Invacare Typhoon II User manual

Invacare® Typhoon II
SERVICE MANUAL
This document contains information on:
Troubleshooting
Maintenance
Repair
Version: 01.10.10

Mobitec Mobilitätshilfen GmbH
Herzog Odilostrasse 101
A-5310 Mondsee
Austria
: [phone]
Fax: [phone]
@: [email protected]
@: [email protected]
WWW: www.mobitec-austria.com
Invacare® n.v.
Autobaan 22
B-8210 Loppem (Brugge)
Belgium
: [phone]
Fax: [phone]
@: [email protected]
WWW: www.invacare.be
Mobitec Rehab AG
Benkenstraße 260
CH-4108 Witterswil
Switzerland
: [phone]
Fax: [phone]
@: [email protected]
@: [email protected]
WWW: www.mobitec-rehab.ch
Invacare Aquatec
Alemannenstraße 10
88316 Isny
Deutschland
[phone]
Fax [phone]
@: [email protected]
WWW: www.invacare-aquatec.de
Invacare® A/S
Sdr. Ringvej 37
DK-2605 Brøndby
Danmark
(Kundeservice): [phone]
Fax (Kundeservice): [phone]
@: [email protected]
WWW: www.invacare.dk
Invacare® SA
c/ Areny, s/n
Polígon Industrial de Celrà
E-17460 Celrà (Girona)
ESPAÑA
: [phone]
Fax: [phone]
@: [email protected]
WWW: www.invacare.es
Invacare® Poirier SAS
Route de St Roch
F-37230 Fondettes
France
: [phone]
Fax: [phone]
@: [email protected]
WWW: www.invacare.fr
Invacare® Ltd
Pencoed Technology Park
Pencoed
Bridgend CF35 5HZ
United Kingdom
(Customer Service): [phone]
Fax (Customer Service): [phone]
@: [email protected]
@: [email protected]
WWW: www.invacare.co.uk
Invacare Mecc San s.r.l.
Via Dei Pini, 62
I - 36016 Thiene (VI)
ITALIA
: [phone]
Fax: [phone]
@: [email protected]
WWW: www.invacare.it
Invacare Ireland Ltd.
Unit 5 Seatown Business Campus
Seatown Rd, Swords
County Dublin
Ireland
: [phone]
Fax: [phone]
@: [email protected]
WWW: www.invacare.ie
Invacare® AS
Grensesvingen 9
Postboks 6230
Etterstad
N-0603 Oslo
Norge
(Kundeservice): [phone]
Fax (Kundeservice): [phone]
@: [email protected]
WWW: www.invacare.no
Invacare® B.V.
Celsiusstraat 46
NL-6716 BZ Ede
Nederland
: [phone]
Fax: [phone]
@: [email protected]
WWW: www.invacare.nl
Invacare Portugal, Lda
Rua Estrada Velha, 949
P-4465-784 Leça do Balio
Portugal
: [phone]
: [phone]
Fax: [phone]
@: [email protected]
WWW: www.invacare.pt
2

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]
@: [email protected]
WWW: www.invacare.se
MÖLNDAL
: [phone]
Fax: [phone]
@: [email protected]
LANDSKRONA
: [phone]
Fax: [phone]
@: [email protected]
OSKARSHAMN
: [phone]
Fax: [phone]
@: [email protected]
3

Table of Contents
Chapter Page
TABLE OF CONTENTS 4
1INTRODUCTION 6
1.1 General information 6
1.2 Notes on transport 6
1.3 Definition and representation of information and safety information in this manual 7
1.4 Hazard symbols and symbols used 8
1.5 Images in this manual 9
2SAFETY AND FITTING INSTRUCTIONS 10
2.1 Before any inspection or repair work 10
2.2 Personal safety equipment 10
2.3 General safety information and information about fitting / removal 10
3TIGHTENING TORQUES 12
4LAYOUT OF MODULES, COMPONENTS AND DISPLAYS AND CONTROLS 13
5SERVICE PLAN (1X ANNUALLY) 14
6OPERATIONAL FAULTS 16
6.1 Operational faults on electric wheelchair with ACS 16
6.1.1 Drive fault diagnosis 16
6.1.2 Fault diagnosis with electric actuator motors 18
6.1.3 REM24 Error Codes and Diagnostic Codes 19
7REPAIR WORK 21
7.1 Replacing and calibrating drive motor 21
7.1.1 Replacing the motor 21
7.1.2 Calibration of GB motors 29
7.2 Replacing electronic components 31
7.3 Removing and fitting batteries 33
7.4 Replacing the main fuse. 39
4

