Invacare Modulite Service Manual

Invacare®Modulite
Supplementtopowerwheelchairservicemanual, ProntoM41,Bora/SpectraXTRSeries,KiteSeries, TDXSP2Series,Storm⁴Series,FDX,Fox
enSeatingSystem
ServiceManual
PROVIDER:Keepthismanual. TheproceduresinthismanualMUSTbeperformedbyaqualied technician.
©2019InvacareCorporation Allrightsreserved.Republication,duplicationormodicationinwholeorinpartisprohibitedwithoutpriorwritten permissionfromInvacare.Trademarksareidentiedby™and®.AlltrademarksareownedbyorlicensedtoInvacare Corporationoritssubsidiariesunlessotherwisenoted.
Contents
1General.........................................4
1.1Introduction..................................4
1.2GeneralInformation............................4
1.3NotesonShipping..............................4
1.4SymbolsinThisManual..........................4
1.5ImagesinThisManual..........................4
2Safety..........................................5
2.1SafetyandFittingInstructions.....................5
3Hygiene.........................................7
3.1HandlingofReturnedUsedProducts................7
4Setup...........................................8
4.1Adjustingseatwidth/backrestwidth................8
4.1.1AdjustingSeatWidth.........................8
4.1.2AdjustingBackrestWidth......................9
4.1.3AdjustingTension-AdjustableBackrest.............10
4.1.4AdjustingFlex3Backrest.......................10
4.1.5AdjustingFlex3manualrecline..................11
4.1.6AdjustingMatrxBackrests.....................12
4.1.7AdjustingFlex3tensionadjustablebackrest........12
4.2Adjustingadapterforuniversalseat.................12
4.2.1Adjustinguniversalseatadapterwidth............12
5Service..........................................14
5.1Imperialtometricconversionchart.................14
5.2TighteningTorques.............................14
5.3OverviewComponents..........................15
5.3.1Overviewseatingsystem......................15
5.3.2Backreststyles..............................15
5.3.3Backrestframes.............................15
5.3.4Armreststyles..............................16
5.3.5RemoteBracketsandHeadrestAdapters...........16
5.3.6Supportoptions.............................18
5.3.7Seatframeandsurface.......................19
5.3.8Overviewseatinterfaces......................19
5.4Replacingbackrest..............................20
5.4.1Replacingstandardbackrest....................20
5.4.2ReplacingFlex3tensionadjustablebackrest........21
5.4.3ReplacingBackrestMountingBracket.............21
5.4.4Replacingbaghooks.........................21
5.5Headrest/Neckrest..............................22
5.5.1ReplacingReaHeadrest.......................22
5.5.2ReplacingReaHeadrestMountingBracket(Sling
Backrest).................................22
5.5.3InstallingElanHeadresttoFlex3Backrest..........22
5.6Replacingposturebelts..........................23
5.6.1Installationonbackrestmountingbracket(backrest
frame)...................................23
5.6.2Installationonbackrestmountingbracket
(telescopicseatframe)......................23
5.6.3Installationonseatframeprole(telescopicseat
frame)...................................23
5.6.4ReplacingH-belt(telescopicseatframe)...........23
5.6.5ReplacingH-belt(backrestframe)................24
5.7Replacingarmrestsandupperbodysupportoptions....24
5.7.1Removing/Installingarmrest...................24
5.7.2Removing/Installingarmrest....................24
5.7.3Replacingskirtguardoninriggedarmrestwith
smallerskirtguard..........................25
5.7.4Adjusting/xingangleoflateralsupports..........25
5.8Replacingremotes/remoteholders..................25
5.8.1ReplacingNucleusMidlineHolder................25
5.8.2Replacingremotebracketforattendant...........26
5.8.3ReplacingRemoteBracketforDLX-ACU200.........26
5.8.4MountingDLX-REM500toSwing-AwayRemote
Holder...................................27
5.8.5MountingPrimaryRemotestoNucleusMidline
Holder...................................27
5.9ChinControl..................................28
5.9.1Maintenance...............................28
5.9.2ReplacingComponents........................28
5.9.3ServicinglinkageofChinControl................30
5.9.4Tighteningpoweredlinkage....................30
5.10Replacinglegrests.............................30
5.10.1Removingthelegrest........................30
5.10.2ReplacingLNXpoweredcenter-mountedlegrest
........................................31
5.10.3Replacinganpoweredlegrestactuator..........31
5.10.4ReplacingLNXpoweredcenter-mountedlegrest
withtelescopingfootboard....................31
5.10.5Replacingfootboard.........................32
5.10.6Replacingthecalfplateonthecenter-mounted
legrest(poweredandmanual).................32
5.10.7Replacingfootplateoncenter-mountedlegrest
(poweredandmanual)......................33
5.11SettingAnteriorTilt............................33
5.12Replacingactuators............................34
5.12.1Replacingactuator—poweredtiltwithxed
pivotpoint................................34
5.12.2Replacingactuator—poweredtiltwithxed
pivotpoint................................34
5.12.3IdentifyingT ypeofActuator(ModulesWithCoG
Shift)....................................35
5.12.4ReplacingTiltActuator.......................35
5.12.5ReplacingLifterActuator.....................36
5.12.6SettingLimitsofActuator(TypeNL).............37
5.12.7ReplacingBallSwitch........................37
5.12.8Replacingreclineactuator....................38
5.12.9Reclineactuator-removingadapter.............38
5.13ReplacingSeatInterface/Frame...................38
5.13.1Replacingseat/seatframewithoutlifter..........38
5.13.2Replacingseatsupport(withoutlifterortilt
module)..................................39
5.13.3ReplacingSeatSupport(ModulesWithCoG
Shift)....................................40
5.13.4ReplacingModules(CoGShiftModules)..........41
Invacare®Modulite

