Invacare Bora XTR Series, Spectra XTR Series Service Manual

Edition: 1528338 Vers. 15 - 03.11.2014

Invacare ® Bora ®/Spectra ® XTR Series
SERVICE MANUAL

SERVICE MANUAL

Invacare

®

- Bora ®/Spectra ® XTR Series

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 ® - Bora ®/Spectra ® XTR Series

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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 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]
@: [e-mail]
@: [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

SERVICE MANUAL

Invacare

®

- Bora ®/Spectra ® XTR Series

4

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]
@: [e-mail]
@: [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]
@: [e-mail]
WWW: www.invacare.de

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Contents

Chapter Page

1 Introduction 9

1.1 General information .................................................................................................................. 9

1.2 Notes on transport .................................................................................................................... 9

1.3 Definition and representation of information and safety information in this manual ...... 10

1.4 Hazard symbols and symbols used ...................................................................................... 11

1.5 Images in this manual ............................................................................................................. 12

2 Safety and fitting instruct ions 13

2.1 Before any inspection or repair work .................................................................................... 13

2.2 Personal safety equipment ..................................................................................................... 13

2.3 General safety information and information about fitting / removal .................................. 13

3 Tightening torques 16
4 Layout of components and component ry 17

4.1 Overview ................................................................................................................................... 17

4.1.1 Wheelchair without lifter ................................................................................................ 17

4.1.2 Wheelchair with lifter ..................................................................................................... 19

4.2 Electronics modules ............................................................................................................... 21

4.2.1 ACS1 60A electronics module ...................................................................................... 23

4.2.2 ACS2 PMB70 / ACS2 PMB70L electronics module ..................................................... 23

4.2.3 ACS2 PMA90LG electronics module ............................................................................ 23

4.2.4 VR2 electronics module ................................................................................................ 23

4.2.5 R-Net electronics module ............................................................................................. 24

4.2.6 Shark electronics module ............................................................................................. 24

4.2.6.1 Shark with 4-pole DCI .............................................................................................. 24

4.2.6.2 Shark with DCI 12-pole ............................................................................................ 24

4.2.7 ACT actuator module .................................................................................................... 24

4.2.7.1 ACT 2 actuator module ............................................................................................ 25

4.2.7.2 ACT 4 actuator module ............................................................................................ 25

4.2.8 R-NET ISM lighting and actuator module ..................................................................... 25

4.2.9 Lighting PCB ................................................................................................................. 26

5 Maintenance plan (1x annually) 27

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6 Operational faults 29

6.1 Drive fault diagnosis ............................................................................................................... 29

6.2 REM24 remote: Error codes and diagnostic codes ............................................................. 31

6.3 VR2 remote: Error codes and diagnostic codes .................................................................. 33

6.4 Shark 2 remote Error codes and diagnostic codes ............................................................. 35

6.5 R-NET remote: Error codes and diagnostic codes .............................................................. 36

7 Repair work 38

7.1 General warning information about fitting work .................................................................. 38

7.2 Replacing drive components ................................................................................................. 38

7.2.1 Replacing the complete drive unit ................................................................................ 40

7.2.2 Replacing the motor ...................................................................................................... 41

7.2.3 Replacing the jaw clutch ............................................................................................... 42

7.2.4 Replace carbon brushes ............................................................................................... 43

7.2.5 Replacing the motor / gearbox unit (SSD motor).......................................................... 44

7.2.6 Replacing or rotating the motor / gearbox unit sealing ring .......................................... 46

7.2.7 Replacing the motor / gearbox coupling (SSD motor) .................................................. 47

7.2.8 Replacing the carbon brushes (SSD motor) ................................................................. 49

7.2.9 Replacing the drive wheel hub (SSD motor) ................................................................ 51

7.2.10 Fitting the clutch rotary knob (SSD motor) ................................................................... 53

7.3 Replacing the electronics ....................................................................................................... 54

7.4 Replacing the G-Trac sensor.................................................................................................. 56

7.5 Operating hours counter ........................................................................................................ 58

