat unit / seat
angle
adjustment
• Cushion
• Check seat angle
adjustment
⇒Replace covers /
upholstery if damaged
⇒Replace parts if damaged
Backrest unit
mechanical
Backrest unit
electrical
• Damage and seams
• Fixings
• Check cabling
• Check function
⇒Replace parts if damaged
⇒Tighten screws
⇒Replace cable or motor if
necessary
Frame
(chassis) /
battery box
• Check fixings, welded
seams and battery box
⇒Tighten screws, replace
components
Wheel
suspension
and wheels
• Check drive wheels for
tight fit and side play
⇒Adjust, replace wheel
hubs
See "Replacing a
drive wheel" on
page 51
• Check steering wheels
for tight fit, float and side
play
⇒Replace wheels, wheel
fork or wheel bearings
See "Replacing
the steering head
bearings on the
front or rear
castor wheels" on
page 42
• Check pneumatic tyres
on the drive wheels
⇒Repair or replace if
damaged
See "Repairing a
flat tyre" on page
49
Drive units,
disengager
• Check functions in drive
and push modes
• Check disengager
⇒Replace motor if
necessary
⇒Tighten screws / nuts,
adjust or replace if
necessary
Footrests • Check welded seams,
interlocking, screws,
footplates
⇒Tighten, replace if
necessary
Electrical
footrests
• Check cabling
• Check contacts
• Check functions
⇒Replace cable if
necessary
Lighting • Check cabling
• Check function
⇒Replace bulbs or cables if
necessary

14
Component Check Action Notes 9
Batteries • Check batteries for
damage
⇒Replace batteries if
necessary
See "Replacing
batteries" on page
30
• Check battery charge ⇒Charge batteries See User Manual
• Check contacts and
terminals for corrosion
⇒Clean contacts and
terminals
See "Replacing
batteries" on page
30 for Safety
Information on
working with
batteries
Remote /
electronics
• Remote,
status display blinking
• Fixing
• Cable, connecting plug
• Joystick function
• Power supply
⇒Evaluate flash code
⇒Tighten, replace
⇒Replace
⇒Replace joystick
⇒Replace cable, connector
plug or console
Walking Beam • Check spring for damage
• Check that the bolts that
hold the spring guides
have become loosened
⇒Replace if damaged
⇒Replace spring guides if
damaged
See "Replacing the
Anti-Dive Spring
and/or its plastic
guides" on page 46
Lifter • Check correct function
• Check function of the
Stability Lock
⇒Repair if necessary

15
6 Operational Faults
6.1 Troubleshooting the Tornado with ACS
If a problem occurs with the wheelchair, then please proceed as follows:
• Identify the possible cause of the fault by using the troubleshooting tables below.
• Check the Status Display on the remote. Identify the error code if it is flashing.
• Perform the necessary checks and repairs as recommended in the table below.
6.1.1 Diagnosing driving faults
PROBLEM OTHER
SYMPTOMS
POSSIBLE
CAUSE
SOLUTION REFERENCE
Wheelchai
r will not
drive
Status display
on remote
lights up
normally and
does not show
an error code
Drive motors
may be
disengaged
• Engage
the drive
motors
See User Manual
Status display
on remote
does not light
up
Batteries may
be defective
• Replace
the
batteries
See "Replacing
batteries" on page 30
Batteries may
be completely
discharged
• Charge
the
batteries
See User Manual
Power supply
to the remote
may be
interrupted
• Check
the main
fuse
See "Replacing the main
fuse" on page 35
• Check
cables
between
modules
for loose
connecti
ons or
damage
See "Checking the
cables" on page 37

16
PROBLEM OTHER
SYMPTOMS
POSSIBLE
CAUSE
SOLUTION REFERENCE
Remote may
be defective
• Exchang
e the
remote
on the
wheelcha
ir for a
different
one to
eliminate
the
possibilit
y that the
remote
may be
the
cause.
See "Replacing the
remote" on page 39
Status display
on remote is
flashing
Various causes • Identify
the error
code
See "REM24 Error
Codes and Diagnostic
Codes" on page 19
Status display
on remote
flashes 2x,
drive mode
display shows
"U"
Speed
reduction
switch on the
lifter may be
defective or
disconnected
• Replace
cable or
switch
See "Adjusting and
replacing the speed
reduction switch" on
page 41

