Invacare Typhoon Service Manual

Invacare® Typhoon
SERVICE MANUAL

This document contains information on:
Troubleshooting
Maintenance
Repair
Version: 26.11.09

2

Mobitec Mobilitätshilfen GmbH

Herzog Odilostrasse 101
A-5310 Mondsee

Austria

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Fax: [phone]
@: [e-mail]
@: [e-mail]
WWW: www.mobitec-austria.com

Invacare® n.v.

Autobaan 22
B-8210 Loppem (Brugge)

Belgium

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Fax: [phone]
@: [e-mail]
WWW: www.invacare.be

Mobitec Rehab AG

Benkenstraße 260
CH-4108 Witterswil

Switzerland

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Fax: [phone]
@: [e-mail]
@: [e-mail]
WWW: www.mobitec-rehab.ch

Invacare Aquatec

Alemannenstraße 10
88316 Isny

Deutschland

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

Invacare® A/S

Sdr. Ringvej 37
DK-2605 Brøndby

Danmark

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Fax (Kundeservice): [phone]
@: [e-mail]
WWW: www.invacare.dk

Invacare® SA

c/ Areny, s/n
Polígon Industrial de Celrà
E-17460 Celrà (Girona)

ESPAÑA

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Fax: [phone]
@: [e-mail]
WWW: www.invacare.es

Invacare® Poirier SAS

Route de St Roch
F-37230 Fondettes

France

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Fax : [phone]
@: [e-mail]
WWW: www.invacare.fr

Invacare® Ltd

Pencoed Technology Park
Pencoed
Bridgend CF35 5HZ

United Kingdom

 (Customer Service): [phone]
Fax (Customer Service): [phone]
@: [e-mail]
@: [e-mail]
WWW: www.invacare.co.uk

Invacare Mecc San s.r.l.

Via Dei Pini, 62
I - 36016 Thiene (VI)

ITALIA

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Fax: [phone]
@: [e-mail]
WWW: www.invacare.it

Invacare Ireland Ltd.

Unit 5 Seatown Business Campus
Seatown Rd, Swords
County Dublin

Ireland

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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]
WWW: www.invacare.no

Invacare® B.V.

Celsiusstraat 46
NL-6716 BZ Ede

Nederland

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Fax: [phone]
@: [e-mail]
WWW: www.invacare.nl

3

Invacare Portugal, Lda

Rua Estrada Velha, 949
P-4465-784 Leça do Balio

Portugal

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 : [phone]

Fax: [phone]
@: [e-mail]
WWW: www.invacare.pt

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]