1General

1.1Introduction

Thisdocumentcontainsimportantinformationabout assembly,adjustmentandadvancedmaintenanceofa productcomponent.Toensuresafetywhenhandlingthe component,readthisdocument,theservicemanualsof thebaseproductandadditionalcomponents,andtheuser manualscarefullyandfollowthesafetyinstructions.
ThecomponentitselfdoesnotbearaCEmarking,butitis partofaproductthatcomplieswiththerespectivevalid regulationsconcerningmedicaldevices.Thecomponents isthereforecoveredbytheCEmarkingoftheproduct.
FindtheusermanualonInvacare’swebsiteorcontact yourInvacarerepresentative.Seeaddressesattheend ofthisdocument.
Invacarereservestherighttoalterproductspecications withoutfurthernotice.
Beforereadingthisdocument,makesureyouhavethe latestversion.Y oundthelatestversionasaPDFonthe Invacarewebsite.
Forpre-saleanduserinformation,seetheusermanual.
Formoreinformationabouttheproduct,forexample productsafetynoticesandproductrecalls,contactyour Invacarerepresentative.Seeaddressesattheendofthis document.

1.2GeneralInformation

Serviceandmaintenanceworkmustbecarriedouttaking thisdocumentintoaccount.
Itisimperativethatyouobservesafetyinformation.
Informationaboutoperationoraboutgeneralmaintenance andcareworkontheproductshouldbetakenfrom servicemanual.
Assemblyofaccessoriesmightnotbedescribedinthis document.Refertothemanualdeliveredwiththe accessory.Additionalmanualscanbeorderedfrom Invacare.Seeaddressesattheendofthisdocument.
Youcanndinformationaboutorderingsparepartsin thesparepartscatalogue.
SparepartsmustmatchoriginalInvacareparts.Onlyuse sparepartswhichhavebeenapprovedbyInvacare.
Theproductmayonlybemaintainedandoverhauledby qualiedpersonnel.
Theminimumrequirementforservicetechniciansis suitabletraining,suchasinthecycleororthopedic
mechanicselds,orsufcientlylong-termjobexperience. Experienceintheuseofelectricalmeasuringequipment (multimeters)isalsoarequirement.SpecialInvacare trainingisrecommended.
Alterationstothemobilitydevicewhichoccurasaresult ofincorrectlyorimproperlyexecutedmaintenanceor overhaulworkleadtotheexclusionofallliabilityonthe sideofInvacare.
Ifyouhaveanyproblemsorquestionscontactyour provider .

1.3NotesonShipping

Ifthemobilitydevicehastobeshippedbacktothe manufacturerformajorrepairs,youshouldalways usetheoriginalpackagingfortransport.
Pleaseattachaprecisedescriptionofthefault.

