Invacare Comet Series, Comet PRO, Comet ULTRA, Comet ALPINE+, Comet ALPINE PLUS Service Manual

Invacare® Comet Series

Comet

PRO

, Comet

ALPINE+

, Comet

ULTRA

enScooter

ServiceManual

DEALER:Keepthismanual.
TheproceduresinthismanualMUSTbeperformedbyaqualied
technician.

©2018InvacareCorporation
Allrightsreserved.Republication,duplicationormodicationinwholeorinpartisprohibitedwithoutpriorwritten
permissionfromInvacare.Trademarksareidentiedby™and®.AlltrademarksareownedbyorlicensedtoInvacare
Corporationoritssubsidiariesunlessotherwisenoted.
Invacarereservestherighttoalterproductspecicationswithoutfurthernotice.

Contents

1General.........................................4

1.1Generalinformation............................4

1.2Notesonshipping..............................4

1.3Symbolsinthismanual..........................4

1.4Imagesinthismanual...........................4

2Safety..........................................5

2.1Safetyandttinginstructions.....................5

3Hygiene.........................................7

3.1Handlingofreturnedusedproducts.................7

4Service..........................................8

4.1Generalsafetyinformationoninstallationwork........8

4.2Troubleshooting...............................8

4.2.1Operationalfaults...........................8

4.2.2Drivefaultdiagnosis..........................8

4.2.3Errorcodesanddiagnosticcodes................9

4.3Tighteningtorques.............................9

4.4Serviceplan(1xannually)........................10

4.5Controls.....................................11

4.5.1Replacingoperatingconsole....................11

4.5.2Replacingcircuitboard........................12

4.5.3Replacingpotentiometer......................12

4.5.4Replacinglifter/liftercontrols...................13

4.5.5Replacingpowermodule......................14

4.5.6Setupsettings..............................15

4.6Shrouds.....................................18

4.6.1Removingshroud............................18

4.6.2Replacingfrontshroud........................18

4.7Lightingunit..................................19

4.7.1Replacingheadlight..........................19

4.7.2Replacingfrontdirectionindicators...............19

4.7.3Replacingcenterbrakelight....................20

4.7.4Replacingrearlights/directionindicators...........20

4.8Wheels......................................21

4.8.1Replacingwheelsuspension....................21

4.8.2Replacingshockabsorber......................22

4.8.3Replacingswingarm.........................22

4.8.4Replacingsteeringcolumn.....................23

4.8.5Replacingfrontwheelsuspension4–wheel.........24

4.8.6ReplacingandAdjustingCentralRearShock

Absorber.................................25

4.8.7Repairingtirepunctures.......................26

4.9Brakes.......................................26

4.9.1Replacinghandbrakes........................26

4.9.2Replacingbrakecable.........................27

4.9.3Replacingsteeringlink/couplingrod..............27

4.9.4Replacingcurvecontroldevice..................28

4.10Drivecomponents.............................29

4.10.1Replacingdriveunit.........................29

4.10.2Replacingcarbonbrushes.....................31

4.11Seatsystem..................................31

4.11.1Replacingseatsuspension/spring...............31

4.11.2Replacingseatsupporttube...................32

4.12Accessories..................................32

4.12.1Accessorieslist.............................32

Comet

1General

1.1Generalinformation

•Serviceandmaintenanceworkmustbecarriedout
takingthisservicemanualintoaccount.

•Itisimperativethatyouobservesafetyinformation.

•Informationaboutoperationoraboutgeneral
maintenanceandcareworkonthemobilitydevice
shouldbetakenfromServicemanual.

•Y oucanndinformationaboutorderingsparepartsin
thesparepartscatalogue.

•SparepartsMUSTmatchoriginalInvacareparts.Only
usesparepartswhichhavebeenapprovedbyInvacare.

•Wereservetherighttomakeanyalterationsonthe
groundsoftechnicalimprovements.

•Formoreinformationabouttheproduct,forexample
productsafetynoticesandproductrecalls,contactyour
localInvacarerepresentative.Foraddressandwebsite
seebackpageofthismanual.

•Themobilitydevicemayonlybemaintainedand
overhauledbyqualiedpersonnel.

•Theminimumrequirementforservicetechniciansis
suitabletraining,suchasinthecycleororthopedic
mechanicselds,orsufcientlylong-termjob
experience.

–Experienceintheuseofelectricalmeasuring

equipment(multimeters)isalsoarequirement.

