Invacare Dragon Vertic Service Manual

Edition: 10.04.12

Invacare® Dragon Vertic
SERVICE INSTRUCTIONS

SERVICE MANUAL

Invacare

®

- Dragon Vertic

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

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SERVICE MANUAL

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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

®

- Dragon Vertic

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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SERVICE MANUAL

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Table of Contents

Chapter Page

1 INTRODUCTION 7

1.1 General information 7

1.2 Notes on transport 7

1.3 Important symbols in this manual 7

2 SAFETY AND ASSEMBLY INSTRUCTIONS 9

2.1 Before any inspection or repair work 9

2.2 General safety information and notes on assembly / disassembly 9

3 TIGHTENING TORQUES 11

4 ALLOCATION OF THE SUB-ASSEMBLIES AND COMPONENTS 12

5 MAINTENANCE PLAN (ONCE A YEAR) 13

6 OPERATIONAL FAULTS 15

6.1 Operational disturbances on wheelchair with ACS 15

6.1.1 Drive disturbance diagnostics 15

6.1.2 Diagnostics involving disturbances with electric regulating motors 17

6.1.3 REM24 error codes and diagnostics codes 18

6.2 Operational faults on a wheelchair fitted with Shark electronics 20

6.2.1 Diagnosis of actuation disorders 20

6.2.2 Shark error codes and diagnostic codes 22

7 REPAIR WORK 24

7.1 General warning information on installation work 24

7.2 Replacing a motor 24

7.3 Replacing the Shark Electronics 28

7.4 Updating the driving program 30

7.5 Changing the batteries 31

7.5.1 Removing the batteries 31

7.5.2 How to handle damaged batteries correctly 32

7.6 Checking and replacing the main fuse 33

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®

- Dragon Vertic

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7.7 Checking the cables 35

7.8 Replacing the Shark II Remote 37

7.9 Replacing the ACS Remote 38

7.10 Replacing the steering head bearings on the steering wheels 40

7.11 Repairing a flat tyre 42

7.11.1 Repairing the flat tyre (pneumatic tyre equipment type 12½ x 2¼") 42

7.11.2 Repairing a flat tyre (pneumatic tyre equipment type 220/120 x 50) 43

7.12 Replacing a drive wheel 45

7.13 Checking a regulating motor 46

7.14 Replacing the verticalizer actuator 46

7.15 Replacing the safety belt 48

7.16 Chest strap 49

7.16.1 Replacing the chest strap 49

7.16.2 Replacing the additional belt 50

8 ADJUSTING THE WHEELCHAIR TO THE USER'S SEATING POSTURE 51

8.1 Adjusting the seat depth 51

8.2 Legrest 53

8.2.1 Setting the lower leg length of the legrest 53

8.3 Changing the height of the backrest 54

8.4 Restraining straps for the legs 57

8.4.1 Opening and closing the restraining strap 57

8.4.2 Adjusting the position of the release lever 57

8.4.3 Adjusting the retaining bar and knee cushions 58

8.4.3.1 Setting the depth of the restraining strap 58

8.4.3.2 Adjusting the height of the knee cushions 59

8.4.3.3 Setting the width of the knee cushions 60

8.5 Adjusting the armrests and the control panel 61

8.5.1 Adapting the height of the armrests 61

8.5.2 Setting the angle of the swing-up armrest 61

8.5.3 Setting the resistance of the swing-up armrest 62

8.5.4 Adapting the control panel to the length of the user’s arm 62

8.5.5 Setting the height of the remote 63

8.5.6 Adjusting the width of the armrests 63

8.6 Adapting the height of the chest belt 64

8.7 Adjusting the headrest 65

8.7.1 Adjusting the height 65

8.7.2 Setting the position 65

8.8 Adjustment of the stand-up angle 66

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SERVICE MANUAL

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1 Introduction

1.1 General information

• 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 electric vehicle 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 electric vehicle 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 electric vehicle 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 I NVACARE.

• If you have any problems or questions please contact INVACARE SERVICE.

1.2 Notes on transport

• If the electric vehicle has to be shipped back to the manufacturer for major repairs, you should
always use the original packaging for transport.

• You should also include as accurate a fault description as possible.

1.3 Important symbols in this manual

General risks

This symbol warns you of general hazards!

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

EXPLOSION HAZARD!

This symbol warns you of an explosion hazard, which can be caused by excessive tyre
pressure in a pneumatic tyre.

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

BURN HAZARD!

This symbol warns you of 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.

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BURN Risk!

This symbol warns of the risk of burns, for example, as a result of hot motor surfaces.

• Follow the instructions in order to avoid injury or damage to the product.

RISK OF CRUSHING!

This symbol warns of a risk of crushing caused by being careless with heavy
components.

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

Wear eye protection

This symbol refers to the requirement for wearing eye protection, for example when
working with batteries.