7.5.1 Replacing the operating hours counter ......................................................................... 58

7.5.2 Replacing the connecting cable of the operating hours counter .................................. 60

7.6 Updating software ................................................................................................................... 62

7.7 Replacing batteries ................................................................................................................. 63

7.7.1 Removing the battery cases ......................................................................................... 64

7.7.2 Removing the batteries ................................................................................................. 66

7.7.3 Correct handling of damaged batteries ........................................................................ 70

7.8 Checking and replacing the main fuse .................................................................................. 71

7.9 Checking the cable .................................................................................................................. 73

7.10 Differences when replacing the REM24 remote ................................................................... 75

7.11 Lighting unit ............................................................................................................................. 76

7.11.1 Replacing front headlight completely (LED lighting unit) .............................................. 76

7.11.2 Replacing the front bulb holder (LED lighting unit) ....................................................... 77

7.11.3 Replacing the rear light completely (LED lighting unit) ................................................. 78

7.11.4 Replacing the complete tail light assembly (conventional lighting system) .................. 79

7.11.5 Replacing the tail light bracket (conventional lighting system) ..................................... 80

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7.12 Anti-tipping mechanism .......................................................................................................... 81

7.12.1 Replacing the anti-tipping mechanism with screw ........................................................ 81

7.12.2 Replacing the anti-tipping mechanism with locking spring ........................................... 82

7.12.3 Replacing a defective locking spring ............................................................................ 83

7.13 Replacing the steering head bearings on the steering wheels .......................................... 84

7.14 Repairing punctures ................................................................................................................ 87

7.14.1 Repairing the rear tyre (wheel size 3.00-8") ................................................................. 87

7.14.2 Repairing a flat tyre (wheel size 280/250-4) ................................................................. 89

7.15 Replacing a drive wheel .......................................................................................................... 91

7.16 Replacing the splash guard .................................................................................................... 93

7.17 Seat system .............................................................................................................................. 95

7.17.1 Checking an adjusting motor ........................................................................................ 95

7.17.2 Replacing the seat tilting (wheelchair without lifter) ..................................................... 96

7.17.3 Replacing the lifter ........................................................................................................ 98

7.18 Backrest unit .......................................................................................................................... 100

7.18.1 Replacing the standard backrest ................................................................................ 100

7.18.2 Adjusting backrest former ........................................................................................... 101

7.19 Seat system Modulite ............................................................................................................ 102

7.19.1 Replacing the tilt actuator ........................................................................................... 102

7.19.2 Replacing the lifter actuator ........................................................................................ 103

7.19.3 Replacing the lifter / seat angle adjustment module ................................................... 104

7.19.4 Replacing the angle sensor ........................................................................................ 107

7.19.5 Replacing the backrest actuator ................................................................................. 108

7.19.6 Backrest actuator - Removing the adapter ................................................................. 109

7.20 Backrest Modulite .................................................................................................................. 110

7.20.1 Replacing the standard backrest ................................................................................ 110

7.20.2 Replacing the backrest mounting bracket .................................................................. 111

7.20.3 Replacing the backrest mounting bracket for SB 53 .................................................. 112

7.21 Adjusting the seat width/ backrest width (Modulite) ......................................................... 113

7.21.1 Adjusting the seat width .............................................................................................. 113

7.21.2 Adjusting the backrest width ....................................................................................... 115

7.21.3 Adjusting the Flex3 backrest....................................................................................... 117

8 Installing accessories 118

8.1 Replacing the holding strap ................................................................................................. 118

8.1.1 Standard seat & Flex2 ................................................................................................ 118

8.1.2 Fixed seat unit ............................................................................................................ 119

8.2 Replacing seat belts (Modulite seat) ................................................................................... 120

8.2.1 Installation on the backrest mounting bracket (simple backrest) ................................ 120

8.2.2 Installation on the backrest mounting bracket (adjustable seat) ................................ 121

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8.2.3 Installation on the seat frame profile (adjustable seat) ............................................... 122

8.3 Luggage carrier ..................................................................................................................... 123