–SpecialInvacaretrainingisrecommended.

•Alterationstothemobilitydevicewhichoccurasaresult
ofincorrectlyorimproperlyexecutedmaintenanceor
overhaulworkleadtotheexclusionofallliabilityon
thesideofINVACARE.

•IfyouhaveanyproblemsorquestionscontactInvacare
Service.

1.2Notesonshipping

•Ifthemobilitydevicehastobeshippedbacktothe
manufacturerformajorrepairs,youshouldalwaysuse
theoriginalpackagingfortransport.

•Pleaseattachaprecisedescriptionofthefault.

1.3Symbolsinthismanual

Inthismanual,hazardstatementsareindicatedbysymbols.
Thesymbolsareaccompaniedbyasignalwordthatindicates
theseverityoftherisk.

WARNING
Indicatesahazardoussituationthatcouldresult
inseriousinjuryordeathifitisnotavoided.

CAUTION
Indicatesahazardoussituationthatcouldresult
inminororslightinjuryifitisnotavoided.

IMPORTANT
Indicatesahazardoussituationthatcouldresult
indamagetopropertyifitisnotavoided.

Givesusefultips,recommendationsand
informationforefcient,trouble-freeuse.

ThisproductcomplieswithDirective93/42/EEC
concerningmedicaldevices.Thelaunchdate
ofthisproductisstatedintheCEdeclaration
ofconformity.

Thissymbolidentiesalistofvarioustools,
componentsanditemswhichyouwillneedin
ordertocarryoutcertainwork.

1.4Imagesinthismanual

Thedetailedimagesinthismanualaregivenmarksto
identifyvariouscomponents.Componentmarksintextand
operationalinstructionsalwaysrelatetotheimagedirectly
above.

4

1603798-B

Safety

2Safety

2.1Safetyandttinginstructions

Thesesafetyinstructionsareintendedtopreventaccidents
atwork,anditisimperativethattheyareobserved.

Beforeanyinspectionorrepairwork

•Readandobservethisrepairmanualandtheassociated
usermanual.

•Observetheminimumrequirementsforcarryingoutthe
work(see1.1Generalinformation,page4).

Personalsafetyequipment

Safetyshoes

Themobilitydevice,andsomeofitscomponents,arevery
heavy.Thesepartscanresultininjuriestothefeetifthey
areallowedtodrop.

•Wearstandardizedsafetyshoesduringallwork.

Eyeprotection

Itispossiblethatbatteryacidcanbedischargedwhen
workingondefectivebatteriesorwhenhandlingbatteries
improperly.

•Alwaysweareyeprotectionwhenworkingonany
defectiveorpossiblydefectivebatteries.

Safetygloves

Itispossiblethatbatteryacidcanbedischargedwhen
workingondefectivebatteriesorwhenhandlingbatteries
improperly.

•Alwayswearacid-proofsafetygloveswhenworkingon
anydefectiveorpossiblydefectivebatteries.

Generalsafetyinformationandinformationabouttting
/removal

DANGER!
RiskofDeath,SeriousInjury,orDamage

Lightedcigarettesdroppedontoanupholstered
seatingsystemcancauseareresultingin
death,seriousinjury,ordamage.Mobilitydevice
occupantsareatparticularriskofdeathor
seriousinjuryfromtheseresandresultingfumes
becausetheymaynothavetheabilitytomove
awayfromthemobilitydevice.

–DONOTsmokewhileusingthismobilitydevice.

WARNING!
RiskofSeriousInjuryorDamage

Storingorusingthemobilitydevicenearopen
ameorcombustibleproductscanresultin
seriousinjuryordamage.

–Avoidstoringorusingthemobilitydevicenear

openameorcombustibleproducts.

CAUTION!
Riskofcrushing

Variouscomponentssuchasthedriveunit,
batteries,seatetcareveryheavy .Thisresultsin
injuryhazardstoyourhands.

–Notethehighweightofsomecomponents.

Thisappliesespeciallytotheremovalofdrive
units,batteriesandtheseat.

CAUTION!
Injuryhazardifthevehiclestartsmoving
unintentionallyduringrepairwork

–Switchthepowersupplyoff(ON/OFFkey).
–Engagethedrive.
–Beforeliftingup,securethevehiclebyusing

chockstoblockthewheels.

CAUTION!
Fireandburnhazardduetoelectricalshort-circuit

–Themobilitydevicemustbecompletely

switchedoffbeforeremovalofvoltage-carrying
components!T odothis,removethebatteries.

