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Invacare TDX SP2 series User manual

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Invacare®TDX®SP2Series
enPowerWheelchair
ServiceManual
DEALER:Keepthismanual.
TheproceduresinthismanualMUSTbeperformedbyaqualied
technician.
©2017InvacareCorporation
Allrightsreserved.Republication,duplicationormodicationinwholeorinpartisprohibitedwithoutpriorwritten
permissionfromInvacare.Trademarksareidentiedby™and®.AlltrademarksareownedbyorlicensedtoInvacare
Corporationoritssubsidiariesunlessotherwisenoted.
Invacarereservestherighttoalterproductspecicationswithoutfurthernotice.
Contents
1General.........................................4
1.1Aboutthismanual..............................4
1.2Generalinformation............................4
1.3Notesonshipping..............................4
1.4Symbolsinthismanual..........................4
1.5Imagesinthismanual...........................4
2Safety..........................................5
2.1Safetyandttinginstructions.....................5
3Hygiene.........................................7
3.1Handlingofreturnedusedproducts.................7
4Setup...........................................8
4.1Adjustingseatingposition........................8
4.1.1Adjustinglowerleglength.....................8
4.1.2Adjustingseatdepth.........................8
4.1.3Adjustingcenterofgravityofseat...............8
4.1.4Moduliteseat..............................9
5Testing..........................................11
5.1Testingmotor.................................11
5.2Testingmotorbrake............................11
5.3Raintest.....................................11
5.4Fieldloadtest.................................11
5.5CheckingBatteryChargeLevel.....................12
6Service..........................................13
6.1Tighteningtorques.............................13
6.2Overviewmobilitydevice.........................13
6.3Chassis......................................14
6.3.1Stabilitylock...............................14
6.3.2WalkingBeams.............................17
6.3.3Steeringheadfront..........................18
6.3.4Removingrearsprings.......................18
6.3.5Installingrearsprings.........................18
6.3.6Replacingbatterytray........................19
6.3.7Replacingbatterybox.........................19
6.3.8Replacingrubberstopper......................20
6.4Drivecomponents..............................20
6.4.1Overviewmotor.............................20
6.4.2Replacingmotor/gearboxunit...................21
6.4.3Replacingorrotatingmotor/gearboxunitsealing
ring.....................................21
6.4.4Replacingmotor/gearboxclutch.................22
6.4.5Replacingcarbonbrushes......................22
6.4.6Replacingdrivewheelhub.....................23
6.4.7Replacingmotor/gearboxunit...................23
6.5Wheels......................................24
6.5.1Replacingriminsertsindrivewheels.............24
6.5.2Replacingcasterfork.........................24
6.5.3Adjustingcasterfork.........................25
6.5.4Replacingcastersondouble-sidedcasterforks......25
6.5.5Replacingcastersonsingle-sidedcasterforks.......26
6.5.6Replacingdrivewheel........................26
6.5.7Replacingtireorinnertube....................26
6.5.8Removingrearsuspension.....................28
6.5.9Removingrearsuspension–alternativemethod.....28
6.5.10Rettingrearsuspension.....................29
6.5.11Rettingrearsuspension–alternativemethod.....29
6.6Shrouds.....................................30
6.6.1Removingfrontshroud........................30
6.6.2Removingrearshroud........................30
6.6.3Removingtopshroud.........................30
6.6.4Replacingmudguard.........................31
6.7Controls.....................................31
6.7.1Replacingpowermodule......................31
6.7.2ReplacingG-Tracsensor.......................31
6.7.3Replacingoperatinghourcounter/connecting
cable....................................31
6.7.4Updatingdrivingprogram......................32
6.7.5Makingbatteriesaccessible....................32
6.7.6Replacingbatteries...........................33
6.7.7Removingthebatteries.......................34
6.7.8Replacingbatteries(Poweredsimpletilt20°).......34
6.7.9Replacingbatteries/replacingbatterycables........35
6.7.10Removingthebatteries......................36
6.7.11Generalinstructionsonhandlingthebatteries.....36
6.7.12Howtohandledamagedbatteriescorrectly.......37
6.7.13Checkingandreplacingmainfuse...............37
6.7.14ReplacingUSBcharger.......................38
6.7.15Checkingcable.............................38
6.7.16Cablerouting..............................38
6.8Lightingunit..................................38
6.8.1Replacingfrontbulb(conventionallighting
system)..................................38
6.8.2Replacingheadlightcomplete(conventionallighting
system)..................................39
6.8.3Replacingheadlightcomplete(LEDlighting
system)..................................39
6.8.4Replacingfrontlampholder(conventionallighting
system)..................................39
6.8.5Replacingfrontlampholder-(conventionallighting
system)..................................40
6.8.6Replacingfrontlampholder-(LEDlighting
system)..................................40
6.8.7Replacingrearbulb(conventionallighting
system)..................................40
6.8.8Replacingrearlightcomplete-(conventional
lightingsystem)............................40
6.8.9Replacingcompleterearlight-(LEDlighting
system)..................................41
6.8.10Replacingrearlampholder-(conventionallighting
system)..................................41
6.9Seating......................................41
7Troubleshooting...................................42
7.1Operationalfaults..............................42
7.2Drivefaultdiagnosis............................42
7.3Chargerfaultdiagnosis..........................45
7.4Serviceplan(1xannually)........................46
8Accessories......................................49
8.1Accessorieslist................................49
Invacare®TDX®SP2Series
1General
1.1Aboutthismanual
•ThismanualreferstocongurationswithModuliteseat
system.Olderspecicationshavebeendescribedin
revision11ofthisservicemanual.