4

Table of Contents

Chapter Page

1 INTRODUCTION 6

1.1 General information 6

1.2 Notes on transport 6

1.3 Important symbols in this manual 6

2 SAFETY AND ASSEMBLY INSTRUCTIONS 8

2.1 Before any inspection or repair work 8

2.2 General safety information and notes on assembly / disassembly 8

3 TIGHTENING TORQUES 9

4 LAYOUT OF COMPONENTS AND MODULES 10

5 SERVICE PLAN (1X ANNUALLY) 11

6 TROUBLESHOOTING THE TYPHOON 13

6.1 Troubleshooting the Typhoon with ACS 13

6.1.1 Diagnosing driving faults 13

6.1.2 Diagnosing problems with electric actuators 15

6.1.3 REM24 Error Codes and Diagnostic Codes 16

7 REPAIR WORK 18

7.1 Replacing a conventional drive motor 18

7.2 Replacing and calibrating a GB drive motor 22

7.2.1 Replacing the motor 22

7.2.1.1 Disassembling the tyre and rim on a vehicle with pneumatic tyres 23

7.2.1.2 Disassembling the rim and the tyre on a vehicle with puncture-proof tyres 24

7.2.1.3 Proceed with removing the motor 24

7.2.1.4 Reassembling the rim and the tyre on a vehicle with pneumatic tyres 27

7.2.1.5 Reassembling the rim and the tyre on a vehicle with puncture-proof tyres 27

7.2.2 Calibrating GB motors 29

7.3 Replacing components of the electronics 31

7.4 Replacing the batteries 33

7.5 Replacing the main fuse 39

5

7.6

Checking the cables 41

7.7 Replacing the ACS Remote 42

7.8 Updating the driving program 44

7.9 Testing an actuator motor 45

7.10 Adjusting and replacing the speed reduction switch 46

7.11 Replacing the steering head bearings on the front or rear castor wheels 47

7.11.1 Front Castor Wheels 47

7.11.2 Rear Castor Wheels 48

7.12 Replacing the Anti-Dive Spring 50

7.13 Repairing a flat tyre (conventional motor) 52

7.14 Repairing a flat tyre (GB motor) 54

7.15 Replacing a drive wheel 55

7.16 Replacing the safety belt 55

6

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 INVACARE.

• 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

WARNING!

This symbol warns you of danger!

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

EXPLOSION HAZARD!

This symbol warns you of an explosion hazard, which, for example, 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 burns due, for example, to leaking battery acid!

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

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.

7

READ WELL BEFORE OPERATION!

This symbol advises you to read information carefully.

8

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 removal of
drive units and batteries!

• Prop up the lifted electric vehicle with appropriate supports before starting the disassembly 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! To
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.

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 trained 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!

9

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!

10

4 Layout of components and modules

The following image shows the Typhoon from above rear, with the seat lifter raised and the rear
cowling removed.

1 Seat tilt actuator
2 Seat-frame / rear cowling anti-collision switch
3 Speed-reduction switch
4 Power module
5 CLAM (Combined Light and Actuator Module)

The following image shows the Typhoon from the front right, with the lifter raised

1 Lifter actuator

11

5 Service plan (1x annually)

Component Check Action Notes

9

Armrests and
side panels

• Armrest damage and
fastening

• Side panel damage
and fixing

⇒ Tighten screws, replace

padding if damaged

⇒ Tighten screws, replace

side panels if damaged

Seat unit / seat
angle adjustment

• Cushion

• Check seat angle

adjustment

⇒ Replace covers /

upholstery if damaged

⇒ Replace parts if damaged

Backrest unit
mechanical

Backrest unit
electrical

• Damage and seams

• Fixings

• Check cabling

• Check function

⇒ Replace parts if damaged
⇒ Tighten screws
⇒ Replace cable or motor if

necessary

Frame (chassis) /
battery box

• Check fixings, welded
seams and battery box

⇒ Tighten screws, replace

components

Wheel
suspension and
wheels

• Check drive wheels for
tight fit and side play

⇒ Adjust, replace wheel

hubs

See "Replacing a
drive wheel" on
page 55

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

⇒ Replace wheels, wheel

fork or wheel bearings

See "Replacing

the steering head
bearings on the

front or rear castor
wheels" on page 47

• Check pneumatic tyres
on the drive wheels

⇒ Repair or replace if

damaged

See "Repairing a

flat tyre
(conventional
motor)" on page

52

Drive units,
disengager

• Check functions in
drive and push modes

• Check disengager

⇒ Replace motor if

necessary

⇒ Tighten screws / nuts,

adjust or replace if
necessary

Footrests

• Check welded seams,
interlocking, screws,
footplates

⇒ Tighten, replace if

necessary

Electrical
footrests

• Check cabling

• Check contacts

• Check functions

⇒ Replace cable if

necessary

Lighting

• Check cabling

• Check function

⇒ Replace bulbs or cables if

necessary

Batteries

• Check batteries for
damage

⇒ Replace batteries if

necessary

See "Replacing
the batteries" on
page 33

• Check battery charge ⇒ Charge batteries

See User Manual

12

Component Check Action Notes

9

• Check contacts and
terminals for corrosion

⇒ Clean contacts and

terminals

See "Replacing
the batteries" on
page 33 for Safety
Information on
working with
batteries

