Invacare Kite Service Manual

Edition: 11.09.2013

Invacare ® Kite
SERVICE MANUAL

SERVICE MANUAL

Invacare ® - Kite

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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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

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Återförsäljare:
Invacare® AB

Fagerstagatan 9
S-163 91 Spånga

Sverige

Tillverkare:
Invacare® Deutschland GmbH

Kleiststraße 49
D-32457 Porta Westfali ca

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 Westfali ca

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 shipping ..................................................................................................................... 9

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

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

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

2 Safety and fitting instructions 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 15
4 Layout of components and componentry 16

4.1 Overview ................................................................................................................................... 16

4.2 Overview of the electronic modules (ACS 2 system) ........................................................... 17

4.2.1 ACS 2 70 / ACS 2 70L / ACS 2 90L electronic module................................................. 19

4.2.2 ACS 2 90LG electronic module .................................................................................... 19

4.2.3 ACT actuator module .................................................................................................... 19

4.2.3.1 ACT 2 actuator module ............................................................................................ 19

4.2.3.2 ACT 4 actuator module ............................................................................................ 20

4.2.4 Lighting PCB ................................................................................................................. 20

5 Service plan (1x annually) 21
6 Operational fa ults 23

6.1 Drive fault diagnosis ............................................................................................................... 23

6.2 ACS2 remotes: Error codes and diagnostic codes .............................................................. 25

7 Test procedures 26

7.1 Testing the motor .................................................................................................................... 26

7.2 Testing the electro-mechanical parking brake ..................................................................... 27

7.3 Checking an actuator .............................................................................................................. 29

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8 Repair w ork 30

8.1 Covers ....................................................................................................................................... 30

8.1.1 Rear cover .................................................................................................................... 30

8.1.2 Middle cover .................................................................................................................. 31

8.1.3 Side cover ..................................................................................................................... 32

8.1.4 Front cover .................................................................................................................... 33

8.1.5 Replacing a front splash guard ..................................................................................... 34

8.1.6 Replacing the splash guard .......................................................................................... 35

8.2 Electronic modules.................................................................................................................. 36

8.2.1 Replacing the power module ........................................................................................ 36

8.2.2 Replacing the actuator module ..................................................................................... 38

8.2.3 Replacing the G-Trac sensor ........................................................................................ 39

8.2.4 Replacing the lighting circuit board ............................................................................... 40

8.2.5 Replace remote ............................................................................................................ 41

8.2.6 Drive program selection after component replacement ................................................ 42

8.2.6.1 Profile selection with remote REM A or REM B ....................................................... 42

8.2.6.2 Profile selection with remote REM 550 .................................................................... 43

8.3 Updating the driving program ................................................................................................ 44

8.4 Batteries ................................................................................................................................... 45

8.4.1 Removing the batteries ................................................................................................. 45

8.4.2 Correct handling of damaged batteries ......................................................................... 48

8.5 Checking and replacing the main fuse .................................................................................. 49

8.6 Checking the cables ................................................................................................................ 51

8.7 Lighting system ....................................................................................................................... 52

8.7.1 Replacing front headlight completely (LED lighting unit) .............................................. 52

8.7.2 Replacing the front bulb holder (LED lighting unit) ....................................................... 54

8.7.3 Replacing the rear light completely (LED lighting unit) ................................................. 55

8.7.4 Replacing light bulbs in the front (Conventional lighting system) .................................. 56

8.7.5 Replacing the head lamps completely (conventional lighting system) .......................... 57

8.7.6 Replacing the headlight bracket (conventional lighting system) ................................... 59

8.7.7 Replacing the rear bulb (conventional lighting unit) ...................................................... 61

8.7.8 Replacing the complete tail light assembly (conventional lighting system) ................... 62

8.7.9 Replacing the tail light bracket (conventional lighting system) ...................................... 63

8.8 Front wheels ............................................................................................................................ 64

8.8.1 Repairing a flat tire in the front ...................................................................................... 64