•Forseatsystems,refertothecorrespondingmanual.
•ForShark,DX,DX2,refertorevision11ofthisservice
manual.
•ForLiNXcontrols,refertoLiNXServiceManual.
1.2Generalinformation
•Serviceandmaintenanceworkmustbecarriedout
takingthisservicemanualintoaccount.
•Itisimperativethatyouobservesafetyinformation.
•Informationaboutoperationoraboutgeneral
maintenanceandcareworkonthemobilitydevice
shouldbetakenfromServicemanual.
•Youcanndinformationaboutorderingsparepartsin
thesparepartscatalogue.
•SparepartsMUSTmatchoriginalInvacareparts.Only
usesparepartswhichhavebeenapprovedbyInvacare.
•Wereservetherighttomakeanyalterationsonthe
groundsoftechnicalimprovements.
•Formoreinformationabouttheproduct,forexample
productsafetynoticesandproductrecalls,contactyour
localInvacarerepresentative.Foraddressandwebsite
seebackpageofthismanual.
•Themobilitydevicemayonlybemaintainedand
overhauledbyqualiedpersonnel.
•Theminimumrequirementforservicetechniciansis
suitabletraining,suchasinthecycleororthopedic
mechanicselds,orsufcientlylong-termjob
experience.
–Experienceintheuseofelectricalmeasuring
equipment(multimeters)isalsoarequirement.
–SpecialInvacaretrainingisrecommended.
•Alterationstothemobilitydevicewhichoccurasaresult
ofincorrectlyorimproperlyexecutedmaintenanceor
overhaulworkleadtotheexclusionofallliabilityon
thesideofINVACARE.
•IfyouhaveanyproblemsorquestionscontactInvacare
Service.
1.3Notesonshipping
•Ifthemobilitydevicehastobeshippedbacktothe
manufacturerformajorrepairs,youshouldalwaysuse
theoriginalpackagingfortransport.
•Pleaseattachaprecisedescriptionofthefault.
1.4Symbolsinthismanual
Inthismanual,hazardstatementsareindicatedbysymbols.
Thesymbolsareaccompaniedbyasignalwordthatindicates
theseverityoftherisk.
WARNING
Indicatesahazardoussituationthatcouldresult
inseriousinjuryordeathifitisnotavoided.
CAUTION
Indicatesahazardoussituationthatcouldresult
inminororslightinjuryifitisnotavoided.
IMPORTANT
Indicatesahazardoussituationthatcouldresult
indamagetopropertyifitisnotavoided.
Givesusefultips,recommendationsand
informationforefcient,trouble-freeuse.
ThisproductcomplieswithDirective93/42/EEC
concerningmedicaldevices.Thelaunchdate
ofthisproductisstatedintheCEdeclaration
ofconformity.
Thissymbolidentiesalistofvarioustools,
componentsanditemswhichyouwillneedin
ordertocarryoutcertainwork.
1.5Imagesinthismanual
Thedetailedimagesinthismanualaregivenmarksto
identifyvariouscomponents.Componentmarksintextand
operationalinstructionsalwaysrelatetotheimagedirectly
above.
4
1532486-L
Safety
2Safety
2.1Safetyandttinginstructions
Thesesafetyinstructionsareintendedtopreventaccidents
atwork,anditisimperativethattheyareobserved.
