These instructions contain information about:
Fault-finding
Repair
Edition: 03.2001
MISTRAL
SERVICE
INSTRUCTIONS
Service Instructions MISTRAL
As at: 04.07.02 Page1
General information
These repair instructions contains all the information necessary for maintenance and overhaul of
the wheelchair.
· 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 wheelchair Operating Manual.
· You can find information about ordering spare parts in the spare parts catalogue.
· We reserve the right to make any alterations on the grounds of technical improvements.
· The wheelchair may only be maintained and overhauled by qualified personnel.
· - The minimum requirement for a maintenance technician is a specialist training e.g. as
bicycle or orthopaedic mechanic, or suitably long experience.
- Experience and knowledge of electrical measuring devices (Multimeter) is also a
requirement.
· If you have any problems or questions please contact INVACARE SERVICE:
Central office: Tel. 05731-754-0
Fax. 05731-754-111
Service Dept.: Tel. 05731-7545-(70-80)
Fax. 05731-7542-(08-16)
Address: Invacare Deutschland GmbH
Dehmer Str. 66
32549 Bad Oeynhausen
PO Box: Invacare Deutschland GmbH
Postfach 60 01 06
32 527 Bad Oeynhausen
· Alterations to the wheelchair 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.
MISTRAL Service Instructions
Page 2 As at: 04.07.02
Notes on transport
· If the wheelchair 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.
The following symbols are used in these repair instructions:
Note:
This symbol identifies general information which indicate special points or simplifications in
dismantling / reassembly.
CAUTION:
it is imperative that you observe any >safety instructions< identified with this symbol
This symbol identifies service work.
ü
Service Instructions MISTRAL
As at: 04.07.02 Page3
Contents
1 SAFETY AND ASSEMBLY INSTRUCTIONS 6
1.1 Before any inspection or repair work: 6
1.2 During dismantling/reassembly 6
1.3 Before operation / after completion of work: 7
2 TOOL LIST 8
3 LAYOUT OF MODULES, COMPONENTS AND DISPLAYS AND
CONTROLS 9
4 ELECTRONIC CONTROLLER COMPONENTS / ELECTRONICS 10
5 INSPECTION PLAN 11
6 OPERATIONAL FAULTS 13
6.1 General 13
6.2 Fault causes 13
7 ERROR CODES FOR REMOTE 15
8 MODULE COMPOSITION / VARIATIONS 16
9 MAINTENANCE AND REPAIR 17
9.1 Chassis 17
9.2 Drive unit, disengaging mechanism, anti-tip mechanism 20
9.2.1 Drive unit 20
9.2.2 Tongue (1.4) / Crank (1.1) 21
9.2.3 Wheel hub (1.13) 21
9.2.4 Disengaging mechanism 22
9.3 Anti-tip mechanism 25
9.3.1 Anti-tip tube (3.1) 26
9.3.2 Anti-tip spring (3.6) 26
9.4 Brake 27
· unscrew cylinder head screw (1.7) 28
· screw on new brake cylinder 28
· check brake for functioning and readjust if necessary (see brake assembly) 28
· unscrew cylinder head screw (1.6 and 1.7) 28
· replace brake lever 28
· check brake for functioning and readjust if necessary (see brake assembly) 28
MISTRAL Service Instructions
Page 4 As at: 04.07.02
9.5
Steering wheels 8" x 2" 29
9.5.1 Removal of steering wheels 30
9.5.2 Solid rubber wheel (steering wheel) (1.2) 30
9.5.3 Deep groove ball bearing (1.6), head tube axle (1.1.2), wheel fork (1.1.1) 30
9.6 Drive wheels 31
9.6.1 Wheel 12-1/2 X 2-1/4 31
9.6.2 Wheel rim halves (2.1 external, 2.2 internal) 32
9.6.3 Reassembly 32
9.6.4 Wheel 12-1/2 X 2-1/4 puncture-proof 33
9.6.5 Wheel rim halves (3.1 external, 3.2 internal) 33
9.6.6 Reassembly 34
9.6.7 Wheel 200 X 50 35
9.6.8 Wheel rim halves (4.1) 35
9.6.9 Reassembly 36
9.7 Battery case 37
9.7.1 Battery case 31 Ah 37
9.7.2 Batteries (1.5) 38