• You must wear safety goggles when this symbol is displayed.

Wear protective gloves

This symbol indicates the requirement to wear protective gloves, for example when
working with batteries.

You must wear protective gloves when this symbol is displayed.

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 i tems 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.

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2 Safety and assembly instructions

These safety instructions are intended to prevent accidents during work and it is imperative that
they are observed.

2.1 Before any inspection or repair work

• Read and observe this repair manual and the associated operating manual!

• Observe the minimum requirements for carrying out the work (see chapter entitled "General

information”)!

2.2 General safety information and notes on assembly / disassembly

Danger of injury by crushing!

• Please note the heavy weight of some components. This applies especially to rem oval of
drive units and batteries!

• Prop up the lifted electric vehicle with appropriate supports before starting the disassem bl y or
assembly!

Danger of fire and burns due to electrical short-circuit!

• The electric vehicle must be switched off before removal of voltage-carrying components! T o
do this, disconnect the batteries!

• When making measurements on voltage-carrying components, avoid short-circuiting the
contacts. Danger of fire and combustion!

Danger of injury and damage to the vehicle can result from incorrect or incomplete

maintenance!

• Only ever use tools which are undamaged in good condition!

• Some moving parts have Teflon bushings! These parts must never be lubricated with grease!

• Never use standard nuts instead of self-locking nuts!

• Always use correctly dimensioned washers or spacers!

• Cable binders which have been cut off during disassembly should be replaced with new ones

during reassembly!

• After completing maintenance work and before operating the electric vehicle, make sure all
fixations are correctly secured! Check all parts for correct interlocking1

• Only operate the electric vehicle with correct tyre pressure (see Technical Specifications)!

• Check electrical components for correct functioning, incorrect polarity of cables can result in

damage to the electronics!

• As a last check, always carry out a test-drive!

Notes

Mark all current settings for the electric vehicle (seat, armrests, backrest etc.), and the cable
connecting plugs associated, before any removals. This makes reassembly easier.
All plugs are fitted with mechanical safety devices which prevent release of the connecting plugs
during operation. To release the connecting plugs the safety devices must be pressed in. When

reassembling, ensure that these safety devices are correctly engaged.

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®

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WARNING: Any alteration to the drive programme can influence vehicle handling and the

tipping stability of the electric vehicle!

• Alterations to the drive programme may only be carried out by t rained Invacare® dealers!

• Invacare® supplies all electric vehicles from the factory with a standard drive programme.

Invacare® can only assume a warranty for the safe vehicle handling of the electric vehicle –
in particular tipping stability - for this standard drive programme!

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3 Tightening torques

The tightening torques stated in the following table are dependent on the thread diameters for the
nuts and bolts for which no special values are determined. All values apply to dry and grease-free
threads.

Thread

M4 M5 M6 M8 M10 M12 M14 M16

Tightening torque

in Nm ±10%

3 Nm

6 Nm 10 Nm 25 Nm 49 Nm 80 Nm 120 Nm 180 Nm

Caution: All other nuts or plastic connectors not noted here must be tightened
FINGERTIGHT!

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®

- Dragon Vertic

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4 Allocation of the sub-assemblies and components

Under the seat:

1) Disengaging mechanism

2) Power module (cover removed)

Under the battery cover

3) Main fuse for the batteries

Under the raised upright mechanism

4) Control box of the verticalizer limit stop

5) Actuator of the verticalizer

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5 Maintenance plan (once a year)

Component Check for Measures Remarks

ü

Armrests and
side sections

• Damage and

fastening of the
armrests

• Damage and screw
connections on the

side sections

• Tighten screws, replace

support plate if damaged

• Tighten screws, replace
side sections if damaged

Chest belt

• Chest belt must fit

snugly. Check velcro
strip for correct
functioning. Velcro
strip must not open

by itself.

• Replace if damaged or if

velcro function is affected.

Electric
backrest (if
available)

• Damage and seams

• Fastening

• Check cable

• Test function

• Replace parts if damaged

• Tighten screws

• Replace cable or motor if

necessary

Upright
mechanism

• Check welding

seams for damage

• Check tight fit of the
screwed fixings

• Check correct
function of the

actuator

• Replace upright

mechanism if necessary

• Tighten screwed fixings

• Replace actuator if

necessary

Frame (chassis)
/ battery
receptacle

• Check fastenings,

welding seams and
battery receptacle

• Tighten screws, replace

components

Wheel
suspension and
wheels

• Check tight fit of the

drive wheels and
axial run out

• Adjust, replace wheel

hubs

See "Replacing a
drive wheel" on
page 45

• Check steering

wheels for tight fit,
float, side play and
correct torque (15
Nm +/- 1.5 Nm)

• Replace wheels, wheel

fork or wheel bearing

See "Replacing the
steering head
bearings on the
steering wheels" on
page 40

• Pneumatic tyres (if

available)