1.4SymbolsinThisManual

Symbolsandsignalwordsareusedinthismanualand applytohazardsorunsafepracticeswhichcouldresultin personalinjuryorpropertydamage.Seetheinformation belowfordenitionsofthesignalwords.
WARNING Indicatesahazardoussituationthatcould resultinseriousinjuryordeathifitisnot avoided.
CAUTION Indicatesahazardoussituationthatcould resultinminororslightinjuryifitisnot avoided.
IMPORTANT Indicatesahazardoussituationthatcould resultindamagetopropertyifitisnot avoided.
Tips Givesusefultips,recommendationsand informationforefcient,trouble-freeuse.
Tools Identiesrequiredtools,componentsand itemswhichareneededtocarryoutcertain work.

1.5ImagesinThisManual

Thedetailedimagesinthismanualaregivenmarksto identifyvariouscomponents.Componentmarksintext andoperationalinstructionsalwaysrelatetotheimage directlyabove.
4
1604311-G
Safety

2Safety

2.1SafetyandFittingInstructions

Thesesafetyinstructionsareintendedtopreventaccidents atwork,anditisimperativethattheyareobserved.
Beforeanyinspectionorrepairwork
Readandobservethisrepairmanualandthe associatedusermanual.
Observetheminimumrequirementsforcarryingout thework(see1.2GeneralInformation,page4).
PersonalSafetyEquipment
Safetyshoes
Themobilitydevice,andsomeofitscomponents,arevery heavy.Thesepartscanresultininjuriestothefeetifthey areallowedtodrop.
Wearstandardizedsafetyshoesduringallwork.
Eyeprotection
Itispossiblethatbatteryacidcanbedischargedwhen workingondefectivebatteriesorwhenhandlingbatteries improperly.
Alwaysweareyeprotectionwhenworkingonany defectiveorpossiblydefectivebatteries.
Safetygloves
Itispossiblethatbatteryacidcanbedischargedwhen workingondefectivebatteriesorwhenhandlingbatteries improperly.
Alwayswearacid-proofsafetygloveswhenworking onanydefectiveorpossiblydefectivebatteries.
GeneralSafetyInformationandInformationAboutFitting /Removal
DANGER! RiskofDeath,SeriousInjury,orDamage
Lightedcigarettesdroppedontoanupholstered seatingsystemcancauseareresultingin death,seriousinjury,ordamage.Mobility deviceoccupantsareatparticularriskofdeath orseriousinjuryfromtheseresandresulting fumesbecausetheymaynothavetheabilityto moveawayfromthemobilitydevice.
–DONOTsmokewhileusingthismobility
device.
WARNING! RiskofSeriousInjuryorDamage
Storingorusingthemobilitydevicenearopen ameorcombustibleproductscanresultin seriousinjuryordamage.
–Avoidstoringorusingthemobilitydevice
nearopenameorcombustibleproducts.
CAUTION! Riskofcrushing
Variouscomponentssuchasthedriveunit, batteries,seatetcareveryheavy.Thisresults ininjuryhazardstoyourhands.
–Notethehighweightofsomecomponents.
Thisappliesespeciallytotheremovalofdrive units,batteriesandtheseat.
CAUTION! Injuryhazardifthemobilitydevicestarts movingunintentionallyduringrepairwork
–Switchthepowersupplyoff(ON/OFFkey). –Engagethedrive. –Beforeliftingup,securethemobilitydevice
byusingchockstoblockthewheels.
CAUTION! Fireandburnhazardduetoelectrical short-circuit
–Themobilitydevicemustbecompletely
switchedoffbeforeremovalof voltage-carryingcomponents!Todo this,removethebatteries.
–Avoidshort-circuitingthecontacts
whencarryingoutmeasurementson voltage-carryingcomponents.
CAUTION! Riskofburnsfromhotsurfacesonthemotor
–Allowthemotorstocooldownbefore
commencingworkonthem.
CAUTION! Injuryhazardandriskofdamagetomobility deviceduetoimproperorincomplete maintenancework
–Useonlyundamagedtoolsingoodcondition. –Somemovingpartsaremountedinsockets
withPTFEcoating(T eon™).Nevergrease thesesockets!
–Neveruse"normal"nutsinsteadof
self-lockingnuts.
–Alwaysusecorrectly-dimensionedwashers
andspacers.
–Whenreassembling,alwaysreplaceanycable
tieswhichwerecutduringdismantling.
–Aftercompletingyourwork/beforerenewed
start-upofthemobilitydevice,checkall connectionsfortighttting.
–Aftercompletingyourwork/beforerenewed
start-upofthemobilitydevice,checkallparts forcorrectlocking.
–Onlyoperatethemobilitydevicewiththe
approvedtyrepressures(seetechnicaldata).
–Checkallelectricalcomponentsforcorrect
function.Notethatincorrectpolaritycan resultindamagetothecontrolsystem.
–Alwayscarryoutatrialrunattheendof
yourwork.
CAUTION! Riskofinjuryanddamagetoproperty,ifthe maximumspeedreductiononawheelchair withalifterdoesnotfunctioncorrectly
Thewheelchair’scontrolunitmustreducethe maximumpossiblespeedassoonasthelifter israised.
–Testthemaximumspeedreductionfor
correctfunctionafteranymaintenancework ormodicationstothewheelchair.
1604311-G5
Invacare®Modulite
CAUTION! Anychangestothedriveprogramcanaffect thedrivingcharacteristicsandthetipping stabilityofthemobilitydevice
–Changestothedriveprogrammayonlybe
carriedoutbytrainedInvacareproviders.
–Invacaresuppliesallmobilitydeviceswitha
standarddriveprogramex-works.Invacare canonlygiveawarrantyforsafemobility devicedrivingbehavior-especiallytipping stability-forthisstandarddriveprogram.
Markallcurrentsettingsforthemobilitydevice (seat,armrests,backrestetc.),andtheassociated cableconnectingplugs,beforedismantling.This makesreassemblyeasier.Allplugsarettedwith mechanicallockswhichpreventreleaseofthe connectingplugsduringoperation.T oreleasethe connectingplugsthesafetylocksmustbepressed in.Whenreassemblingensurethatthesesafety locksarecorrectlyengaged.
61604311-G