Beforeanyinspectionorrepairwork
•Readandobservethisrepairmanualandtheassociated
usermanual.
•Observetheminimumrequirementsforcarryingoutthe
work(see1.2Generalinformation,page4).
Personalsafetyequipment
Safetyshoes
Themobilitydevice,andsomeofitscomponents,arevery
heavy.Thesepartscanresultininjuriestothefeetifthey
areallowedtodrop.
•Wearstandardizedsafetyshoesduringallwork.
Eyeprotection
Itispossiblethatbatteryacidcanbedischargedwhen
workingondefectivebatteriesorwhenhandlingbatteries
improperly.
•Alwaysweareyeprotectionwhenworkingonany
defectiveorpossiblydefectivebatteries.
Safetygloves
Itispossiblethatbatteryacidcanbedischargedwhen
workingondefectivebatteriesorwhenhandlingbatteries
improperly.
•Alwayswearacid-proofsafetygloveswhenworkingon
anydefectiveorpossiblydefectivebatteries.
Generalsafetyinformationandinformationabouttting
/removal
DANGER!
RiskofDeath,SeriousInjury,orDamage
Lightedcigarettesdroppedontoanupholstered
seatingsystemcancauseareresultingin
death,seriousinjury,ordamage.Mobilitydevice
occupantsareatparticularriskofdeathor
seriousinjuryfromtheseresandresultingfumes
becausetheymaynothavetheabilitytomove
awayfromthemobilitydevice.
–DONOTsmokewhileusingthismobilitydevice.
WARNING!
RiskofSeriousInjuryorDamage
Storingorusingthemobilitydevicenearopen
ameorcombustibleproductscanresultin
seriousinjuryordamage.
–Avoidstoringorusingthemobilitydevicenear
openameorcombustibleproducts.
CAUTION!
Riskofcrushing
Variouscomponentssuchasthedriveunit,
batteries,seatetcareveryheavy.Thisresultsin
injuryhazardstoyourhands.
–Notethehighweightofsomecomponents.
Thisappliesespeciallytotheremovalofdrive
units,batteriesandtheseat.
CAUTION!
Injuryhazardifthevehiclestartsmoving
unintentionallyduringrepairwork
–Switchthepowersupplyoff(ON/OFFkey).
–Engagethedrive.
–Beforeliftingup,securethevehiclebyusing
chockstoblockthewheels.
CAUTION!
Fireandburnhazardduetoelectricalshort-circuit
–Themobilitydevicemustbecompletely
switchedoffbeforeremovalofvoltage-carrying
components!Todothis,removethebatteries.
–Avoidshort-circuitingthecontactswhen
carryingoutmeasurementsonvoltage-carrying
components.
CAUTION!
Riskofburnsfromhotsurfacesonthemotor
–Allowthemotorstocooldownbefore
commencingworkonthem.
CAUTION!
Injuryhazardandriskofdamagetovehicledue
toimproperorincompletemaintenancework
–Useonlyundamagedtoolsingoodcondition.
–Somemovingpartsaremountedinsockets
withPTFEcoating(Teon™).Nevergrease
thesesockets!
–Neveruse"normal"nutsinsteadofself-locking
nuts.
–Alwaysusecorrectly-dimensionedwashersand
spacers.
–Whenreassembling,alwaysreplaceanycable
tieswhichwerecutduringdismantling.
–Aftercompletingyourwork/beforerenewed
start-upofthemobilitydevice,checkall
connectionsfortighttting.
–Aftercompletingyourwork/beforerenewed
start-upofthemobilitydevice,checkallparts
forcorrectlocking.
–Onlyoperatethevehiclewiththeapprovedtire
pressures(seetechnicaldata).
–Checkallelectricalcomponentsforcorrect
function.Notethatincorrectpolaritycanresult
indamagetotheelectronics.
–Alwayscarryoutatrialrunattheendofyour
work.
CAUTION!
Riskofinjuryanddamagetoproperty,ifthe
maximumspeedreductiononawheelchairwith
alifterdoesnotfunctioncorrectly
Thewheelchair’scontrolunitmustreducethe
maximumpossiblespeedassoonasthelifteris
raised.
–Testthemaximumspeedreductionforcorrect
functionafteranymaintenanceworkor
modicationstothewheelchair.
1532486-L5
Invacare®TDX®SP2Series
CAUTION!