7.5 Checking the cables 41
7.6 Replacing the ACS Remote 42
7.7 Updating the driving program 44
7.8 Checking an actuator motor 45
7.9 Adjusting and replacing the speed reduction switch 46
7.10 Replacing the Locking-Gas Cylinder 47
7.11 Replacing the steering head bearings on the front and rear steering wheels 53
7.11.1 Front steering wheels 53
7.11.2 Rear steering wheels and 54
7.12 Replacing the safety belt 56
5

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.
6

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.
7

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.
8

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.
9

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!
10

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.
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!
11

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.
12

4 Layout of modules, components and displays and
controls
The following figure shows the Typhoon II from behind with extended seat lifter and the rear
panelling removed.
1 Seat lean adjustment
2 Seat frames / rear panelling anti-collision
switch
3 Speed controller
4 Main module (power module)
5 Lighting/actuator module
The following figure shows the Typhoon II from front right with raised lifter.
1 Lifter servo motor
13

5 Service plan (1x annually)
Component Check Remedy Note 
Armrests and side
panels
•Armrest damage
and fastening
•Side panel damage
and fixing
⇒Tighten screws, replace
top surface if damaged
⇒Tighten screws, replace
side panels if damaged
Seat unit /
adjustable seat
inclination
•Top surface
•Check adjustable
seat inclination
⇒Replace cover /
upholstery if damaged.
⇒Replace parts if damaged.
Mechanical backrest
Electrical backrest
•Damage and
seams
•Fixing
•Check cable
•Check function
⇒Replace parts if damaged.
⇒Tighten screws
⇒Replace cable or motor if
necessary
Frame (chassis) /
battery mounting
•Check fixings,
welded seams and
battery mounting
⇒Tighten screws, replace
components
•Check the locking-
gas cylinder
⇒Repair or replace if
damaged
⇒Replace the locking-gas
cylinder every 2 years!
See "Replacing
the Locking-Gas
Cylinder" on
page 47
Locking-Gas
Cylinder
•Check adjustment ⇒Adjust it See "Replacing
the Locking-Gas
Cylinder" on
page 47
Wheel suspension
and wheels
•Check drive wheels
for tight fit and side
play
⇒Adjust, replace wheel
hubs
See "Replacing
and calibrating
drive motor" on
page 21
•Check steering
wheels for tight fit,
float, side play and
correct torque (15
Nm +/- 1.5 Nm)
⇒Replace wheels, wheel
fork or wheel bearings
See "Replacing
the steering head
bearings on the
front and rear
steering wheels"
on page 53
•Check drive wheel
pneumatic tyres
⇒Repair or replace if
damaged
see operating
manual
Drive units, clutch
mechanism
•Check functions in
drive and push
modes
•Check clutch
mechanism
⇒Replace motor if
necessary
⇒Tighten screws / nuts,
adjust or replace if
necessary
Legrests •Check welded
seams, interlocking,
screws, footplates
⇒Tighten, remove if
necessary
Electrical legrests •Check cable
•Check contacts
•check functions
⇒Replace cable if
necessary
Lighting •Check cable
•Check function
⇒Replace bulbs or cable if
necessary
14


Component Check Remedy Note
Batteries •Check batteries for
damage
⇒Replace batteries if
necessary
See "Removing
and fitting
batteries" on page
33
•Check battery
voltage
⇒charge batteries See operating
manual
•Check contacts and
terminals
⇒Clean contacts and
terminals
See "Removing
and fitting
batteries" on page
33 for safety
information on
handling batteries
Remote / drive
electronics
•Remote, status
display blinking
•Fixing
•Cable, connecting
plug
•Joystick function
•Power supply
⇒Evaluate blinking code
⇒Tighten, replace
⇒Replace
⇒Replace joystick
⇒Replace cable, connecting
plug or console
Lifter module •Check for correct
functioning
•Check locking
device function.
⇒Repair if necessary.
Drive program •Check drive
electronics program
version Newer
version available?
•Update software See "Updating the
driving program"
on page 44
15

6 Operational faults
6.1 Operational faults on electric wheelchair with ACS
If you have problems with the wheelchair, please proceed as follows:
•First assess the possible cause of the problem using the following table.
•Check the status display on the remote. Evaluate the blink error code.
•Carry out the necessary checks and repairs as recommended in the following table.
NOTE:
You can find more information about operational faults on electric wheelchairs with GB motors in
the document entitled “Dynamic DX-GB-AS Power Module - Assembly Instructions”, order no.
1441533
6.1.1 Drive fault diagnosis
PROBLEM OTHER
SYMPTOMS POSSIBLE CAUSE SOLUTION Documentation
Wheelchair
will not
start
Remote
status display
illuminates
normally
without
showing an
error code
Drive motors
possibly
disengaged
•Re-engage drive
motors
See operating manual
Remote
status display
does not
illuminate
Batteries
possibly
defective
•Replace
batteries
See "Removing and
fitting batteries" on
page 33
Batteries
possibly over-
discharged
•Pre-charge
batteries
See operating manual
Power supply
to remote
possibly
interrupted
•Check master
fuse
See "Replacing the
main fuse" on page
39
•Check cable
between
modules for
loose
connections or
damage
See "Checking the
cables" on page 41
Remote
possibly
defective
•Replace the
remote on the
wheelchair in
order to rule out
the possibility
that the remote
is causing the
fault.
See "Replacing the
ACS Remote" on
page 42
Remote
status display
blinking
Various causes •Assess error
code
See "REM24 Error
Codes and
Diagnostic Codes"
on page 19
16

