Invacare Tornado User manual

Invacare® Tornado
SERVICE MANUAL
These instructions contain information about:
Troubleshooting
Repair
Edition: 03.2004

Service Manual Tornado
As at: 19.03.2004 Page 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:
Invacare® Deutschland GmbH
Kleiststraße 49
32457 Porta Westfalica
Deutschland
(Technische Hotline): 01 80 - 5 26 22 64
Fax (Technische Hotline): 01 80 - 5 26 22 75
Invacare® A/S
Sdr. Ringvej 39
2605 Brøndby
Danmark
(Kundeservice): +45 - (0) 3690 0000
Fax (Kundeservice): +45 - (0) 3690 0001
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
Invacare® POIRIER
Les Roches
F-37230 Fondettes
France
(Service Après-Vente):+33 - (0) 2 47 - 62 64 66
Fax (Service Après-Vente):+33 - (0) 2 47 - 42 12 24

Tornado Service Manual
Page 2 As at:19.03.2004
Invacare® Ltd
South Road
Bridgend
Mid Glamorgan - CF31-3PY
United Kingdom
(Customer Service): +44 - (0) 1656 - 647 327
Fax (Customer Service): +44 - (0) 1656 - 649 016
Invacare Mecc San s.r.l.
Via Dei Pini, 62
I - 36016 Thiene (VI)
ITALIA
: +39 - (0) 445-380059
Fax: +39 - (0) 445-380034
Invacare® AS
Grensesvingen 9
0603 Oslo
Norge
(Kundeservice): +47 - 22 57 95 10
Fax (Kundeservice): +47 - 22 57 95 01
Invacare® B.V.
Celsiusstraat 46
NL-6716 BZ Ede
The Netherlands
: +31 - (0) 318 - 69 57 57
Fax: +31 - (0) 318 - 69 57 58
Invacare® PORTUGAL Lda
Rua Senhora de Campanhã, 105
4369-001 Porto
PORTUGAL
: [phone]
Fax: [phone]
Invacare® AB
Fagerstagatan 9
163 91 Spånga
Sverige
(Kundtjänst): +46 - (0) 8 761 70 90
Fax (Kundtjänst): +46 - (0) 8 761 81 08
[email protected]
Service
Invacare
JÄRFÄLLA
: +46 - (0) 8 – 621 08 44
Fax: +46 - (0) 8 – 621 08 45
[email protected]
Invacare® n.v.
Autobaan 14
8210 Loppem (Brugge)
BELGIUM
: [phone]
Fax: [phone]
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]

Service Manual Tornado
As at: 19.03.2004 Page 3

Tornado Service Manual
Page 4 As at:19.03.2004
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.
The following symbols are used in these repair instructions:
Note:
This symbol identifies general information which indicate special points or simplifications in
dismantling / reassembly.
CAUTION:
it is imperative that you observe any >safety instructions< identified with this symbol.
This symbol identifies service work.
9

Service Manual Tornado
As at: 19.03.2004 Page 5
Contents
1 SAFETY AND ASSEMBLY INSTRUCTIONS 7
1.1 Before any inspection or repair work 7
1.2 During dismantling/reassembly 7
1.3 After completion of work / before operating the wheelchair: 8
2 TOOL LIST 9
2.1 Tightening torques and Loctite 10
3 LAYOUT OF COMPONENTS AND MODULES 11
4 SERVICE PLAN (1X ANNUALLY) 13
5 TROUBLESHOOTING THE TORNADO 15
5.1 Troubleshooting the Tornado with ACS 15
5.1.1 Diagnosing driving faults 15
5.1.2 Diagnosing problems with electric actuators 17
5.1.3 REM24 Error Codes and Diagnostic Codes 18
5.2 Troubleshooting the Invacare® Tornado with Shark Remote 20
5.2.1 Diagnosing driving faults 20
5.2.2 Shark Error Codes and Diagnostic Codes 22
6 REPAIR WORK 24
6.1 Replacing the drive motors 24
6.2 Replacing components of the ACS or Shark electronics 27
6.3 Replacing batteries 29
6.4 Replacing the main fuse 34
6.5 Checking the cables 36
6.6 Replacing the remote 38
6.7 Testing an actuator motor 39
6.8 Adjusting and replacing the speed reduction switch 40
6.9 Replacing the steering head bearings on the front or rear castor wheels 41
6.9.1 Front Castor Wheels 41
6.9.2 Rear Castor Wheels 43

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6.10 Replacing the Anti-Dive Spring and/or its plastic guides 45
6.11 Repairing a flat tyre 48
6.12 Replacing a drive wheel 50

Service Manual Tornado
As at: 19.03.2004 Page 7
1 Safety and assembly instructions
These safety instructions are intended to prevent accidents during work and it is imperative that they are
observed.
1.1 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”).
Caution:
• Please note the heavy weight of some components. This applies especially to removal of drive
units and batteries.
• 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 !
• Use only undamaged tools in good condition.
1.2 During dismantling/reassembly
• Mark all current settings for the wheelchair (seat, armrests, backrest etc.), and the cable connecting plugs
associated, before any removals. This makes reassembly easier.
Caution:
• Prop up the lifted wheelchair with appropriate supports before starting the disassembly or
assembly.
• Never use standard nuts instead of self-locking nuts.
• Always use correctly dimensioned washers or spacers.
Note:
• 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.
• Cable binders which have been cut off during disassembly should be replaced by new
ones during reassembly.
9

Tornado Service Manual
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1.3 After completion of work / before operating the wheelchair:
Caution:
• Check all fixings for tight fit.
• Check all parts for correct interlocking.
• Only operate wheelchair with correct tyre pressure (2.5 bar).
• 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.