3Hygiene

3.1HandlingofReturnedUsedProducts

Whenreconditioningorrepairingreturnedmobilitydevices:
T akeprecautionsforyourselfandtheproduct.
Useprotectionequipmentasspeciedlocally.
BeforeTransport(AccordingtoBiologicalAgentsOrdinance)
Treatproductaccordingtofollowingprocesssteps:
Hygiene
ProcessStepComponent
ApplicationConditioning
ManualcleaningSurfaceofuseddeviceBeforerepairor
reconditioning
DisinfectionSurfaceofuseddeviceBeforerepairor
reconditioning
*Invacareusesdetergent"Nücoseptspecial"1.5%inwaterml/ml
DisinfectionTools
Disposablewipes(eece)
Brushestocleanareasdifculttoaccess
FurtherInformation
FormoreinformationcontactyourInvacareservicedepartment.
technique
Usesaturatedtowel toapplycleaning detergentandremove residuesafterimpact.
Usesaturated disinfectantwipes andclean*thedevice surface.
WorkStation
Cleaningand disinfection
Cleaningand disinfection
1604311-G
7
Invacare®Modulite

4Setup

4.1Adjustingseatwidth/backrestwidth

Forseatframesandsurfaces,see5.3.7Seatframeandsurface,page19,forbackpostsandbackrestframes,see5.3.3 Backrestframes,page15andforbackreststyles,see5.3.2Backreststyles,page15.