8.8.2 Replacing the steering head bearings on the steering wheels ..................................... 64

8.8.3 Changing a front wheel (normal front wheel) ................................................................ 67

8.8.4 Changing a front wheel (suspended front wheel) ......................................................... 69

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8.9 Drive wheels ............................................................................................................................. 70

8.9.1 Replacing the drive wheel ............................................................................................. 70

8.9.2 Replacing a tyre or inner tube ....................................................................................... 71

8.9.2.1 Replacing puncture-protected tyres ......................................................................... 71

8.9.2.2 Replacing puncture-proof tyres ................................................................................ 73

8.9.3 Replacing the drive wheel hub ...................................................................................... 74

8.10 Drive unit .................................................................................................................................. 75

8.10.1 Replacing the motor/transmission unit .......................................................................... 75

8.10.2 Replacing or rotating the motor / gearbox unit sealing ring .......................................... 77

8.10.3 Replacing the motor / gearbox coupling ....................................................................... 78

8.10.4 Replacing the carbon brushes ...................................................................................... 80

8.11 Replacing the rubber sh o ck absorbers ................................................................................. 82

8.12 Replacing the tube frame ........................................................................................................ 84

8.13 Replacing the double bearing of the Dual Swing Technology (D.S.T.) .............................. 86

8.14 Replacing the battery boxes ................................................................................................... 88

8.15 Seat system .............................................................................................................................. 89

8.15.1 Replacing the tilt actuator ............................................................................................. 89

8.15.2 Replacing the tilt module ............................................................................................... 91

8.15.3 Replacing the lifter / tilt module ..................................................................................... 93

8.16 Backrest unit ............................................................................................................................ 97

8.16.1 Replacing the standard backrest .................................................................................. 97

8.16.2 Replacing a standard backrest with quick release ........................................................ 99

8.16.3 Replacing a Flex2 backrest ........................................................................................ 100

8.16.4 Adjusting backrest former ........................................................................................... 101

8.17 Seat system Modulite ............................................................................................................ 102

8.17.1 Replacing the tilt actuator ........................................................................................... 102

8.17.2 Replacing the lifter actuator ........................................................................................ 103

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

8.17.4 Replacing the backrest actuator ................................................................................. 107

8.18 Backrest Modulite .................................................................................................................. 108

8.18.1 Replacing the standard backrest ................................................................................ 108

8.18.2 Replacing the backrest mounting bracket .................................................................. 109

8.18.3 Replacing the backrest mounting bracket for SB 53 .................................................. 110

8.19 Adjusting the seat width/ backrest width (Modulite) ......................................................... 111

8.19.1 Adjusting the seat width .............................................................................................. 111

8.19.2 Adjusting the backrest width ....................................................................................... 113

8.19.3 Adjusting the Flex3 backrest ....................................................................................... 115

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9 Installing accessories 116

9.1 Replacing the holding strap ................................................................................................. 116

9.2 Replacing seat belts (Modulite seat) ................................................................................... 117

9.2.1 Installation on the backrest mounting bracket (simple backrest) ................................ 117

9.2.2 Installation on the backrest mounting bracket (adjustable seat) ................................. 118

9.2.3 Installation on the seat frame profile (adjustable seat) ............................................... 119

9.3 Operating hours counter ...................................................................................................... 120

9.3.1 Replacing the operating hours counter ....................................................................... 120

9.3.2 Replacing the connecting cable of the operating hours counter ................................. 122

9.4 Luggage carrier ...................................................................................................................... 124

9.5 Further accessories ............................................................................................................... 125

10 Adjusting the seati ng pos ition 126

10.1 Adjusting the lower leg length and seat depth ................................................................... 127

10.1.1 Adjusting the lower leg length ..................................................................................... 127

10.1.2 Adjusting the seat depth ............................................................................................. 127

10.2 Adjusting the seat angle ....................................................................................................... 128

10.2.1 12° Adjusting the seat angle with Standard seat or Flex2 seat .................................. 129

10.2.2 20° Adjusting the seat angle Flex2 seat or Modulite seat ........................................... 131

10.3 Adjusting the c enter of gravity of the seat .......................................................................... 133

10.3.1 Standard seat .............................................................................................................. 137

10.3.2 Flex2 seat ................................................................................................................... 138

10.3.3 Modulite seat ............................................................................................................... 141

10.3.3.1 Adjustable seats .................................................................................................... 143

10.3.3.2 Simple seat ............................................................................................................ 144

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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 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 shipping

• 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.

