Invacare Tornado Manuale utente

Invacare® Tornado

SERVICE MANUAL

These instructions contain information about:

Troubleshooting

Repair

Edition: 03.2004

Service Manual Tornado

As at: 19.03.2004 Page 1

General information

These repair instructions contain 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.

• 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 wheelchair 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 wheelchair 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:

Invacare® Deutschland GmbH

Kleiststraße 49

32457 Porta Westfalica

Deutschland

(Technische Hotline): 01 80 - 5 26 22 64

Fax (Technische Hotline): 01 80 - 5 26 22 75

Invacare® A/S

Sdr. Ringvej 39

2605 Brøndby

Danmark

(Kundeservice): +45 - (0) 3690 0000

Fax (Kundeservice): +45 - (0) 3690 0001

Invacare®, SA

c/ Areny, s/n

Poligon Industrial de Celrà

17460 Celrà (Girona)

ESPAÑA

: +34 - (0) 972 - 49 32 00

Fax: +34 - (0) 972 - 49 32 20

Invacare® POIRIER

Les Roches

F-37230 Fondettes

France

(Service Après-Vente):+33 - (0) 2 47 - 62 64 66

Fax (Service Après-Vente):+33 - (0) 2 47 - 42 12 24

Tornado Service Manual

Page 2 As at:19.03.2004

Invacare® Ltd

South Road

Bridgend

Mid Glamorgan - CF31-3PY

United Kingdom

(Customer Service): +44 - (0) 1656 - 647 327

Fax (Customer Service): +44 - (0) 1656 - 649 016

Invacare Mecc San s.r.l.

Via Dei Pini, 62

I - 36016 Thiene (VI)

ITALIA

: +39 - (0) 445-380059

Fax: +39 - (0) 445-380034

Invacare® AS

Grensesvingen 9

0603 Oslo

Norge

(Kundeservice): +47 - 22 57 95 10

Fax (Kundeservice): +47 - 22 57 95 01

Invacare® B.V.

Celsiusstraat 46

NL-6716 BZ Ede

The Netherlands

: +31 - (0) 318 - 69 57 57

Fax: +31 - (0) 318 - 69 57 58

Invacare® PORTUGAL Lda

Rua Senhora de Campanhã, 105

4369-001 Porto

PORTUGAL

: +351-225105946

Fax: +351-225105739

Invacare® AB

Fagerstagatan 9

163 91 Spånga

Sverige

(Kundtjänst): +46 - (0) 8 761 70 90

Fax (Kundtjänst): +46 - (0) 8 761 81 08

[email protected]

Service

Invacare

JÄRFÄLLA

: +46 - (0) 8 – 621 08 44

Fax: +46 - (0) 8 – 621 08 45

[email protected]

Invacare® n.v.

Autobaan 14

8210 Loppem (Brugge)

BELGIUM

: +32 (50) 831010

Fax: +32 (50) 831011

MÖLNDAL

: +46 - (0) 31 – 86 36 00

Fax: +46 - (0) 31 – 86 36 06

[email protected]

LANDSKRONA

: +46 - (0) 418 – 285 40

Fax: +46 - (0) 418 – 180 89

[email protected]

OSKARSHAMN

: +46 - (0) 491 – 101 40

Fax: +46 - (0) 491 – 101 80

[email protected]

Service Manual Tornado

As at: 19.03.2004 Page 3

Tornado Service Manual

Page 4 As at:19.03.2004

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.

Service Manual Tornado

As at: 19.03.2004 Page 5

Contents

1 SAFETY AND ASSEMBLY INSTRUCTIONS 7

1.1 Before any inspection or repair work 7

1.2 During dismantling/reassembly 7

1.3 After completion of work / before operating the wheelchair: 8

2 TOOL LIST 9

2.1 Tightening torques and Loctite 10

3 LAYOUT OF COMPONENTS AND MODULES 11

4 SERVICE PLAN (1X ANNUALLY) 13

5 TROUBLESHOOTING THE TORNADO 15

5.1 Troubleshooting the Tornado with ACS 15

5.1.1 Diagnosing driving faults 15

5.1.2 Diagnosing problems with electric actuators 17

5.1.3 REM24 Error Codes and Diagnostic Codes 18

5.2 Troubleshooting the Invacare® Tornado with Shark Remote 20

5.2.1 Diagnosing driving faults 20

5.2.2 Shark Error Codes and Diagnostic Codes 22

6 REPAIR WORK 24

6.1 Replacing the drive motors 24

6.2 Replacing components of the ACS or Shark electronics 27

6.3 Replacing batteries 29

6.4 Replacing the main fuse 34

6.5 Checking the cables 36

6.6 Replacing the remote 38

6.7 Testing an actuator motor 39

6.8 Adjusting and replacing the speed reduction switch 40

6.9 Replacing the steering head bearings on the front or rear castor wheels 41

6.9.1 Front Castor Wheels 41

6.9.2 Rear Castor Wheels 43

Tornado Service Manual

Page 6 As at:19.03.2004

6.10 Replacing the Anti-Dive Spring and/or its plastic guides 45

6.11 Repairing a flat tyre 48

6.12 Replacing a drive wheel 50

Service Manual Tornado

As at: 19.03.2004 Page 7

1 Safety and assembly instructions

These safety instructions are intended to prevent accidents during 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 entitled "General information”).

Caution:

• Please note the heavy 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,

disconnect the batteries or remove them.

• 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:

• Prop up the lifted wheelchair with appropriate supports before starting the disassembly or

assembly.

• 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.

Tornado Service Manual

Page 8 As at:19.03.2004

1.3 After completion of work / before operating the wheelchair:

Caution:

• Check all fixings for tight fit.

• Check all parts for correct interlocking.

• Only operate wheelchair with correct tyre pressure (2.5 bar).

• 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.

Service Manual Tornado

As at: 19.03.2004 Page 9

2 Tool list

You will need a standard tool set with at least the following:

• set of open and ring spanners (6 – 24 mm)

• set of Allen keys (1.5 - 10 mm)

• torque wrench (commercial)

• socket spanner set

• set of screwdrivers (0.5 - 1.6 mm)

• 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 (commercially available, make Tigtemeyer)

• pop riveting tool

• stepped mandrel

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