–Avoidshort-circuitingthecontactswhen

carryingoutmeasurementsonvoltage-carrying
components.

CAUTION!
Riskofburnsfromhotsurfacesonthemotor

–Allowthemotorstocooldownbefore

commencingworkonthem.

CAUTION!
Injuryhazardandriskofdamagetovehicledue
toimproperorincompletemaintenancework

–Useonlyundamagedtoolsingoodcondition.
–Somemovingpartsaremountedinsockets

withPTFEcoating(Teon™).Nevergrease
thesesockets!

–Neveruse"normal"nutsinsteadofself-locking

nuts.

–Alwaysusecorrectly-dimensionedwashersand

spacers.

–Whenreassembling,alwaysreplaceanycable

tieswhichwerecutduringdismantling.

–Aftercompletingyourwork/beforerenewed

start-upofthemobilitydevice,checkall
connectionsfortighttting.

–Aftercompletingyourwork/beforerenewed

start-upofthemobilitydevice,checkallparts
forcorrectlocking.

–Onlyoperatethevehiclewiththeapprovedtire

pressures(seetechnicaldata).

–Checkallelectricalcomponentsforcorrect

function.Notethatincorrectpolaritycanresult
indamagetotheelectronics.

–Alwayscarryoutatrialrunattheendofyour

work.

CAUTION!
Riskofinjuryanddamagetoproperty,ifthe
maximumspeedreductiononawheelchairwith
alifterdoesnotfunctioncorrectly

Thewheelchair’scontrolunitmustreducethe
maximumpossiblespeedassoonasthelifteris
raised.

–T estthemaximumspeedreductionforcorrect

functionafteranymaintenanceworkor
modicationstothewheelchair.

1603798-B5

Comet

CAUTION!
Anychangestothedriveprogramcanaffectthe
drivingcharacteristicsandthetippingstability
ofthevehicle

–Changestothedriveprogrammayonlybe

carriedoutbytrainedInvacarespecialist
dealers.

–Invacaresuppliesallmobilitydeviceswitha

standarddriveprogramex-works.Invacarecan
onlygiveawarrantyforsafevehicledriving
behavior-especiallytippingstability-forthis
standarddriveprogram.

Markallcurrentsettingsforthemobilitydevice
(seat,armrests,backrestetc.),andtheassociated
cableconnectingplugs,beforedismantling.This
makesreassemblyeasier.Allplugsarettedwith
mechanicalsafetydeviceswhichpreventreleaseof
theconnectingplugsduringoperation.T oreleasethe
connectingplugsthesafetydevicesmustbepressed
in.Whenreassemblingensurethatthesesafety
devicesarecorrectlyengaged.

61603798-B

Hygiene

3Hygiene

3.1Handlingofreturnedusedproducts

Whenreconditioningorrepairingreturnedmobilitydevices:

•T akeprecautionsforyourselfandtheproduct.

•Useprotectionequipmentasspeciedlocally.

Beforetransport(accordingtoBiologicalAgentsOrdinance)

Treatproductaccordingtofollowingprocesssteps:

Processstep

Component

ApplicationConditioningtechniqueWorkstation

ManualcleaningSurfaceofuseddeviceBeforerepairor

reconditioning

Usesaturatedtowel
toapplycleaning
detergentandremove
residuesafterimpact.

Cleaningand
disinfection

DisinfectionSurfaceofuseddeviceBeforerepairor

reconditioning

Usesaturated
disinfectantwipes
andclean*thedevice
surface.

Cleaningand
disinfection

*Invacareusesdetergent"Nücoseptspecial"1.5%inwat erml/ml

Disinfectiontools

•Onewaywipes(eece)

•Brushestocleandifculttoaccessareas

Furtherinformation

FormoreinformationcontactyourInvacareServicedepartment.

1603798-B

7

Comet

4Service

4.1Generalsafetyinformationoninstallation
work

Riskofdamagetomobilitydevice

Collisionscanbecausedifshimringsareremoved
fromthedrivewheelsduringinstallationwork.
Shimringsarefrequentlyplacedbetweendrive
shaftandwheelhubtocompensatetolerances.
Collisionscanbecausediftheseshimringsare
removedandnotre-installed.

–Installallshimringsinexactlythesame

positionstheywereinbeforedismantling.

4.2Troubleshooting

4.2.1Operationalfaults

Proceedasfollowsifyouhaveanyproblems:

1.Firstassessthepossiblecauseoftheproblemusingthe
followingtable.