9.7.3 Battery case 50 Ah 40
9.7.4 Batteries (1.6) 41
9.8 Lighting 43
9.8 Electronics 50
9.9 Seat unit, seat angle adjustment, armrest and side panel 60
9.9.1 Seat unit, seat angle adjustment 60
9.9.2 Armrests and side panels 65
9.10 Side panel (1) 66
9.11 Side panel mounting (1.2 left, 1.3 right) 66
9.11.1 Clamping lever (1.12) 66
9.12 Backrest unit 67
9.12.1 Backrest detachable 67
9.12.2 Connecting strut (1.9) 68
9.12.3 Backrest padding fixing(1.12 left, 1.13 right) , backrest tube (1.11) , handle (1.1) 68
9.12.4 Backrest element adjustable 69
9.12.5 Backrest removal 71
9.12.6 Fixing the headrest 76
9.12.7 Headrest shell (1.4) 76
10 FOOTRESTS / LEG SUPPORTS 77
10.1.1 Footrest upper part standard 80 77
10.1.2 Turning knuckle (1.14) 79
10.2 Loosen machine screw with Phillips head (1.15) 79
10.2.1 Interlock 79
10.2.2 Clamp (1.3) 80
10.2.3 Footrest tube (1.1) 81
10.2.4 Footrest lower part 82
10.2.5 Calf strap (2.11) 83
10.2.6 Footplate (2.5 ) / Circular washer (2.8) 83
10.2.7 Push-in tube (2.1) 84
10.2.8 Reassembly takes place in the reverse order. 84
10.2.9 Leg support upper part with preset angle adjustment 85
10.2.10 Interlock 86
10.2.10 Interlock 86
Service Instructions MISTRAL
As at: 04.07.02 Page5
10.2.11
Footrest (VARI F, 90°-65°) with fixed footplates 87
10.2.12 Footrest LH (90°-65°) with angle-adjustable footplate 91
10.2.13 Leg support manually height-adjustable with angle adjustment 96
10.2.14 Leg support manually height-adjustable with ergonomic length adjustment 102
10.2.15 Leg support RH electrical height adjustment with ergonomic length adjustment 108
10.3 Accessories 116
10.3.1 Kerb climber 116
10.4 Kerb climber complete 116
10.5 Lining BB 1517 DU (1.4) 117
10.5.1 Cane holder complete 118
MISTRAL Service Instructions
Page 6 As at: 04.07.02
1 Safety and assembly instructions
The safety instructions are intended as prevention of accidents at work and it is imperative that
they are observed.
1.1 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 "
General information”).
CAUTION:
· Please note the high weight of some components. This applies especially to removal of
drive units and batteries.
· The wheelchair must be switched off before removal of voltage-carrying components.
To do this remove the battery.
· When making measurements on voltage-carrying components, avoid short-circuiting
the contacts.
Danger of fire and combustion !
· Use only undamaged tools in good condition.
1.2 During dismantling/reassembly
· Mark all current settings for the wheelchair (seat, armrests, backrest etc.), and the cable
connecting plugs associated, before any removals. This makes reassembly easier.
CAUTION:
· Support the wheelchair when raised with suitable equipment before beginning
removal or reassembly.
· Never use "standard" nuts instead of self-locking nuts.
· Always use correctly dimensioned washers or spacers.
NOTE:
· 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.
· Cable binders which have been cut off during disassembly should be replaced
by new ones during reassembly.
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Service Instructions MISTRAL
As at: 04.07.02 Page7
1.3 Before operation / after completion of work:
CAUTION:
· Check all fixings for tight fit.
· Check all parts for correct interlocking.
· Only operate wheelchair with correct tyre pressure (2.5 bar).
· Check electoral components for correct functioning, as incorrect cable polarity
can lead to "reverse" functioning (e.g. electrical leg supports).
As a last check always
carry out a trial run.