Anychangestothedriveprogramcanaffectthe
drivingcharacteristicsandthetippingstability
ofthevehicle
–Changestothedriveprogrammayonlybe
carriedoutbytrainedInvacarespecialist
dealers.
–Invacaresuppliesallmobilitydeviceswitha
standarddriveprogramex-works.Invacarecan
onlygiveawarrantyforsafevehicledriving
behavior-especiallytippingstability-forthis
standarddriveprogram.
Markallcurrentsettingsforthemobilitydevice
(seat,armrests,backrestetc.),andtheassociated
cableconnectingplugs,beforedismantling.This
makesreassemblyeasier.Allplugsarettedwith
mechanicalsafetydeviceswhichpreventreleaseof
theconnectingplugsduringoperation.Toreleasethe
connectingplugsthesafetydevicesmustbepressed
in.Whenreassemblingensurethatthesesafety
devicesarecorrectlyengaged.
61532486-L
Hygiene
3Hygiene
3.1Handlingofreturnedusedproducts
Whenreconditioningorrepairingreturnedmobilitydevices:
•Takeprecautionsforyourselfandtheproduct.
•Useprotectionequipmentasspeciedlocally.
Beforetransport(accordingtoBiologicalAgentsOrdinance)
Treatproductaccordingtofollowingprocesssteps:
Processstep
Component
ApplicationConditioningtechniqueWorkstation
ManualcleaningSurfaceofuseddeviceBeforerepairor
reconditioning
Usesaturatedtowel
toapplycleaning
detergentandremove
residuesafterimpact.
Cleaningand
disinfection
DisinfectionSurfaceofuseddeviceBeforerepairor
reconditioning
Usesaturated
disinfectantwipes
andclean*thedevice
surface.
Cleaningand
disinfection
*Invacareusesdetergent"Nücoseptspecial"1.5%inwaterml/ml
Disinfectiontools
•Onewaywipes(eece)
•Brushestocleandifculttoaccessareas
Furtherinformation
FormoreinformationcontactyourInvacareServicedepartment.
1532486-L
7
Invacare®TDX®SP2Series
4Setup
4.1Adjustingseatingposition
Adjustingtheseatingpositioninordertoadaptthemobility
deviceoptimallytotherequirementsoftheuser,we
recommendthatyouaskyourauthorisedInvacare®dealer
toadjustseatdepthindividually.Adaptingtheseattothe
user'sseatingpositiondependsontheseatthathasbeen
tted,andshouldbecarriedoutinthefollowingsequence.
1.Adjustingthelowerleglengthandseatdepth.See
chapter4.1.1Adjustinglowerleglength,page8.
2.Adjustingthecenterofgravityoftheseatframe.See
chapter4.1.3Adjustingcenterofgravityofseat,page8.
3.Checkingthattheswivelcastorscanmovefreely.
4.Repetitionofsteps2to4,ifnecessary.
WARNING!
Riskofinjuryaftertiltingofmobilitycaused
byblockedsteeringwheels
–Alwayschecktheseatdepthsettingsfor
bothforwardandreversemovement.Make
surethatsteeringwheelscanrotatefreely
andhavenotcontacttoanyxedmobility
devicecomponent.
CAUTION!
Riskoftippingover
Anychangeintheseatingpositioncan
negativelyinuencethestabilityofthe
mobilitydevice.
–Alwaysmakesurethatthemobilitydevice
isstableandwillnottipover,after
adjustingseatingposition.
WARNING!
Anychangestothedriveprogramcanaffect
thedrivingcharacteristicsandthetipping
stabilityofthemobilitydevice
–Changestothedriveprogrammayonlybe
carriedoutbytrainedInvacare®providers.
–Invacare®suppliesallmobilitydevices
withastandarddriveprogramex-works.
Invacare®canonlygiveawarrantyforsafe
vehicledrivingbehavior-especiallythe
tippingstability-forthisstandarddrive
program.
WARNING!
Riskofcrushing
Theseatisveryheavy.Riskofinjurytohands
andfeet.
–Payattentiontothehandandfeet.
–Useproperliftingtechniques.
4.1.1Adjustinglowerleglength
Invacareoffersarangeoflegrestswhichcanbeadjusted
individually.Seeusermanual.
4.1.2Adjustingseatdepth
A:Seatdepth
B:Centerofgravityoftheseat/seatposition
SeatdepthAcanbeadjustedbymovingbackrestinrelation
toseatsurface.