Remote /
electronics

• Remote,
status display blinking

• Fixing

• Cable, connecting plug

• Joystick function

• Power supply

⇒ Evaluate flash code
⇒ Tighten, replace
⇒ Replace
⇒ Replace joystick
⇒ Replace cable, connector

plug or console

Walking Beam

• Check spring for
damage

⇒ Replace if damaged

See "Replacing

the Anti-Dive
Spring" on page

50

Lifter

• Check correct function

• Check function of the

Stability Lock

⇒ Repair if necessary

Driving
Programme

• Check the programme

version of the driving
electronics. Is there a
newer version
available?

• Update the software.

See "Updating the "
on page 44

13

6 Troubleshooting the Typhoon

6.1 Troubleshooting the Typhoon with ACS

If a problem occurs with the wheelchair, then please proceed as follows:

• Identify the possible cause of the fault by using the troubleshooting tables below.

• Check the Status Display on the remote. Identify the error code if it is flashing.

• Perform the necessary checks and repairs as recommended in the table below.

Note

For more information on troubleshooting the Typhoon with GB motors, please see the “Dynamic
DX-GB-AS Power Module - Installation Manual”, Order Nr. 1441533

6.1.1 Diagnosing driving faults

PROBLEM OTHER

SYMPTOMS

POSSIBLE
CAUSE

SOLUTION REFERENCE

Wheelchai
r will not
drive

Status display
on remote
lights up
normally and
does not show
an error code

Drive motors
may be
disengaged

• Engage
the drive
motors

See User Manual

Status display

on remote
does not light
up

Batteries may
be defective

• Replace
the batteries

See "Replacing the
batteries" on page 33

Batteries may

be completely
discharged

• Charge
the batteries

See User Manual

Power supply

to the remote
may be
interrupted

• Check
the main fuse

See "Replacing the main
fuse" on page 39

• Check
cables
between
modules for
loose
connections or
damage

See "Checking the
cables" on page 41

Remote may

be defective

• Exchang
e the remote
on the
wheelchair for
a different one
to eliminate
the possibility
that the
remote may
be the cause.

See "Replacing the ACS
Remote" on page 42

Status display

on remote is
flashing

Various causes

• Identify
the error code

See "REM24 Error
Codes and Diagnostic
Codes" on page 16

14

PROBLEM OTHER

SYMPTOMS

POSSIBLE
CAUSE

SOLUTION REFERENCE

Status display

on remote
flashes 2x,
drive mode
display shows
"U"

Speed
reduction
switch on the
lifter may be
defective or
disconnected

• Replace
cable or
switch

See "Adjusting and
replacing the speed
reduction switch" on
page 46

Wheelchai
r does not
drive
smoothly

None Batteries may

be defective
(voltage not
stable)

• Replace
the batteries

See "Replacing the
batteries" on page 33

Drive motor(s)

may be
defective

• Replace
the drive
motor(s)

See "Replacing a
conventional drive
motor" on page 18 and
"Replacing and
calibrating a GB drive
motor" on page 22

Batteries
cannot be
charged

None Batteries may

be defective

• Replace
the batteries

See "Replacing the
batteries" on page 33

LEDs on the

charger are
flashing

Charger may
be defective

• Replace
the charger

See User Manual of the
charger

Wheelchai
r drives
too slowly

Status display
on remote
flashes 2x,
drive mode
display shows
"U"

Seat lifter is not
in driving
position (either
too high or too
low), and has
activated the
automatic
speed
reduction.