2.Checkoperatingconsolestatusdisplay.Evaluateash
code.

3.Carryoutnecessarychecksandrepairsasrecommended
inthefollowingtable.

4.2.2Drivefaultdiagnosis

ProblemOthersymptomsPossiblecauseSolution

Documentation

BatteriesdefectiveReplacebatteriesSeeusermanual

Completely
dischargedbattery

Pre-chargebatteries

Powersupplyto
operatingconsole
interrupted

CheckmainfuseSeeusermanualfor

mainfuseposition

Checkcablebetween
modulesforloose
connectionsor
damage

SeeReplacingpower

module

Statusdisplayon
operatingconsole
doesnotilluminate

Operatingconsole
defective

Replaceoperating
console

See4.5.1Replacing

operatingconsole,
page11

Scooterwillnotstart

Statusdisplayon
operatingconsole
ashing

Variouscauses

AssesserrorcodeSeecontrolsuser

manual

Drivemotor(s)
defective

Replacemotor(s)

See

Scooterjuddersindrivemode

None

Drivelever
potentiometer
defective

Replace
potentiometer

See4.5.3Replacing

potentiometer,page
12

None

BatteriesdefectiveReplacebatteriesSeeusermanual Batteriesnotbeingcharged

LEDsashingon
charger

ChargerdefectiveReplacechargerSeechargeruser

manual

Operatingconsole
defective

Replaceoperating
console

See4.5.1Replacing

operatingconsole,
page11

Scooterrunstooslowly

None

BatteriesdefectiveReplacebatteriesSeeusermanual

Curvecontroldevice
forbendtravelnot
adjusted

Adjustcurvecontrol
device

Scooterdoesnotreducespeed
onbends

None

Curvecontroldevice
defective

Replacecurve
controldevice

See4.9.4Replacing

curvecontroldevice,
page28

81603798-B

Service

4.2.3Errorcodesanddiagnosticcodes

FlashcodeFault

Consequenceforthe
scooterComments

1

Batteriesmustbe
charged

Continuestodrive•Thebatteriesaredischarged.Chargethebatteries

assoonaspossible.

2

BatteryvoltagetoolowStopsdriving•Thebatteriesaredepleted.Chargebatteries.

•Ifyouswitchthescooteroffforafewminutes,the
batteriescanoftenrecuperatetosuchastagethata
shortjourneyisstillpossible.Y oushouldonlydothis
inanemergency,however ,becausethiscausesthe
batteriestobecomeexcessivelydischarged.

3

BatteryvoltagetoohighStopsdriving•Thebatteryvoltageistoohigh.Ifthebatterycharger

isconnected,disconnectitfromthescooter .

•Theelectronicsystemchargesthebatterieswhen
runningdownhillandwhenbraking.Thisfaultis
causedwhenthebatteryvoltagebecomestoohigh
duringthisprocess.Switchthescooteroffandon
again.

4

PowertimeexceededStopsdriving•Themaximumcurrentwasexceededovertoolonga

period,probablybecausethemotorwasoverloaded
orhasbeenworkingagainstanimmovableresistance.
Switchthescooteroff,waitafewminutesandthen
switchonagain.

•Theelectronicsystemhasdeterminedamotor
short-circuit.Checkthewiringharnessforshort-circuit
andcheckthemotor .

•ContactyourInvacareprovider.

5

BrakefailureStopsdriving•Ensurethatthedisengagingleverisintheengaged

position.

•Thereisadefectinthebrakingcoilorinthecabling.
Checkthemagneticbrakeandcablingforopen
orshort-circuitedcircuitry.ContactyourInvacare
provider .

6

Noneutralposition
whenswitchingscooter
on.

Stopsdriving•Driveleverisnotinneutralwhenthekeyswitchwas

turned.Putthedriveleverinneutral,turnthepower
offandthenturnonagain.

•Itmaybenecessarytoreplacethedrivelever.
ContactyourInvacareprovider .

7

Faultinspeed
potentiometer

Stopsdriving•Thedrivelevercontrolscouldbefaultyor

incorrectlyconnected.Checkthecablingforopen
orshort-circuitedcircuitry.

•Potentiometerisnotcorrectlyadjustedandmustbe
replaced.ContactyourInvacareprovider .

8

MotorvoltageerrorStopsdriving•Themotororitscablingisdefective.Checkthe

cablingforopenorshort-circuitedcircuitry.