• Repair or replace if

damaged

See "Repairing a
flat tyre" on page
42

• Check support

rollers of the legrest
receptacles for

damage

• Replace support rollers if

necessary

Drive units,
coupling
mechanism

• Check functions

during drive
operation and when
pushing

• Check coupling

mechanism

• Replace motor if

necessary

• Tighten screws/nuts,
adjust or replace if
necessary

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®

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Component Check for Measures Remarks

ü

Legrests

• Check welding

seams, locking
devices, screws and

foot plates

• Tighten or replace if

necessary

Electric legrests
(if available)

• Check cable

• Check contacts

• Check functions

• Replace cable if

necessary

Lighting (if
available)

• Check cable

• Check function

• Replace bulbs or cable if

necessary

Batteries

• Check batteries for

damage

• Replace batteries if

necessary

See "Changing the
batteries" on page
31

• Check battery

voltage

• Charge batteries

See instruction
manual

• Check contacts and

pole clamps

• Clean contacts and pole

clamps

See "Changing the
batteries" on page
31 for safety
information when
handling batteries

Remote / drive
electronic
system

• Remote, status

display flashing

• Fastening

• Cable, plug

connection

• Joystick function

• Voltage supply

• Evaluate flashing code

• Tighten, replace

• Replace

• Replace joystick

• Replace cable, plug

connection or remote

Driving
Programme

• Check the

programme version
of the driving
electronics. Is there
a newer version

available?

• Update the software.

See "Updating the "
on page 30

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6 Operational Faults

6.1 Operational disturbances on wheelchair with ACS

In the event of problems with the wheelchair, please proceed as follows:
Begin by assessing the possible cause of disturbance on the basis of the following tables.

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

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

6.1.1 Drive disturbance diagnostics

PROBLEM

OTHER
SYMPTOMS

POSSIBLE
CAUSE

SOLUTION DOCUMENTATION

Wheelchair

will not
start up

Status display
on the remote
illuminates as
usual and does
not display an
error code

Drive motors
possibly
disengaged

• Engage drive

motors

See instruction manual

Status display

on the remote is

not illuminated

Batteries
possibly faulty

• Replace

batteries

See "Changing the
batteries" on page 31

Battery power

possibly low

• Recharge

batteries

See instruction manual

Power supply to

remote possibly
interrupted

• Check main

fuse

See "Checking and

replacing the main fuse
" on page 33

• Check cable

between the
modules for
loose
connections or

damage

See "Checking the
cables" on page 35

Remote possibly

faulty

• Replace

remote on the
wheelchair in
order to
exclude the
possibility that
the remote is

the cause.

See "Replacing the

Shark II Remote" on
page 37

Status display

on the remote is

flashing

Various causes

• Evaluate error

code

See "

REM24 error codes

and diagnostics codes"

on page

18

Status display

on remote
flashes twice,
drive display is
on "U"

Speed controller

on the
verticalizer
actuator is

possibly faulty or

not connected

• Replace the

actuator

See "Replacing the
verticalizer actuator "

on

page 46

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Wheelchair

judders

during drive

operation

None

Batteries
possibly faulty
(unstable
voltage)

• Replace

batteries

See "Changing the
batteries" on page 31

Drive motor(s)

possibly faulty

• Replace

motor(s)

See "Replacing a motor

"

on page 24

Batteries

are not
being

charged

None Batteries

possibly faulty

• Replace

batteries

See "Changing the
batteries" on page 31

LEDs flashing

on charger

Charger possibly

faulty

• Replace

charger

See charger instruction
manual

Wheelchair

driving too
slowly

Status display
on remote
flashes twice,
drive display is
on "U"

Seat lifter is not
in drive position
(either too high
or too low) and
has activated

automatic speed

control.

• Move seat lifter

to drive
position

See instruction manual

None Remote is

possibly faulty

• Replace

remote

See "Replacing the

Shark II Remote" on
page 37

Batteries

possibly faulty

• Replace

batteries

See "Changing the
batteries" on page 31

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6.1.2 Diagnostics involving disturbances with electric regul at ing motors

Assess the cause of the disturbance involving an electric regulating motor on the basis of the
following table:

PROBLEM

OTHER
SYMPTOMS

POSSIBLE
CAUSE

SOLUTION DOCUMENTATION

Electric
regulating
motor not
reacting

Remote displays

flashing "E",
status diode on
light/regulating

module does not

extinguish even
if the remote is
shut down or
disconnected

Light
/regulating
module faulty

• Replace

light /regulating

module

See "Replacing the Shark
Electronics" on page 28

None

Cable possibly

severed or
damaged

•

Check that

the cable has
not been
severed or
damaged.
Replace cable
if necessary

See "Checking the
cables" on page 35

Electric

regulating

motor possibly

faulty

• Test
regulating
motor

See "Checking a

regulating motor " on
page 46

Remote

possibly faulty

• Replace
remote on
wheelchair in
order to
exclude the
possibility that
the remote is
the cause of
the
disturbance.