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1.3 Definition and representation of information and safety
information in t his 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.

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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 examp le 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.

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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 to prevent accidents at work, and it is imperative that they
are observed.

2.1 Before any inspection or repai r 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 discharge d when worki n g o n d efective 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 discharge d when worki n g o n d efective 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 informati on a nd 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!

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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 da n g er 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 d amage to property, if the maxim u m speed reduction on a
wheelchair with a lifter does not fun ction 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.

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 chan g es 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!

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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 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.

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4 Layout of components and componentry

4.1 Overview

Under the rear cover:

1) G-Trac sensor

2) Power module

3) Lighting PCB

4) Actuator module
The electronic modules used are

described in Chapter 4.2.

Electric seat tilting:

1) Actuator motor

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4.2 Overview of the electronic modules (ACS 2 system)

Different electronic modules can be fitted to the mobility aid.

1

2
3
4
5

6
7
8

9

Battery plug

Lighting cable
Contact bridge
Lighting circuit board
Lighting according to German
Road Traffic Act (StVZO).
LED lighting
Extension cable
Actuator cable lifter

Extension cable

10

11
12

13
14

15

16

End position switch "lower

position"
End position switch "upper
position"
Remotes
ACS attendant control,
switchable
Bus cables
Bus cables

ACT

17

18
19
A
B
C
D
E
F

G

G-Trac sensor

Bus cables
Power module
To the motor M1
To the motor M2
To the tilt actuator
To the lifter actuator
To the lifter actuator
Actuator left legrest

Actuator right legrest

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Before you connect mobility aid components such as actuators or motors, please begin by
ascertaining which module is installed. Please refer to the following table for an overview of ACS 2
modules.

Electronicmodule Name Description

ACS 2 70

ACS 2 70L
ACS 2 90L
ACS 2 90L G

ACS 2 wiith ACT actuator module

See chapter 4.2.1
See chapter 4.2.1
See chapter 4.2.1
See chapter 4.2.2

See chapter 4.2.3
The actuator module is

optional.

Actuator module
ACT 2
ACT 4

See chapter 4.2.3.1
See chapter 4.2.3.2
The actuator module is
optional.

Lighting PCB See chapter 4.2.4

The lighting PCB 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 ACS 2 70 / ACS 2 70L / ACS 2 90L electronic module

Connections

1) Battery 24V

2) Bus cable (to remote or ACT)

3) Bus cable (to remote or ACT)

4) Motor M1

5) Light (optional)

6) Motor M2

Rubber stoppers for free slots

2) & 3) Order number: 1552876

4.2.2 ACS 2 90LG electronic module

Connections

7) Battery 24V

8) Cable to G-Trac sensor (GYRO)

9) Bus cable (to remote or ACT)

10) Motor M1

11) Light

12) Motor M2

4.2.3 ACT actuator module

Different adjusting motors, also known as actuators, can be fitted to the mobility aid. These
actuators are either connected directly to the power module or to a separate actuator module. The
actuator module is connected to the power module via a bus cable.

4.2.3.1 ACT 2 actuator module

Connections

1) ACI*

2) Bus cable (ACT or power module)

3) Bus cable (ACT or power module)

4) Actuator - Channel 2

5) 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.

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4.2.3.2 ACT 4 actuator module

Connections

1) ACI*

2) Bus cable (ACT or power module)

3) Bus cable (ACT or power 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.

4.2.4 Lighting PCB

Connections

1) Driving light & l.h. indicator 1

2) Driving light & l.h. indicator 2

3) Power module

4) Driving light & r.h. indicator 1

5) Driving light & r.h. indicator 2

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

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5 Service plan (1x annually)

CAUTION!