PROBLEM OTHER
SYMPTOMS POSSIBLE CAUSE SOLUTION Documentation
Status display
on remote
blinking 2x,
drive display
on "U"
Speed
controller on
lifter possibly
defective or not
connected
•Replace cable
or switch
See "Adjusting and
replacing the speed
reduction switch" on
page 46
Wheelchair
judders in
drive mode
None Batteries
possibly
defective
(voltage
unstable)
•Replace
batteries
See "Removing and
fitting batteries" on
page 33
Drive motor(s)
possibly
defective
•Replace
motor(s)
See "Replacing and
calibrating drive
motor" on page 21
Batteries
not being
charged
None Batteries
possibly
defective
•Replace
batteries
See "Removing and
fitting batteries" on
page 33
LEDs blinking
on charging
unit
Charging
device possibly
defective
•Replace
charging unit
See charging unit
operating manual
Wheelchair
runs too
slowly
Status display
on remote
blinking 2x,
drive display
on "U"
Seat lifter is not
in drive position
(either too high
or too low) and
has activated
automatic
speed
regulation.
•Run the seat
lifter to the drive
position
See operating manual
Speed
controller on
seat lifter may
be badly
adjusted.
•Adjust regulator See "Adjusting and
replacing the speed
reduction switch" on
page 46
None Remote
possibly
defective
•Replace remote See "Replacing the
ACS Remote" on
page 42
Batteries
possibly
defective
•Replace
batteries
See "Removing and
fitting batteries" on
page 33
17

6.1.2 Fault diagnosis with electric actuator motors
Please use the following table to assess fault causes when using electric actuator motors.
PROBLEM OTHER
SYMPTOMS POSSIBLE CAUSE SOLUTION Documentation
Electric
actuator
motor does
not react
Remote shows
blinking "E",
status diode on
lighting/actuator
module does not
go out even if
the remote is
switched off or
disconnected.
Lighting /
actuator
module
defective
•Replace
lighting/actuator
module
See "Replacing
electronic
components" on
page 31
None Cable
possibly
disconnected
or damaged
•Check to
ensure that the
cable has not
been
disconnected
or damaged.
Replace cable
if necessary
See "Checking the
cables" on page 41
Electrical
actuator
motor
possibly
defective
•Test actuator
motor
See "Checking an
actuator motor" on
page 45
Remote
possibly
defective
•Replace the
remote on the
wheelchair in
order to rule
out the
possibility that
the remote is
causing the
fault.
See "Replacing the
ACS Remote" on
page 42
18

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 electronic
components" on page 31
2 x flashes Accessory error
(e.g. actuator
short-circuit)
•Check accessory
connections, check
accessories
See "Checking an
actuator motor" on page
45
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 Connection on the
left motor
loose/defective
•Check plug-in
connections.
See "Checking the
cables" on page 41
Left motor
defective.
•Check/replace motor See "Replacing and
calibrating drive motor"
on page 21
4 x flashes Connection on the
right motor
loose/defective
•Check plug-in
connections.
See "Checking the
cables" on page 41
Right motor
defective.
•Check/replace motor See "Replacing and
calibrating drive motor"
on page 21
5 x flashes Fault/brake fault
on left-hand motor.
Connection
loose/defective or
motor defective.
•Check plug-in
connections.
See "Checking the
cables" on page 41
Left motor
disengaged (GB-
motors)
•Engage motor. Shut
electronics down and then
switch on again.
See User Manual
Both motors
disengaged
(standard motors)
•Engage motors. Shut
electronics down and then
switch on again.
See User Manual
6 x flashes Fault/brake fault
on right-hand
motor. Connection
loose/defective or
motor defective.
•Check plug-in
connections.
See "Checking the
cables" on page 41
Right motor
disengaged (GB-
motors)
•Engage motor. Shut
electronics down and then
switch on again.
See User Manual
7 x flashes Battery dead •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
19

Flash code: Meaning: Solution: Notes
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 electronic
components" on page 31
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 electronic
components" on page 31
20