MISTRAL Service Instructions
Page 8 As at: 04.07.02
2 Tool list
You will need a standard tool set with at least the following:
· set of open and ring spanner
· set of Allen keys
· torque wrench (commercial)
· socket spanner set
· set of screwdrivers
· oblique pliers
· flat-nosed pliers
· circlip pliers
· pointed pliers
· cable lug pliers
· wooden or plastic hammer
· tyre repair kit (commercial)
· tyre pressure indicator
· valve removal tool
· wheel bearing puller
· Multimeter with probes and various cable clips
· soldering iron 30 W
· front wheel hub puller (available from INVACARE Service)
· circlip pliers for Star lock caps (commercial, e.g. Tigtemeyer)
· pop riveting tool
· stepped mandril
Service Instructions MISTRAL
As at: 04.07.02 Page9
3 Layout of modules, components and displays and controls
The following figures show the layout of "MISTRAL" modules.
Removal and reassembly of spare parts is described in Chapter 9.
1 Chassis
2 Drive unit, disengaging
mechanism, anti-tip
mechanism
3 Brake (no diagram)
4 Steering wheel
5 Drive wheel
6 Battery case
7 Lighting
8 Electronics
9 Seat unit, seat angle
adjustment, armrests,
side panels
10 Backrest
11 Leg supports
12 Accessories (no
diagram) kerb climber,
cane holder
MISTRAL Service Instructions
Page 10 As at: 04.07.02
4 Electronic control l e r components / Electronics
1. Remote
2. Lighting
3. Drive RH
4. Connecting cable remote
– battery – drive units
5. Battery case
6. Drive unit LH
7. 2 batteries 12 V
8. Strip fuse holder with
strip fuse
9. Battery bridge
10. Battery cable
11. ACS-Clam (light-m otor
module combined)
12. Lighting
13. Electr. leg supports
Service Instructions MISTRAL
As at: 04.07.02 Page11
5 Inspection plan
Component Check Remedy Chapter
ü
Armrests and
side panels
· Armrest damage and
fastening
· Side panel damage and
fixing
Þ Tighten screws, replace
padding
Þ Tighten screws, replace
side panels
9.9
9.9
Seat unit / seat
angle
adjustment
· Check seat angle
adjustment
Þ Replace parts
9.9
Back unit
mechanical
Back unit
electrical
· Damage and seams
· Fixings
· Check cabling
· Check function
Þ Replace parts
Þ Tighten screws
Þ Replace cable or motor if
necessary
9.10
Chassis with
battery case
strap / battery
case fixing
· Fixings, welded seams,
reflectors and battery
case strap. Check
Þ Tighten screws, replace
components
9.1
Wheel
suspension and
wheels
· Check drive wheels for
tight fit and side play
· Check steering wheels for
tight fit, float and side play
· Check steering wheel
forks
· Check tyres
Þ Adjust, replace wheel
hubs
Þ Replace wheels, wheel
fork or wheel bearings
Þ Replace
Þ Fit new
9.5
9.4
9.4
9.4
Drive units,
disengaging
mechanism
· Check functions in drive
and push modes
· Check disengaging
mechanism
Þ Replace motor if
necessary
Þ Tighten screws / nuts,
adjust or replace if
necessary
9.2
9.2
Footrests
· Check welded seams,
interlocking, screws,
footplates
Þ Tighten, replace
9.11
Electrical leg
supports
· Check cabling
· Check contacts
· Check functions
Þ Replace cable if
necessary
9.11
Lighting
· Check cabling
· Check function
Þ Replace cable or bulbs if
necessary
9.11
MISTRAL Service Instructions
Page 12 As at: 04.07.02
Component Check Remedy Chapter
ü
Batteries
· Damage to batteries and
case, contact corrosion
· Check contacts, terminals
· Check battery voltage
Þ Clean contacts, replace
batteries or case
Þ Tighten, replace
Þ Charge batteries / replace
9.6
Remote /
electronics
· Remote,
status display blinking
· Fixing
· Cable, connecting plug
· Joystick function
· Power supply
Þ Evaluate blinking code
Þ Tighten, replace
Þ Replace
Þ Replace joystick
Þ Replace cable, connector
plug or console
7
9.8
9.6, 9.8
9.8
9.6
Service Instructions MISTRAL
As at: 04.07.02 Page13
6 Operational faults
6.1 General
If faults occur in drive mode or power supply proceed as follows:
· First assess the fault causes described in Chapter 6.2.
· Check the status display on the remote and assess the error codes in accordance with
Chapter 7.
· Carry out the necessary testing / repairs. While doing this please note the references to the
appropriate chapter in the manual or to the appropriate documentation.