Danger of injury and d amage to property, if the maxim u m speed reduction on a
wheelchair with a lifter does not fun ction correctly!

The wheelchair’s control unit must redu ce 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 8.9.3.

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

• Replace wheels,
wheel fork or
wheel bearings

See chapter 8.8.2

• Pneumatic tyres (if
fitted)

• Repair or replace
if damaged

See chapter 8.9.2.

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

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Component Check Remedy Notes

ü

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 8.4.

• Check battery
voltage

• Charge batteries

See operating
manual

• Check contacts and
terminals

• Clean contacts
and terminals

Please refer to the
safety information
in Chapter 8.4 for
handling batteries

Remote /
electronic
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 supply • Tighten cables
and connecting
plugs, replace if
necessary

Drive program

• Check drive

electronics program
version

• Update software if
newer version
available.

See chapter 8.3.

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6 Operational faults

Different power modules can be installed in the mobility aid in connection with different remotes.
The rectification of operational faults depends on the installed power module in each case.

The power modules used are described in 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 aid, 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 8.4.

Completely

discharge
battery

Pre-charge
batteries

See operating manual

Power supply

to remote
interrupted

Check master
fuse

See chapter 8.5.

Check cables

between the
modules for loose
connections and
damage

See chapter 8.6.

Remote

defective

Replace remote See chapter 8.2.5.

Remote status

display blinking

Various
causes

Assess error code See chapter 6.2.

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PROBLEM OTHER

SYMPTOMS

POSSIBLE
CAUSE

SOLUTION Documentation

Mobility

device
judders in
drive mode

None

Batteries
defective
(unstable
voltage)

Replace batteries See chapter 8.4.

Drive motor(s)

defective

Replace motor(s) See chapter 8.10.1.

Replace carbon

brushes

See chapter 8.10.4.

Batteries

not being

charged

None Batteries

defective

Replace batteries See chapter 8.4.

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 8.2.5.

Batteries

defective

Replace batteries See chapter 8.4.

Electrical
actuator
does not
respond

Remote
displays
flashing "E",
status diode
on
light/actuator
module does
not extinguish
even if the
remote is shut
down or
disconnected

Lighting/actuat
or module
faulty

Replace
lighting/actuator
module

See chapter 8.1.5.

None Cable

disconnected
or damaged

Ensure correct
cable
connection,
replace cable if
necessary

See chapter 8.6.

Electrical

actuator faulty

Check actuator See chapter 7.3.

Remote faulty Replacing the

remote

See chapter 8.2.5.

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6.2 ACS2 rem ot es : Error codes and diagnos t ic codes

The drive electronics can automatically rectify some faults. In this case the status display will stop
blinking. Switch the remote on and off again several times. Wait around 5 seconds each time
before switching the remote on again. If this does not rectify the fault, determine the cause using
the blink codes from the following table.

BLINK CODE POSSIBLE CAUSE SOLUTION DOCUMENTATION

1 x blink

Module defective Replace defective module See chapter 8.1.5.

2 x blink

Accessory error (for
example short circuit in the
actuator)

Check accessory
connections, check
accessory

See chapter 7.3.

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

If the lifter is raised, lower it
slowly until the status

display stops blinking. If the

lifter is too low, raise it
slowly until the status
display stops blinking. Only
drive when the seat is at
driving height.

See operating manual

3 x blink

Error in motor M1
Connection loose/faulty or
motor faulty

Check connection plug,
check motor

See chapters 8.6 and

7.1

4 x blink

Error in motor M2
Connection loose/faulty or
motor faulty

Check connection plug,
check motor

See chapters 8.6 and

7.1

5 x blink

Fault/brake fault in motor
M1. Connection loose or
faulty or motor faulty

Check connection plug,
check motor

See chapters 8.6 and

7.1

6 x blink

Fault/brake fault in motor
M2. Connection loose or
faulty or motor faulty

Check connection plug,
check motor

See chapters 8.6 and

7.1

7 x blink

Completely discharge
battery

Pre-charge battery

See operating manual

8 x blink

Battery voltage too high Switch lighting to low

battery voltage
Check battery charger

See charging unit
operating manual

9 or 10 x blink

Faulty data transmission
between modules

Remove electronic modules

except for the power
module and the remote.
Replace the modules one
after another in order to
ensure which was the one
causing the fault.