Service Manual Tornado
As at: 19.03.2004 Page 9
2 Tool list
You will need a standard tool set with at least the following:
• set of open and ring spanners (6 – 24 mm)
• set of Allen keys (1.5 - 10 mm)
• torque wrench (commercial)
• socket spanner set
• set of screwdrivers (0.5 - 1.6 mm)
• oblique pliers
• flat-nosed pliers
• circlip pliers
• pointed pliers
• cable lug pliers
• wooden or plastic hammer
• tyre repair kit (commercial)
• tyre pressure indicator
• valve removal tool
• wheel bearing puller
• multimeter with probes and various cable clips
• soldering iron 30 W
• front wheel hub puller (available from INVACARE Service)
• circlip pliers for star lock caps (commercially available, make Tigtemeyer)
• pop riveting tool
• stepped mandrel

Tornado Service Manual
Page 10 As at:19.03.2004
2.1 Tightening torques and Loctite
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 diameter
Unit M5 M6 M8 M10 M12 M16
Torque Nm 3.4-4.9 5.9-7.8 14-19 25-34 44-61 115-155
mkp 0.35-0.80 0.60-0.80 1.4-1.9 2.6-3.5 4.5-6.2 11.5-16
Spanner width mm 8 10 13 17 19 24
For comparison!
Lever arm on ring
spanner DIN 838 mm 180 190 215 240 265 285
Therefore achievable
torque Nm 56 63 70 84 101 125
Caution:All other nuts or plastic connectors not noted here must be tightened FINGERTIGHT!
Caution: Tighten the front wheel on the castor fork fingertight and without play! Apply micro-
encapsulated adhesive to the thread! INVACARE uses VIBRATITE VC3 for this purpose.
Caution: When reassembling the front wheel fork in the head tube, ensure that the fork is free-
moving! The union should be tightened fingertight, and should not result in stiff
movement of the head tube bearing.

Service Manual Tornado
As at: 19.03.2004 Page 11
3 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

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

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As at: 19.03.2004 Page 13
4 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 50
• 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 41
• Check pneumatic tyres on
the drive wheels Repair or replace if damaged See "Repairing a
flat tyre" on page
48
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

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Component Check Action Notes 9
Batteries • Check batteries for
damage Replace batteries if necessary See "Replacing
batteries" on page
29
• Check battery charge Charge batteries See User Manual
• Check contacts and
terminals for corrosion Clean contacts and terminals See "Replacing
batteries" on page
29 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 45
Lifter • Check correct function
• Check function of the
Stability Lock
Repair if necessary

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As at: 19.03.2004 Page 15
5 Troubleshooting the Tornado
5.1 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.
5.1.1 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 29
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 34
• Check cables
between
modules for
loose
connections or
damage
See "Checking the
cables" on page 36
Remote may
be defective • Exchange
the remote on
the wheelchair
for a different
one to
eliminate the
possibility that
the remote
may be the
cause.
See "Replacing the
remote" on page 38
Status display
on remote is
flashing
Various causes • Identify the
error code See "REM24 Error
Codes and Diagnostic
Codes" on page 18

Tornado Service Manual
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PROBLEM OTHER
SYMPTOMS POSSIBLE CAUSE SOLUTION REFERENCE
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 40
Wheelchai
r does not
drive
smoothly
None Batteries may
be defective
(voltage not
stable)
• Replace the
batteries See "Replacing
batteries" on page 29
Drive motor(s)
may be
defective
• Replace the
drive motor(s) See "Replacing the drive
motors" on page 24
Batteries
cannot be
charged
None Batteries may
be defective • Replace the
batteries See "Replacing
batteries" on page 29
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 40
None Remote may
be defective • Replace the
remote See "Replacing the
remote" on page 38
Batteries may
be defective • Replace the
batteries See "Replacing
batteries" on page 29

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As at: 19.03.2004 Page 17
5.1.2 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
27
None Cable may
be
disconnected
or damaged
• Check that
the cable is
not
disconnected
or damaged. If
necessary,
replace the
cable
See "Checking the cables"
on page 36
Electric
actuator may
be defective
• Test the
actuator See "Testing an actuator
motor" on page 39
Remote may
be defective • Exchange
the remote on
the wheelchair
for a different
one to
eliminate the
possibility that
the remote
may be the
cause.
See "Replacing the
remote" on page 38

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5.1.3 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 27
2 x flashes Accessory error (e.g.
actuator short-circuit) • Check accessory
connections, check
accessories
See "Testing an
actuator motor" on
page 39
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 36
See "Replacing
the drive motors"
on page 24
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 36
See "Replacing
the drive motors"
on page 24
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 36
See "Replacing
the drive motors"
on page 24
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 36
See "Replacing
the drive motors"
on page 24

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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 27
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 27