6.2 Fault causes
Wheelchair will not
engage motors
drive motors disengaged
batteries
defective
replace batteries
delete status display on
remote
pre-charge
batteries
completely
discharge battery
check battery
fuses
check voltage at
remote
power supply
interrupted
check voltage at
batteries
status display
blinking on
wheelchair
assess error code
error code 1-12
Chapt. 9.6
Operating
manual
Chapt. 9.6
Chapt. 9.6
Chapt. 7
Chapt. 9.6
MISTRAL Service Instructions
Page 14 As at: 04.07.02
replace drive unit
drive unit
defective
Wheelchair judders in drive mode
Chapt. 9.2
replace battery
replace charging
device
batteries defective
charging device defective
Cannot charge batteries
Chapt. 9.6
warning horn defective
replace remote
lighting defective
check / replace
cabling or bulbs
Chapt. 9.8
Chapt. 9.7
electrical leg support defective
check / replace
cabling or motor
pneumatic backrest adjustment defective
check / replace
release unit / Bowden
cable, gas-filled
spring
Chapt. 9.11
Chapt. 9.10
electrical backrest adjustment defective
check / replace
cabling ,control unit,
moto r
Chapt. 9.8
Chapt. 9.10
Service Instructions MISTRAL
As at: 04.07.02 Page15
7 Error codes for remote
Before assessing the error codes, carry out the following test:
· Turn the remote on and off several times. Before you switch on wait approx.. 5 seconds.
The test checks whether the error can be automatically rectified by the electronics, and if
necessary deactivates the blinking status display at the remote. If this is not the case, you can
locate the fault using the blink codes as follows:
· turn the remote on and off
· check which blink code is showing by counting
· wait for the blink code pause (approx. 2-3 seconds)
· re-count the code.
Blink code: Meaning: Immediate measure:
1 x blink
Module defective - Replace module
Chapt. 9.8
2 x blink
Accessory fault -
3 x blink
Fault in right-hand motor.
Connection
loose/defective
· Check connecting
plugs
Check drive unit /
battery Chapt. 9.2
/ 9.6
4 x blink
Fault in left-hand motor.
Connection
loose/defective or motor
defective
· Check connecting
plugs
Check drive unit /
battery Chapt. 9.2
/ 9.6
5 x blink
Fault/brake fault on righthand motor. Connection
loose/defective or motor
defective
Motors disengaged
· Check connecting
plugs
· Engage motors Turn
the remote on and off
Check drive unit /
battery
Chapt. 9.2 / 9.6
6 x blink
Fault/brake fault on lefthand motor. Connection
loose/defective or motor
defective.
· Check connecting
plugs
Check drive unit /
battery Chapt. 9.2
/ 9.6
7 x blink
Completely discharge
battery
· Pre-charge battery
Check battery
Chapt. 9.6
8 x blink
Battery voltage too high - Check battery
Chapt. 9.6
9 or 10 x blink
Faulty data transmission
between modules
- Check drive unit /
battery Chapt. 9.2
/ 9.6
11 x blink
Motors overloaded
· Turn remote on and
off
12 x blink
Compatibility problems - Check drive unit /
battery Chapt. 9.2
/ 9.6
MISTRAL Service Instructions
Page 16 As at: 04.07.02
8 Module composition / variations
The Mistral can be supplied the following options from start of production:
· Batteries (Chapt. 9.6)
31 Ah
50 Ah
· Brake (Chapt. 9.3)
· Drive wheels (Chapt. 9.5)
12-1/2 x 1-1/4 (pneumatic tyre)
12-1/2 x 1-1/4 (puncture-proof)
200 x 50
· Lighting (9.7)
· Remote and accessories (9.8)
Compact
ACS operation for attendant
"Commando" attendant operation for backrest adjustable
"Commando" attendant operation for backrest detachable
Swivelling table
Operating console holder height-adjustable / swivelling
· Backrest elements (9.10)
Backrest element adjustable