8.4 Further accessories .............................................................................................................. 124

9 Adjusting the seating posit ion 125

9.1 Adjusting the lower leg length and seat depth................................................................... 126

9.1.1 Adjusting the lo we r l eg length ..................................................................................... 126

9.1.2 Adjusting the seat depth ............................................................................................. 126

9.2 Adjusting the center of gravity of the seat ......................................................................... 128

9.2.1 Standard seat ............................................................................................................. 130

9.2.2 Flex2 seat ................................................................................................................... 132

9.2.3 Modulite seat .............................................................................................................. 133

9.2.3.1 Adjustable seats .................................................................................................... 135

9.2.3.2 Simple seat ............................................................................................................ 136

9.2.3.3 Screw on position of the seat frame ...................................................................... 137

9.2.3.4 Seat depth setting facilities .................................................................................... 139

9.3 Check the tipping stability .................................................................................................... 141

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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 device

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 device 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 device 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 device has to be shipped back to the manufacturer for major repairs, you should
always use the original packaging for transport.

• You must include a precise fault description.

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1.3 Definition and represe nt a ti on 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 immedia te ha zards.

• The following lines in italics refer to actions which serve to avoid such hazards.

WARNING!

The signal word "WARNING!" refers to possi b ly-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 hazard s due to inattentive working with heavy
components.

• Always follow the instructions to avoid injury to the user or damage to the product!

EXPL O SIO N 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.

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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.

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 as prevention of accidents at work and it is imperative that
they are observed.

2.1 Before any inspection or re pai r w ork

• 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

Safet y 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 / rem oval

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!

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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!

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 th e maximum speed reduction on a
wheelchair with a lifter does not functio n 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.

ATTENTION!

Danger of injury due to improper retrofitti n g o f electric adjustment options.

Retrofitting electric adjustment options is a fundamental change to the configuration and can
have a negative impact on the driving characteristics and tipping stability of the electric
wheelchair.

• Retrofitting may only be performed by trained Invacare® dealers.

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Note

Mark all current settings for the mobility device (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 devices with a standard drive program ex-works. Invacare®
can only give a warranty for safe vehicle driving behaviour - especially the 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 improp erly 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

4.1.1 Wheelchair without lifter

Underneath the seat:

1) Seat disengager

2) Electronics module
The electronics modules used are

described in Chapter 4.2.

Power seat tilting

3) Adjusting motor

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Actuator module

4) Actuator module
The actuator module is fitted under the

seat support.

G-Trac sensor

5) G-Trac sensor
The optional G-Trac sensor is located in

the front, next to the battery connector.

Operation hour counter

6) Operation hour counter
The optional operation hour counter is

mounted laterally on the frame.

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4.1.2 Wheelchair with lifter

In front of the batteries under the
plastic cover:

1) Electronics module

2) Lighting PCB (optional)

3) Plastic cover

The electronics modules used are
described in Chapter 4.2.

Actuator module

4) Actuator module 1 (optional)

5) Actuator module 2 (optional)

6) Actuator motor backrest (optional)
The actuator modules are fitted under the

seat support.

Electric seat adjustment

6) Actuator motor backrest (optional)

7) Actuator motor seat tilting

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Electric lifter

8) Lifter motor

G-Trac sensor

9) G-Trac sensor
The optional G-Trac sensor is located in

the front, next to the battery connector.

Operation hour counter

10) Operation hour counter

The optional operation hour counter is
mounted laterally on the frame.

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4.2 Electronics modules

A variety of electronics modules can be fitted to the mobility device.
Before you connect any mobility device components such as adjusting motors/actuators or motors

to the electronics modules, you should first ensure that you know exactly which electronics module
has been fitted. Please refer to the following table for an overview.

Electronics module Designation Joystick boxes Notes

ACS1 60A

ACS1 60A with
ACT actuator
module

REM24 remote

The actuator module
is optional.

ACS2 PMB70
ACS2 PMB70L
ACS2 PMA90LG

ACS2 with ACT
actuator modul

G90A
REM A
REM B
REM 550

The actuator module
is optional.