4.1.1AdjustingSeatWidth

Youcanonlyadjusttheseatwidthforthetelescopicseatframe.
Theseatisavailableindifferentseatwidthranges:
380mm/430mm
480mm/530mm
550mm.
Theseatwidthof550mmcannotberetrotted.ContactInvacareformoreinformation.
Whenswitchingbetweenthedifferentseatwidthranges,severalpartsoftheseatsuchaslegrestxationor screwedconnectionsmustbereplaced.Contactyourproviderorcheckthesparepartscatalogue.
Whenmodifyingtheseatwidth,thebackrestwidthmustalsobecorrespondinglyadapted.See4.1.2AdjustingBackrest Width,page9.
3mmAllenkey(Seatplates)
TX25T orxkey(Slingseat)
5mmAllenkey
13mmwrench
TX40T orxkey
BackrestpostsforFlex3onlyadjustuptoaseatwidthsettingof480mm.Theremaining50mmareadjusted viabackrestplates.
RemovingSeatPlate
1.Removebackrestcushionandseatcushion.
2.Removebackrestfrombackrestmountingbracket.See
4.1.2AdjustingBackrestWidth,page9.
3.LoosenandremovescrewsA.
4.RemovemiddleseatplateB.
5.LoosenandremovescrewsC.
6.RemovelateralseatplatesD.
7.Iftted,removespacerbetweenplatesandframe.
Fig.4-1
RemovingSlingSeat
1.Removebackrestcushionandseatcushion.
2.Removebackrestfrombackrestmountingbracket.See
4.1.2AdjustingBackrestWidth,page9.
3.LoosenandremovescrewsAonbothsides.
4.RemoveslingseatB.
Fig.4-2
81604311-G
AdjustingWidth
Setup
Fig.4-3Seatframeofmodelswithouttilt-orlifter-tiltmodules
1.LoosenandremovescrewsA.
2.LoosenandremovescrewsBandnutsC.
3.Ifrequired,replacelegrestxationD.
4.Adjustseatrailconnectorandlegrestxationtodesired seatwidthaccordingtotable:
ScrewPosition
F
G
H
I
J
SeatWidth
380mm
430mm
480mm
530mm
550mm(optional)
InstallingParts
1.Installpartsinreverseorder .
2.Testallfunctions.

4.1.2AdjustingBackrestWidth

Fig.4-4Seatframeofmodelswithtilt-orlifter-tiltmodules
Fig.4-5Mountingpositionsfor
differentseatwidthsonseatrail
connector withouttilt-orlifter-tiltmodule
servesasexample.
E
.Variantonmodel
Fig.4-6Mountingpositionsfor differentseatwidthsonlegrest
xations
D
.
Thebackrestwidthof550mmcannotberetrotted.ContactInvacareformoreinformation.
Backrestwidthisadjustedbyperformingthefollowingtasks:
1.Adjustingbackrestposts.
2.Adjustingbackrest. a.T ension-adjustablebackrest:See4.1.3AdjustingT ension-AdjustableBackrest,page10. b.Flex3backrest:See4.1.4AdjustingFlex3Backrest,page10.
3.Replacingbackrestcushion(theseareavailableinvariouswidths). Whenmodifyingbackrestwidth,seatwidthmustalsobecorrespondinglyadapted.See4.1.1AdjustingSeatWidth, page8.
3mmAllenkey
5mmAllenkey
13mmwrench
Forscrewpositionperbackrestwidth,refertotablebelow.
Fig.4-7Upperactuatorxationbracket.
Fig.4-8Loweractuatorxationbracket.
1604311-G9
Invacare®Modulite
Screwposition
A
B
C
D
E
Backrestwidth
550mm(optional)
530mm*
480mm
430mm
380mm
*BackpostsforFlex3seatonlyadjustuptoaseatwidthsettingof480mm.Theremaining50mmareadjustedvia thebackrestplates.
1.Removebackrestcushion.
2.Loosenstrapsofslingbackrestorremoveplatesof Flex3backrest.
3.Removebackrestfrombackrestmountingbracket.
4.LoosenandremovebothscrewsAofbothxation bracketsF.
5.RemoveshroudsBofbothxationbracketsF.
6.LoosenandremoveboltsCandnutsDofbothxation bracketsF.
7.AdjustbackrestxationEfornewbackrestwidth accordingtotableabove.
8.InsertboltsCandtightenwithnutsD.
9.InstallshroudsB.
10.InsertandtightenscrewsA.
Fig.4-9T opactuatorxationbracketservesasanexample.
11.Installbackresttomountingbracket.
12.Adjuststrapsofslingbackresttonewwidthorinstall adjustedFlex3backrest.
13.Installbackrestcushion.
14.Testallfunctions.