Pneumatic backrest adjustment
Electrical backrest adjustment
· Headrest (9-10)
· Footrests / leg supports (9.11)
Standard 80
With preset angle adjustment
Vari 90° - 65°
Angle-adjustable footplates
Leg supports manually height-adjustable with angle adjustment
Leg supports manually height-adjustable with ergonomic length adjustment
Leg supports with electrical height adjustment
· Kerb climber (9.12)
· Cane holder (9.12)
Service Instructions MISTRAL
As at: 04.07.02 Page17
9 Maintenance and repair
9.1 Chassis
Pos Qty. Item No./Pcs. Item Description
1.1 2 B210001.P18 Frame tube, RAL 5025 Pearl Gentian Blue
1.1 2 B210001.P91 Frame tube, RAL 1028 Melon Yellow
1.1 2 B210001.P92 Frame tube, Silver Grey gloss
1.2 1 B284012.P28 Battery case fixing RH
1.3 1 B284005.P28 Battery case fixing LH
1.4 2 B210015.00 Transport shackle
1.5 4 G00106 Washer 8.4 x 17 x 1.6
1.6 4 F20105 Hexagon nut M8 self-locking
1.7 1 B284020 Battery case fastening strap LH
1.8 1 B284021 Battery case fastening strap RH
1.9 2 D90195 Countersunk screw with Allen key M8 x 16 ULS
A2
1.10 2 G10103 Washer 8.4 x 25 x 2
1.11 2 F00002 Hexagon nut M8 self-locking
1.12 4 B284031 Cover plugs
MISTRAL Service Instructions
Page 18 As at: 04.07.02
Pos Qty. Item No./Pcs. Item Description
1.13 1 B212007 Scissor stay complete
1.13.1 2 B212006.P28 Scissor stay
1.13.2 1 B212008.99 Straight pin Ø 8 x 110
1.13.3 2 B212009.99 Straight pin Ø 10 x 125
1.13.4 2 K32302 Star lock cap 8 mm, black
1.13.5 4 K32303 Star lock cap 10 mm, black
1.14 1 B290001 "Mistral" nameplate
Note:
Repair work to the chassis is easier to carry out if the complete seat unit has been
dismantled beforehand.
Removal of seat unit
· carefully lever off Star lock caps (A , B) with screwdriver
· pull out straight pins
· the complete seat unit can then be removed upwards
Scissor stay (1.13, 1.13.1)
· carefully lever off Star lock caps (1.13.5) with
screwdriver
· pull out straight pins (1.13.3)
· carefully lever off Star lock cap (1.13.4) with
screwdriver
· pull out straight pins (1.13.2)
· insert new scissor stay(s) (1.13.1)
Note:
Use new Star lock caps when reassembling.
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Service Instructions MISTRAL
As at: 04.07.02 Page19
Battery case fastening strap (1.7 left, 1.8 right)
· loosen countersunk screw with Allen key (1.9) and
hexagon nut (1.11)
· insert new battery case fastening strap (1.7 RH or
1.8LH)
Battery case fixing (1.2 right, 1.3 left) / transport shackle (1.4)
· unscrew hexagon nut M8 (1.6)
· remove battery fastening (1.2 or. 1.3)
· carefully tap transport shackle (1.4) out with wood
block and hammer
· insert new transport shackle or new battery fastening
Reassembly takes place in the reverse order.
MISTRAL Service Instructions
Page 20 As at: 04.07.02
9.2 Drive unit, disengaging mechanism, anti-tip mechanism
9.2.1 Drive unit
Pos Qty. Item No./Pcs. Item Description
1 1 B253001 Drive unit complete
1.1 2 B222003 Crank
1.2 2 B222012 Lining 20x1x28,6
1.3 2 B222013 Lining 18x3x29
1.4 2 B222023.00 Spring
1.5 2 B222014 Stop
1.6 2 DG00001 Hexagon bolt M12 x 45
1.7 2 F00105 Hexagon nut M12
1.8 1 P00038 Drive unit LH
1.9 1 P00039 Drive unit RH
1.10 2 N23004 Feather key A 6 x 6 x 40
1.11 6 D50120 Cylinder-head screw with Allen key M6 x 40
1.12 6 D50133 Cylinder-head screw with Allen key M6 x 30
1.13 2 N322007 Wheel hub
1.14 2 Z122014 Wheel hub cover
1.15 2 D60200 Countersunk screw with Allen key M8 x 30-8.8
PB
Service Instructions MISTRAL
As at: 04.07.02 Page21
Note:
Repair work is easier to carry out if the complete seat unit has been dismantled
beforehand.