17
PROBLEM OTHER
SYMPTOMS
POSSIBLE
CAUSE
SOLUTION REFERENCE
Wheelchai
r does not
drive
smoothly
None Batteries may
be defective
(voltage not
stable)
• Replace
the
batteries
See "Replacing
batteries" on page 30
Drive motor(s)
may be
defective
• Replace
the drive
motor(s)
See "Replacing the drive
motors" on page 25
Batteries
cannot be
charged
None Batteries may
be defective
• Replace
the
batteries
See "Replacing
batteries" on page 30
LEDs on the
charger are
flashing
Charger may
be defective
• Replace
the
charger
See User Manual of the
charger
Wheelchai
r drives
too slowly
Status display
on remote
flashes 2x,
drive mode
display shows
"U"
Seat lifter is not
in driving
position (either
too high or too
low), and has
activated the
automatic
speed
reduction.
• Return
seat lifter
to driving
position
See User Manual
Speed-
reduction
micro-switch on
the seat lifter
may be badly
adjusted
• Adjust
the
micro-
switch
See "Adjusting and
replacing the speed
reduction switch" on
page 41
None Remote may
be defective
• Replace
the
remote
See "Replacing the
remote" on page 39
Batteries may
be defective • Replace
the
batteries
See "Replacing
batteries" on page 30

18
6.1.2 Diagnosing problems with electric actuators
In case an electric actuator will not function, identify the source of the problem using the following
table:
PROBLEM OTHER
SYMPTOMS
POSSIBLE
CAUSE
SOLUTION REFERENCE
Electric
Actuator
does not
function
Remote
displays a
flashing "E",
status diode on
the CLAM does
not go out,
even if the
remote is
switched off or
disconnected
CLAM is
defective
• Replace
the
CLAM
See "Replacing
components of the ACS or
Shark electronics" on page
28
None Cable may
be
disconnected
or damaged
• Check
that the
cable is
not
disconne
cted or
damaged
. If
necessar
y,
replace
the cable
See "Checking the cables"
on page 37
Electric
actuator may
be defective
• Test the
actuator
See "Testing an actuator
motor" on page 40
Remote may
be defective
• Exchang
e the
remote
on the
wheelcha
ir for a
different
one to
eliminate
the
possibilit
y that the
remote
may be
the
cause.
See "Replacing the
remote" on page 39

19
6.1.3 REM24 Error Codes and Diagnostic Codes
The drive electronics are capable of rectifying some errors automatically. In this case the status
display will cease to flash. Please switch the remote on and off several times. Wait approx. 5
seconds each time before switching the remote on again. If this does not rectify the error, locate
the error using the flash codes shown below.
Flash code: Meaning: Solution: Notes
1 x flash Module defective Replace defective
module
See "Replacing
components of
the ACS or Shark
electronics" on
page 28
2 x flashes Accessory error (e.g.
actuator short-circuit)
• Check accessory
connections, check
accessories
See "Testing an
actuator motor" on
page 40
Lifter raised or lowered
too far (seat not at driving
height)
• If lifter is raised,
lower in stages until
the status display
stops flashing. If
lowered too far, raise
lifter in stages until
the status display
stops flashing. If at all
possible, only drive
when the seat is at
driving height.
See User Manual
3 x flashes Fault in right-hand motor.
Connection
loose/defective or motor
defective
• Check
connecting plugs
• Check motor
See "Checking
the cables" on
page 37
See "Replacing
the drive motors"
on page 25
4 x flashes Fault in left-hand motor.
Connection
loose/defective or motor
defective
• Check
connecting plugs
• Check motor
See "Checking
the cables" on
page 37
See "Replacing
the drive motors"
on page 25
5 x flashes Fault/brake fault on right-
hand motor. Connection
loose/defective or motor
defective
• Check connecting
plugs
See "Checking
the cables" on
page 37
See "Replacing
the drive motors"
on page 25
6 x flashes Fault/brake fault on left-
hand motor. Connection
loose/defective or motor
defective.
• Check connecting
plugs
See "Checking
the cables" on
page 37
See "Replacing
the drive motors"
on page 25

20
Flash code: Meaning: Solution: Notes
7 x flashes Completely discharge
battery
• Pre-charge battery See User Manual
8 x flashes Battery voltage too high • Switch lights
on to lower battery
voltage
• Check battery
charger
See User Manual
of battery charger
9 or 10 x flashes Faulty data transmission
between modules
- Remove all
electronic
modules except
the Power Module
and the Remote.
Re-attach
modules one by
one to determine
which one is
causing the fault.
See "Replacing
components of
the ACS or Shark
electronics" on
page 28
11 x flashes Motors overloaded /
overheated
• Switch remote on
and off / wait if
necessary
-
12 x flashes Module used has
compatibility problems
• Remove
incorrect module
See "Replacing
components of
the ACS or Shark
electronics" on
page 28