4.1.3AdjustingT ension-AdjustableBackrest

Thetension-adjustablebackrestcanbeindividuallyadaptedtotheuser'sbackshape.
1.Pullfrontandrearfacesofbackrestupholstery(1)apart andremove.Backrestupholsteryfrontandrearfaces areheldtogetherusinghook-and-loopstraps.
2.Openhook-and-loopstrapsofbackrestbelt(2)and adjusttorequiredlength.
3.Re-installbackrestupholsteryandxitwith hook-and-loopstraps.
Fig.4-10

4.1.4AdjustingFlex3Backrest

Phillipsscrewdriver
5mmAllenkey
101604311-G
1.
Loosenandremovescrews(3).
2.Removefrontlateralplates(2and4)frombackrest(1).
3.
Setup
Fig.4-11
Fig.4-12
RemovebothPhillipsscrewsAonmiddleplate.
4.Shiftpositionofrearplatehalves(threesettingsarepossibleusingdrillholes).
BeforepullingFlex3backrestapart,a"1"willbevisibleinthesmall,rectangularcut-out.
AfterpullingFlex3backrestapart,a"2"willbevisibleinthesmall,rectangularcut-out.
5.Re-inserttwoscrewsAintomiddleplate.
6.Retightenfrontlateralplates(2and4).

4.1.5AdjustingFlex3manualrecline

Tools:
6mmAllenkey
AsecondinnerholelineBallowsneadjustmentsof3.75°.
Bracketforseatwidth53isinrigged,seebelow.
RegularseatwidthSeatwidth53
1604311-G
11
Invacare®Modulite
1.LoosenscrewinpositionAorB.
2.Adjustreclinetodesiredangle.
3.TightenscrewsinpositionAorB.

4.1.6AdjustingMatrxBackrests

Seecorrespondingmanual.

4.1.7AdjustingFlex3tensionadjustablebackrest

ForadjustmentofFlex3tensionadjustablebackrest,seeusermanual.

4.2Adjustingadapterforuniversalseat

4.2.1Adjustinguniversalseatadapterwidth

Tools:
3mmAllenkey
10mmwrench
1.
LoosenandremovefourscrewsA.
2.Putseatingplateontopofadapterplates.
3.
FastenadapterplatesAtoseatplateofseatBinareaC.
Forsmoothnessofadjustmentyoucanusebuttonheadscrews.
Makesurerubberstrapsonbackofadapterplatesfacetheframe.
Tooptimizeseatingpositionmoveelementbackorforthinslotbeforefasteningtoframe.
12
1604311-G
4.
InsertfourscrewsA.
5.Tightenfourscrews.
Setup
1604311-G13
Invacare®Modulite

5Service

5.1Imperialtometricconversionchart

Youcanusethischartasanorientationtondtheright toolsize.
IMPERIALMETRIC
inch
5/64
3/32
7/64
1/8
9/64
5/32
11/64
3/16
13/64
7/32
15/64
1/4
17/64
9/32
19/64
5/16
21/64
11/32
23/64
3/8
25/64
13/32
27/64
7/16
29/64
15/32
31/64
1/2
33/64
17/32
35/64
9/16
37/64
19/32
mm
1.9844
2.3813
2.7781
3.1750
3.5719
3.9688
4.3656
4.7625
5.1594
5.5563
5.9531
6.3500
6.7469
7.1438
7.5406
7.9375
8.3344
8.7313
9.1281
9.5250
9.9219
10.3188
10.7156
11.1125
11.5094
11.9063
12.3031
12.7000
13.0969
13.4938
13.8906
14.2875
14.6844
15.0813
IMPERIALMETRIC
inch
39/64
5/8
41/64
21/32
43/64
11/16
45/64
23/32
47/64
3/4
49/64
25/32
51/64
13/16
53/64
27/32
55/64
7/8
mm
15.4781
15.8750
16.2719
16.6688
17.0656
17.4625
17.8594
18.2563
18.6531
19.0500
19.4469
19.8438
20.2406
20.6375
21.0344
21.4313
21.8281
22.2250

5.2TighteningT orques

CAUTION! Riskofdamagetomobilitydevicedueto improperlytightenedscrews,nutsorplastic connections.
–Alwaystightenscrews,nutsetc.tothestated
tighteningtorque.
–Onlytightenscrewsornutswhicharenot
listedherengertight.
Thetighteningtorquesstatedinthefollowinglistare basedonthethreaddiameterforthenutsandboltsfor whichnospecicvalueshavebeendetermined.Allvalues assumedryandde-greasedthreads.
ThreadTighteningTorquein
Nm±10%
M43Nm
M5
M610Nm
M825Nm
M1049Nm
M1280Nm
M14120Nm
M16180Nm
6Nm
14
1604311-G
Loading...
+ 30 hidden pages