VR2 VR2 remote

R-Net R-Net remote

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Electronics module Designation Joystick boxes Notes

Shark

Shark with lighting
PCB

Shark II remote

The lighting PCB is
optional.

ACT actuator
module

The actuator module

is optional.

R-NET ISM lighting
and actuator
module

The module is

optional.

Lighting PCB The lightin g PC B is

optional.

G-Trac sensor The G-Trac sensor is

optional.

Operation hour
counter

The operation hour

counter is optional.

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4.2.1 ACS1 60A electronics module

Connections

1) Motor M2

2) Battery 24V

3) Bus cable (to remote or ACT)

4) Bus cable (to remote or ACT)

5) Motor M1

4.2.2 ACS2 PMB70 / ACS2 PMB70L electronics 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

4.2.3 ACS2 PMA90LG electronics module

Connections

1) Battery 24 V

2) Cable to G-Trac sensor (GYRO)

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

4.2.4 VR2 electronics module

Connections

1) Joystick box

2) Lock (INHIBIT 2)

3) Actuator 1

4) Actuator 2

5) On-board battery charger

6) Motor M1

7) Battery 24V

8) Motor M2

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4.2.5 R-Net electronics module

Connections

1) Bus

2) Lock (INHIBIT 2)

3) Actuator 1

4) Actuator 2

5) On-board battery charger

6) Motor M1

7) Battery 24V

8) Motor M2

4.2.6 Shark electronics module

4.2.6.1 Shark with 4-pole DCI

BUS CABLE

Connections

1) Joystick box

2) DCI for actuators (4-pole)

3) Right-hand motor M1

4) Battery 24V

5) Left-hand motor M2

4.2.6.2 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

4.2.7 ACT actuator module

A range of adjusting motors, also known as actuators, can be fitted to the mobility device. These
actuators are either connected directly to the electronics module or to a separate actuator module.
The actuator module is connected with the electronics module via a bus cable.

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4.2.7.1 AC T 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.

4.2.7.2 AC T 4 actuator module

Connections

1) ACI*

2) Bus cable (to remote or electronics

module)

3) Bus cable (to remote or electronics
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.

4.2.8 R-NET ISM lighting and actuator module

A range of adjusting motors, also known as actuators, can be fitted to the wheelchair. These
actuators are either connected directly to the electronics module or to a separate actuator module.
The actuator module is connected with the electronics module via a bus cable.

In addition, the lighting can be connected to the R-NET ISM. An additional lighting PCB is not then
required.

SERVICE MANUAL

Invacare

®

- Bora ®/Spectra ® XTR Series

26

Connections

1) Bus cable (to remote or ACT)

2) Light left

3) Adjusting motor/actuator - Channel 1

4) Adjusting motor/actuator - Channel 3

5) Adjusting motor/actuator - Channel 5

6) INH 4*

7) INH 5*

8) Adjusting motor/actuator - Channel 6

9) Adjusting motor/actuator - Channel 4

10) Adjusting motor/actuator - Channel 2

11) Light right

12) Bus cable (to remote or ACT)

* The INH connection is used for actuator limitation or speed reduction.

4.2.9 Lighting PCB

The lighting PCB connections are printed on the circuit board itself.

Invacare ® - Bora ®/Spectra ® XTR Series

SERVICE MANUAL

27

5 Maintenance plan (1x annually)

CAUTION!

Danger of injury and damage to property, if th e maximum speed reduction on a
wheelchair with a lifter does not functio n 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

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 lock

• Seat lock defective • Replace seat lock

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

Wheel
suspension and
wheels

• Check drive wheels
for tight fit and side
play

• Adjust, replace
wheel hubs

See chapter 7.15.

• Check steering
wheels for tight fit,
float and side play

• Replace wheels,
wheel fork or
wheel bearings

See chapter 7.11.

• Pneumatic tyres (if
fitted)

• Repair or replace
if damaged

See chapter 7.14.