See "Replacing the Shark

II Remote" on page 37

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6.1.3 REM24 error codes and diagnostics codes

The drive electronic system can automatically rectify certain disturbances. In this case the status
display stops flashing. Please switch the remote on and off several times. Wait approximately 5
seconds each time before switching the remote on again. In case the error is not rectified by this,
assess the cause on the basis of the following flashing code.

Flashing code: Significance: Solution: Flashing code:

Flashes once

Module faulty Replace faulty module

See "Replacing

the Shark
Electronics" on
page 28

Flashes twice

Faulty accessory (e.g.
short circuit on regulating
motor)

• Check
accessory
connections,
check
accessories

See "Checking a

regulating motor
" on page 46

Lifter too high or too low
(seat not at drive height)

• Whils

t the lifter
is raised, lower
slowly until the

status display

stops flashing.

If the lifter is
too low, raise

slowly until the

status display

stops flashing.

Only drive
when the seat
is at the
correct drive
height.

See instruction
manual

Flashes three times

Fault on r.h. motor.

Connection loose or faulty

or motor faulty

• Check the
connecting plug

• Check the motor

See "Checking
the cables" on
page 35

See "Replacing a

motor" on page
24

Flashes four times

Fault on l.h. motor.

Connection loose or faulty

or motor faulty

• Check the
connecting plug

• Check the motor

See "Checking
the cables" on
page 35

See "Replacing a

motor" on page
24

Flashes five times

Fault/brake fault on r.h.
motor. Connection loose
or faulty or motor faulty

•

Check the connecting

plus

See "Checking
the cables" on
page 35

See "Replacing a

motor" on page
24

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Flashing code: Significance: Solution: Flashing code:
Flashes six times

Fault/brake fault on l.h.
motor. Connection loose
or faulty or motor faulty

•

Check the connecting

plus

See "Checking
the cables" on
page 35

See "Replacing a

motor" on page
24

Flashes seven times

Battery on low

• Charge battery

See instruction
manual

Flashes eight times

Battery voltage too high

• Switch lighting to low
battery voltage

• Check battery charger

See instruction
manual for charger

Flashes nine or ten
times

Faulty data transfer
between the modules

-

Remove electronic

modules with the
exception of the
main module and
the remote. Install
the modules one
after the other in
order to determine
which one is
causing the
disturbance.

See "Replacing

the Shark
Electronics" on
page 28

Flashes eleven times

Drive motors overloaded /
overheated

•

Switch remote on and

off / wait if necessary

-

Flashes twelve times

Compatibility problems
between the modules

• Remove incorrect
module

See "Replacing

the Shark
Electronics" on
page 28

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6.2 Operational faults on a wheelchair fitted with Shark electronics

Please proceed as follows in the event of operational faults:

• First of all analyse the possible cause of the disorder on the basis of the following tables.

• Check the status display on the remote. Analyse the f lashing error code.

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

6.2.1 Diagnosis of actuation disorders

PROBLEM

OTHER
SYMPTOMS

POSSIBLE
CAUSE

• SOLUTION

DOCUMENTATION

Wheelchair
will not start
up

Status display on
the remote
illuminated as
normal and does
not indicate a
disorder code

Actuation motors
may be
disengaged

• Clutch in actuation

motors

See operating
instructions

Status display on

the remote is not
illuminated

Batteries may be
faulty

• Replace the batteries

See "Changing the

batteries" on page
31

Batteries may be

almost empty

• Charge batteries

See User Manual

Power supply to

the remote may
be interrupted

• Check the main fuse

See "Checking and

replacing the main
fuse " on page 33

• Check the cable

between the
modules for any
loose connections or

damage

Siehe "Checking
the cables" on
page 35

Remote may be

faulty

• Change the remote

on the wheelchair to
be able to exclude
the remote being the

cause of the fault.

See "Replacing the
Shark II Remote"
on page 37

Status display on

remote flashing

Various causes

• Analyse error code

See "Shark error

codes and
diagnostic codes"
on page 22

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Wheelchair

jerky in
drive

operation

None

Batteries may be
faulty (instable
voltage)

• Replace the batteries

See "Changing the

batteries" on page
31

Actuation

motor(s) may be
faulty

• Replace motor(s)

Siehe "Replacing a

motor" on page 24

Batteries

not being
charged

None Batteries may be

faulty

• Replace batteries

See "Changing the

batteries" on page
31

LEDs flashing on

charger

Charger may be
faulty

• Replace charger

See operating
instructions for
battery charger

Wheelchair
drives too
slowly

None

Batteries may be

faulty

• Replace batteries

See "Changing the

batteries" on page
31