9

Miscellaneousinternal
fault

Stopsdriving•ContactyourInvacareprovider.

10

Push/freewheelmode
error

Stopsmoving

•Thescooterhasexceededthepermissiblemaximum
speedduringpushingorfreewheeling.Switchthe
electronicssystemoffandonagain.

4.3Tighteningtorques

CAUTION!
Riskofdamagetomobilitydevicedueto
improperlytightenedscrews,nutsorplastic
connections.

–Alwaystightenscrews,nutsetc.tothestated

tighteningtorque.

–Onlytightenscrewsornutswhicharenotlisted

herengertight.

Thetighteningtorquesstatedinthefollowinglistarebased
onthethreaddiameterforthenutsandboltsforwhichno
specicvalueshavebeendetermined.Allvaluesassume
dryandde-greasedthreads.

ThreadTighteningtorquein

Nm±10%

M43Nm

M5

6Nm

1603798-B9

Comet

ThreadTighteningtorquein

Nm±10%

M610Nm

M825Nm

M1049Nm

ThreadTighteningtorquein

Nm±10%

M1280Nm

M14120Nm

M16180Nm

4.4Serviceplan(1xannually)

Component

CheckRemedy

Notes

Checkwelded
seams,xingsand
upholstery

Tightenscrews,
replacepartsif
damaged

Seat

Checkseat
suspension

Greasethespring
generously,replace
partsifdamaged

SeeReplacingseat

suspension/spring

Checkxings,
weldedseamsand
batterymounting

Frames(chassis)/batterymounting

Checkbatteryxing
straps

Tightenscrews,
replacepartsif
damaged

Checkdrivewheels
fortightt

Tightenhubnuts,
replaceifnecessary

Checkfrontwheels
fortightt,oat
andsideplay

Adjust/replace

Checkpneumatic
tire

Repairorreplaceif
damaged

Seeusermanual

Tightenscrews

Wheelsuspensionandwheels

Checktrackingand
steeringlink

Checktrackingand
steering

BrakeCheckbrake

functioninpushing
mode

Adjustorreplace
brake

ShockabsorberCheckshock

absorber

Adjustorreplace
shockabsorber

Checkfunctions
indriveandpush
modes

Replacemotorif
necessary

Driveunits,couplingmechanism

Checkclutch
mechanism

Tightenscrews/
nuts,adjustor
replace

Checkfunction Lighting

Checkcable/plug
connections

Replacelightbulbs
orcable

Checkbatteriesfor
damage

ReplacebatteriesSeeusermanual

Checkbattery
voltage

ChargebatteriesSeeusermanual

Batteries

Checkcontactsand
terminals

Cleancontactsand
terminals

101603798-B

Service

Component

CheckRemedy

Notes

Checkstatusdisplay
(ashing)

Evaluateashcode

CheckxingTightenorreplace

xing

Checkcable,
connectingplug

Replacecable,
connectingplug

Checkdrivelever
function

Replacedrivelever

Drivecontrols

CheckpowersupplyReplacecable,

connectingplug
orconsole

Driveprogram

Checkdrive
programversion.
Newversion
available?

Updatesoftware

Checkcableand
connectingplug

Adjustorreplace
sensoroncurve
controldevice

Curvecontrolinbends

Checkfunction

Screws

Checkscrewsfor
tightt

Tightenscrewsif
necessary

4.5Controls

4.5.1Replacingoperatingconsole

CAUTION!
Riskofburnsifpowercableisshorted

–Turnoffthepowercompletelybeforeremoving

anypowersupplycomponentsofmobility
device.Thereforetakeoutbatteries.

–Avoidbridgingofcontactsduringmeasurements

onliveelectricalcomponents.

Riskofdamagetooperatingconsole/circuit
boardbyinstanthighcurrent/voltage

–Unplugbatterycablebeforeremoving/installing

operatingconsole.

–Makesureallpinsarecorrectlyconnected.

Theplugsontheoperatingconsolecannotbe
wronglyconnectedbecauseallplugshaveadifferent
sizeandonlytinonesocket.

•Phillipsscrewdriver

Settingbatterygaugeismandatorywhenretrotting
operatingconsole.

Settingwheeldiameterismandatorywhen
retrottingoperatingconsole.

1.Removeseat.

2.Removeshroud.

3.

DisconnectbatterycableA.

4.

RemovetopshroudAfromsteeringcolumnB.

1603798-B

11