See chapter 8.1.5.

11 x blink

Drive motors overloaded /
overheated

Switch remote on and off /
wait if necessary

-

12 x blink

Compatibility problems
between modules

Remove incorrect module See chapter 8.1.5.

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7 Test procedures

7.1 Testing the motor

Requirements:

• digital multimeter with resistance measurement

• Use the remote to identify which motor is possibly defective, as described in chapter 6.2.

• Switch the electronics OFF on the remote.

• Remove the rear cover, as described in chapter 8.1.1.

• Take exact note of the positions of all cables and the sockets that they are connected to. Mark

the connectors and sockets or take a photograph with a digital camera.

• Disconnect the motor plug (1) of the motor to be tested from the power module.

• Connect the digital multimeter to the motor plug contacts (3) and measure the resistance

between the contacts.

Note

A resistance of between 0.5 and 5 ohms indicates a motor ready for operation.
A resistance of between 15 ohms and infinity indicates a defective motor. High resistances are

normally caused by bad connections or worn carbon brushes.

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7.2 Testing the electro-mechanical parking brake

Note

This test should only be carried out on mobility aids with conventional motor/transmission units.

CAUTION!

Material damage can be caused to the electronic module due to short-circuits in the
electro-mechanical brake.

• NEVER connect an electro-mechanical brake to an intact electronic module with a short-circuit!

• Always replace short-circuited brakes immediately.

Note

A defective motor can damage the power module, but a defective power module cannot camage
the motor.

Requirements:

• digital multimeter with resistance measurement

• Use the remote to identify which motor is possibly defective, as described in chapter 6.2.

• Switch the electronics OFF on the remote.

• Remove the rear cover, as described in chapter 8.1.1.

• Take exact note of the positions of all cables and the sockets that they are connected to. Mark

the connectors and sockets or take a photograph with a digital camera.

• Disconnect the motor plug (1) of the motor to be tested from the power module.

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• Connect the digital multimeter to the adjacent central motor plug contacts (3) and measure the
resistance between the contacts.

• If there is a defect, replace the motor and send it to Invacare® Service for inspection or repair.

Note

A resistance of between 40 and 80 ohms indicates an intact brake.
A resistance of 0 ohms or a very high resistance (mega-ohms or infinity) indicates a short-circuit,

a bad connection or a defective brake.

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7.3 Checking an actuator

Requirements:

• digital multimeter with resistance measurement

• Switch the electronics OFF on the remote.

• Remove the rear cover, as described in chapter 8.1.1.

• Take exact note of the positions of all cables and the sockets that they are connected to. Mark

the connectors and sockets or take a photograph with a digital camera.

Disconnect the motor plug (1) of the motor to be tested from the actuator module.

• Check the electrical resistance at the

plug (1) of the actuator.
The plug can have a different shape than
show in the illustration.

• If the resistance is close to infinity, the motor
is probably burnt out.

• If the resistance is below 1 Ω, the motor has
a short-circuit.

• The motor must be replaced in both cases.

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8 Repair work

CAUTION!

Danger of injury and d amage to property, if the maxim u m speed reduction on a
wheelchair with a lifter does not fun ction 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.

8.1 Covers

8.1.1 Rear cover

Removing the rear cover:

• Loosen and remove the left and right thumbscrews (1) on the rear cover (2).

• Carefully pull the rear cover backwards and off.

• On models with LED lighting system (tail lights in the rear cover):

Pull both of the tail light plugs off of the lighting circuit board.

Assembling the rear cover:

• On models with LED lighting system:
Plug both of the tail light plugs back into the lighting circuit board.

• Push the rear cover over the battery box from the back. Pay attention to the electrical cables
while doing so.

• Tighten both thumbscrews hand-tight.