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®

- Bora ®/Spectra ® XTR Series

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Component Check Remedy Notes

ü

Drive units,
coupling
mechanism

• Check functions in
drive and push
modes

• Check coupling
mechanism

• Replace motor if
necessary.

• Tighten
screws/nuts,
adjust or replace if
necessary

Legrests

• Check welded
seams, interlocking,
screws, footplates

• Tighten, replace if
necessary

Power legrests
(if fitted)

• Check cable

• Check contacts

• check functions

• Replace cable if

necessary

Lighting (if
fitted)

• Check cable

• Check function

• Replace lamp or

cable if necessary

Batteries

• Check batteries for
damage

• Replace batteries
if necessary

See chapter 7.7.

• Check battery
voltage

• Charge batteries

See operating
manual

• Check contacts and
terminals

• Clean contacts
and terminals

Please refer to the
safety information
in Chapter 7.7 for
handling batteries

Battery case

• Check locking
system, it must
engage completely.

• Replace if
necessary

Remote /
electronics
module

• Remote, status
display blinking

• Evaluate
error/blink code

• Fixings • Tighten fixings,
replace if
necessary

• Cables and

connecting plugs

• Tighten cables
and connecting
plugs, replace if
necessary

• Drive lever function • Replace drive
lever if necessary

• Replace remote if
necessary

• Power suppl y • Tighten cables
and connecting
plugs, replace if
necessary

Drive program

• Check drive

electronics program
version

• Update software if
newer version
available.

See chapter 7.6.

Invacare ® - Bora ®/Spectra ® XTR Series

SERVICE MANUAL

29

6 Operational faults

The various electronics modules can be fitted in connection with differing remotes in the mobility
device. Rectification of operational faults is dependent on the electronics module fitted.

The electronics modules used are described in Chapter 4.2.

NOTE:

The tables for rectification of operational faults listed in the following chapters are only an excerpt
from the original manufacturer's manuals.

You can obtain the original manuals from Invacare®.

If you have problems with the mobility device, please proceed as follows:

• First assess the possible cause of the problem using the following table.

• Check the remote status display. Evaluate the error code.

• Carry out the necessary checks and repairs as recommended in the following table.

6.1 Drive fault diagnosis

Problem Other

Symptoms

Possible
Cause

Solution Documentation

Mobility
device will
not start

The remote
status display
illuminates
normally and
does not show
an error code.

Drive motors
disengaged

Engage drive
motors

See operating manual

Remote status
display does not
illuminate

batteries
defective

Replace batteries See chapter 7.7.

Completely
discharge
battery

Pre-charge
batteries

See operating manual

Power suppl y
to remote
interrupted

Check master
fuse

See chapter 7.2.9.

Check cables
between the
modules for loose
connections and
damage

See chapter 7.9.

Remote
defective

Replace remote See chapter 7.10.

Remote status
display blinking

Various
causes

Assess error code See chapter 6.2.

Mobility
device
judders in
drive mode

None

Batteries
defective
(unstable
voltage)

Replace batteries See chapter 7.7.

Drive motor(s)
defective

Replace motor(s) See chapter 7.2 .

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30

Problem Other

Symptoms

Possible
Cause

Solution Documentation

Replace carbon

brushes

See chapter 7.2.4.

Batteries
not being
charged

None Batteries

defective

Replace batteries See chapter 7.7.

LEDs blinking
on charging unit

Charging unit
defective

Replace charging
unit

See charging unit
operating manual

Mobility
device
runs too
slowly

None Remote

defective

Replace remote See chapter 7.10.

Batteries
defective

Replace batteries See chapter 7.7.

Electrical
adjustment
motor
does not
react

Remote shows
a blinking "E",
status diode on
lighting/actuator
module does
not go out even
if remote is
switched off or
disconnected.

Lighting /
actuator
module
defective

Replace lighting /
actuator module

See chapter 7.2.9.

None Cable

disconnected
or damaged

Safeguard cable
connection,
replace cable if
necessary

See chapter 7.9.

Electrical
adjusting
motor
defective

Check adjusting
motor

See chapter 7.17.

Remote
defective

Replace remote See chapter 7.10.