Removal of seat unit
· carefully lever off Star lock caps (A , B) with screwdriver
· pull out straight pins
· the complete seat unit can then be removed upwards
9.2.2 Tongue (1.4) / Crank (1.1)
· dismantle drive gear (see chapter drive gear)
· support drive unit with woodblock (weight)
· unscrew hexagon bolt (1.6) /nut (1.7)
· replace spring(1.4)
· unscrew cylinder-head screw (1.11, 1.12)
· replace crank (1.1)
9.2.3 Wheel hub (1.13)
· Engage motor
· Lay wheelchair on soft bed on its side, so that the drive
wheel to be removed is at the top or
use suitable support
(e. g. wooden block) and prop the wheelchair up so that the
drive wheels are free.
· Loosen countersunk screw (1.15) with cover (1.14) and pull
drive wheel complete with wheel hub off the drive motor
(the axle has a feather key (1.10) fitted).
NOTE:
When removing the wheel hub (1.13) do not lose the feather key (1.10) in gear axle.
Reassembly takes place in the reverse order.
(Observe position of groove in wheel and feather key on axle).
ü
ü
MISTRAL Service Instructions
Page 22 As at: 04.07.02
9.2.4 Disengaging mechanism
Pos Qty. Item No./Pcs. Item Description
2 1 B252012 Disengaging mechanism complete
2.1 2 B252007.99 Disengaging rod complete
2.2 2 B252017.99 Ball joint with M8 thread
2.3 2 F00103 Hexagon nut M6
2.4 2 F00104 Hexagon nut M8
2.5 2 K32301 Star lock cap 6 mm, black
2.6 1 B252004.P28 Disengaging lever, matt black
2.7 1 B252011 Plastic handle
2.8 1 B252001.P28 Turning knuckle RH, matt black
2.9 1 B252014.P28 Turning knuckle LH, matt black
2.10 1 B252005.P28 Lining 22x8,2x20
Pos Qty. Item No./Pcs. Item Description
2.11 2 J30007 Dowel pin 4 x 20
2.12 2 B252009.P28 Disengaging strut
Service Instructions MISTRAL
As at: 04.07.02 Page23
2.13 2 D50108 Cylinder-head screw with Allen key M6 x 25
2.14 1 D50051 Cylinder-head screw with Allen key M6 x 16
2.15 3 F20109 Hexagon nut M6 self-locking
2.16 2 B252016.89 Washer T 2.5
After repair work to the disengaging mechanism it must be adjusted and checked
for correct functioning.
Disengaging rod (2.1)
· carefully lever off Star lock cap (2.5) with screwdriver
· pull out disengaging rod (2.1) from turning knuckle (2.8 or
2.9)
· unscrew disengaging rod (2.1) from ball joint (2.2)
Ball joint (2.2)
· unscrew hexagon cap nut (2.4)
· pull out ball joint (2.2) upwards and unscrew out of
disengaging rod (2.1)
· insert new ball joint
Disengaging strut (2.12)
· unscrew cylinder head screw (2.13, 1.14)
· remove disengaging strut (2.12)
Plastic handle (2.7), disengaging lever (2.6) / lining (2.10)
· pull off plastic handle (2.7)
· carefully drill out dowel pin (2.11)
· remove disengaging lever (2.6) from turning knuckle
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MISTRAL Service Instructions
Page 24 As at: 04.07.02
Turning knuckle (2.8 right, 2.9 left)
· dismantle disengaging lever (2.6) or lining (2.10)
· unscrew cylinder head screw (2.13)
· remove disengaging lever ( 2.6) or lining (2.10) from turning
knuckle (2.8 or 2.9)
Functional check of disengaging mechanism
· prop the wheelchair up so that the drive wheels are free.
· set the switch lever to the horizontal position (both drive wheels should not be able to be
turned by hand)
· slowly turn the switch lever upwards and try to turn the drive wheels at the same time
Both drive wheels should be simultaneously disengaged (the wheels can be turned).
NOTE:
When the switch lever is in the upper position both drive wheels must be freely rotating.
If this is not the case, the disengaging mechanism must be readjusted.