• Return
seat lifter to
driving
position

See User Manual

Speed-

reduction
micro-switch on
the seat lifter
may be badly
adjusted

• Adjust
the micro­switch

See "Adjusting and
replacing the speed
reduction switch" on
page 46

None Remote may

be defective

• Replace
the remote

See "Replacing the ACS
Remote" on page 42

Batteries may

be defective

• Replace
the batteries

See "Replacing the
batteries" on page 33

15

6.1.2 Diagnosing problems with electric actuators

In case an electric actuator will not function, identify the source of the problem using the following
table:

PROBLEM OTHER

SYMPTOMS

POSSIBLE
CAUSE

SOLUTION REFERENCE

Electric
Actuator
does not
function

Remote
displays a
flashing "E",
status diode on
the CLAM does
not go out,
even if the
remote is
switched off or
disconnected

CLAM is
defective

• Replace
the CLAM

See "Replacing

components of the
electronics" on page 31

None Cable may

be
disconnected
or damaged

• Check
that the cable
is not
disconnected
or damaged. If
necessary,
replace the
cable

See "Checking the
cables" on page 41

Electric

actuator may
be defective

• Test the
actuator

See "Testing an actuator
motor" on page 45

Remote may

be defective

• Exchang
e the remote
on the
wheelchair for
a different one
to eliminate
the possibility
that the
remote may
be the cause.

See "Replacing the ACS
Remote" on page 42

16

6.1.3 REM24 Error Codes and Diagnostic Codes

The drive electronics are capable of rectifying some errors automatically. In this case the status
display will cease to flash. Please switch the remote on and off several times. Wait approx. 5
seconds each time before switching the remote on again. If this does not rectify the error, locate
the error using the flash codes shown below.

Flash code: Meaning: Solution: Notes
1 x flash

Module defective

• Replace defective module

See "Replacing
components of the
electronics" on page 31

2 x flashes

Accessory error
(e.g. actuator
short-circuit)

• Check accessory
connections, check
accessories

See "Testing an actuator
motor" on page 45

Lifter raised or
lowered too far
(seat not at driving
height)

• If lifter is raised, lower in
stages until the status
display stops flashing. If
lowered too far, raise lifter
in stages until the status
display stops flashing. If
at all possible, only drive
when the seat is at driving
height.

See User Manual

3 x flashes

Connection on the
left motor
loose/defective

• Check plug-in
connections.

See "Checking the
cables" on page 41

Left motor
defective.

• Check/replace motor

See "Replacing and
calibrating a GB drive
motor" on page 22

4 x flashes

Connection on the
right motor
loose/defective

• Check plug-in
connections.

See "Checking the
cables" on page 41

Right motor
defective.

• Check/replace motor

See "Replacing and
calibrating a GB drive
motor" on page 22

5 x flashes

Fault/brake fault
on left-hand motor.
Connection
loose/defective or
motor defective.

• Check plug-in
connections.

See "Checking the
cables" on page 41

Left motor
disengaged (GB­motors)

• Engage motor. Shut
electronics down and then
switch on again.

See User Manual

Both motors
disengaged
(standard motors)

• Engage motors. Shut
electronics down and then
switch on again.

See User Manual

6 x flashes

Fault/brake fault
on right-hand
motor. Connection
loose/defective or
motor defective.

• Check plug-in
connections.

See "Checking the
cables" on page 41

Right motor
disengaged (GB­motors)

• Engage motor. Shut
electronics down and then
switch on again.

See User Manual

7 x flashes

Battery dead

• Pre-charge battery

See User Manual

17

Flash code: Meaning: Solution: Notes
8 x flashes

Battery voltage too
high

• Switch lights on to lower
battery voltage

• Check battery charger

See User Manual of battery
charger

9 or 10 x
flashes

Faulty data
transmission
between modules

• -

Remove all electronic
modules except the Power
Module and the Remote.
Re-attach modules one by
one to determine which one
is causing the fault.
See "Replacing
components of the
electronics" on page 31

11 x flashes

Motors overloaded
/ overheated

• Switch remote on and off /
wait if necessary

-

12 x flashes

Module used has
compatibility
problems

• Remove incorrect module

See "Replacing
components of the
electronics" on page 31