Adjusting the disengaging mechanism
· loosen hexagon nut (2.3) on disengaging rod (2.1)
· carefully lever off ball joint (2.4) with screwdriver
· screw disengaging rod more or less into the ball joint
· set the ball joint on again and push down until the ball has engaged properly
· when adjustment is correct retighten hexagon nut
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Service Instructions MISTRAL
As at: 04.07.02 Page25
9.3 Anti-tip mechanism
Pos Qty. Item No./Pcs. Item Description
3 2 B222022 Anti-tip mechanism complete
3.1 1 B222017.P28 Anti-tip tube; matt black
3.2 1 M14905 Support wheel
3.3 1 D50138 Cylinder-head screw with Allen key M6 x 40
3.4 1 F20109 Hexagon nut M6 self-locking
3.5 1 G00115 Washer 6.4 x 12.5 x 1.6
3.6 1 B222019.99 Anti-tip spring
MISTRAL Service Instructions
Page 26 As at: 04.07.02
Support wheel (3.2), Anti-tip tube (3.1), Anti-tip spring (3.6)
Support wheel (3.2)
· unscrew cylinder-head screw (3.3) and hexagon nut (3.4)
· remove support wheel (3.2)
9.3.1 Anti-tip tube (3.1)
· loosen Allen screw (1.11, 1.12) on crank (1.1)
· pull out anti-tip tube (3.1)
· dismantle support wheel (3.2)
· when reassembling ensure that anti-tip spring (3.6)
engages
9.3.2 Anti-tip spring (3.6)
· dismantle anti-tip tube
· push anti-tip spring (3.6) completely home on both sides
(e.g. with Allen key)
· pull out anti-tip spring e.g. with pointed pliers
· when reassembling ensure that anti-tip spring (3.6)
engages in anti-tip tube (3.1)
Reassembly takes place in the reverse order.
Service Instructions MISTRAL
As at: 04.07.02 Page27
9.4 Brake
Pos Qty. Item No./Pcs. Item Description
1 1 B2XX002 Brake complete
1.1 1 B231007 Brake lever LH
1.2 1 B231006 Brake lever RH
1.3 2 5007791 Brake lever handle
1.4 8 F20109 Hexagon nut M6 self-locking
1.5 4 D50051 Cylinder-head screw with Allen key M6 x 16
1.6 2 D50004 Cylinder-head screw with Allen key M6 x 30
1.7 2 D50122 Cylinder-head screw with Allen key M6 x 45
1.8 2 1400669 Brake cylinder
1.9 2 1400666-2 Connection piece
1.10 2 1400671-2 Cap
1.11 8 G00115 Washer 6.4 x 12.5 x 1.6
1.12 1 B231001.P28 Brake bracket RH
1.13 1 B231002.P28 Brake bracket LH
1.14 1 1400670 Spring LH
1.15 1 1400671 Spring RH
MISTRAL Service Instructions
Page 28 As at: 04.07.02
Brake installation
· Screw the brake bracket RH (1.12) or LH (1.13)
loosely to the LH or RH battery holder with cylinder
head screws (1.5).
· Align the brake brackets so that the brake acts firmly
when operated, and so that there is enough play
between the wheel and the brake cylinder in drive
mode.
Replacing the brake cylinder (1.8)
· unscrew cylinder head screw (1.7)
· screw on new brake cylinder
· check brake for functioning and readjust if necessary (see brake assembly)
Replacing the brake lever (1.1 LH, 1.2 RH)
· unscrew cylinder head screw (1.6 and 1.7)
· replace brake lever
· check brake for functioning and readjust if necessary (see brake assembly)
Service Instructions MISTRAL
As at: 04.07.02 Page29
9.5 Steering wheels 8" x 2"
Pos Qty. Item No./Pcs. Item Description
1 1 B222011 Wheel suspension 200 x 50 complete
1.1 1 B222015 Wheel fork complete
1.1.1 1 B222001.79 Wheel fork
1.1.2 1 B222002.99 Head tube axle
1.1.3 2 F00115 Hexagon nut M12 x 1.5 self-locking
1.2 1 5004320 Solid rubber wheel 8" x 2" with bearing
1.3 1 D08196 Hexagon bolt M8 x 90
1.4 1 F20105 Hexagon nut M8
1.5 1 B210013 Protective cap
1.6 2 2701003 Bearings R8-2RS 1/2" x 1.1/8" x 5/16
1.7 4 G00106 Washer 8.4 x 17 x 1.6
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