Moduliteseat
Theseatdepthisadjustedbyshiftingthepositionofthe
backrest.SeeUserManual.
Seatsystems
Fordetailson
•Standardseat
•Flexseat
•Contourseat
•Maxseat
refertorevision11ofthisservicemanual.
FordetailsonModuliteseatseebelow.
4.1.3Adjustingcenterofgravityofseat
Thecenterofgravityofseat(CoG)canbeadjustedby
mountingseatframefarthertowardsfrontortherearof
seat.
CAUTION!
Theseatingsystemofthemobilitydeviceis
deliveredexworkswithastandardadjustment
ofcenterofgravity(CoG),whichmeets80–90%
ofuserrequirements.CoGcanbeadjusted
individually.However,anychangeinthis
adjustmentsettingcannegativelyinuencethe
stabilityofthepowerwheelchair.
–Youmustperformanindividualriskanalysis
everytimeyouchangethecenterofgravity
oftheseatingposition,inordertoensurethe
safetyandstabilityofthepowerwheelchair.
A:Seatdepth
B:Centerofgravityoftheseat/seatposition
81532486-L
Setup
Theuserweightandseatdepthhavestrong
inuencesonthechoiceofthecenterofgravity
(CoG).Iftheuserisheavyandtheseatdepthis
greater,thefocusshouldbethefartherback.For
bestpossibledrivingcharacteristicsofrear-wheel
drivewheelchairs,theweightshouldbedistributed:
30–40%frontand60-70%rear .Forcenterwheel
drivestheweightshouldbedistributed25%front,
50%centerand25%rear.
CAUTION!
Riskofdamageduetocollisionsofthelegrests
withotherpartsofthemobilitydevice
–Setthelegreststothesmallestanglebefore
adjustingtheseatcenterofgravity.
–Payattentionwithadjustingseatcenterof
gravitythatlegrestsdonottouchanyother
partsofwheelchair.Thisensuresthatthe
legrestscannotcollidewithotherpartsof
wheelchair.
Seatsystems
Fordetailson
•Standardseat
•Flexseat
•Contourseat
•Maxseat
refertorevision11ofthisservicemanual.
FordetailsonModuliteseatseebelow.
4.1.4Moduliteseat
TheModuliteseatisavailableintwoversions:
•Telescopicseatframe(plateandstrap):Adjustmentof
centerofgravityviathelateralproles,asdescribed
belowin“Telescopicseatframe”.
•Onepieceseatplate:Adjustmentofcenterofgravity
viatheoblongholesoftheseatadapterasdescribed
belowinchapter“Onepieceseatplate”.
Telescopicseatframe
•6mmAllenkey
1.Removeseatplateorslingseat(1),seechapter
“Adjustingseatwidth”inModuliteservicemanual.
2.LoosenAllenscrews(2)infrontandrear,leftandright
–DONOTremove.
3.Shiftpositionofseat.
4.Tightenscrews.
5.Installseatplateorslingseat.
Onepieceseatplate(TDXSP2/TDXSP2NB)
•6mmAllenkey
1.Removeseatplate(1)orslingseat.Seechapter
“Adjustingseatwidth”inModuliteservicemanual.
2.LoosenAllenscrews(2)and(3)infrontandrear,left
andright–DONOTremove.
3.Shiftpositionofseatframe.
4.Tightenscrews.
5.Installseatplate.
Imperialtometricconversionchart
Youcanusethischartasanorientationtondtheright
toolsize.
IMPERIALMETRIC
inch
mm
5/64
1.9844
3/32
2.3813
7/64
2.7781
1/8
3.1750
9/64
3.5719
5/32
3.9688
11/64
4.3656
3/16
4.7625
13/64
5.1594
7/32
5.5563
15/64
5.9531
1/4
6.3500
17/64
6.7469
9/32
7.1438
1532486-L9
Invacare®TDX®SP2Series
IMPERIALMETRIC
inch
mm
19/64
7.5406
5/16
7.9375
21/64
8.3344
11/32
8.7313
23/64
9.1281
3/8
9.5250
25/64
9.9219
13/32
10.3188
27/64
10.7156
7/16
11.1125
29/64
11.5094
15/32
11.9063
31/64
12.3031
1/2
12.7000
33/64
13.0969
17/32
13.4938
35/64
13.8906
9/16
14.2875
37/64
14.6844
IMPERIALMETRIC
inch
mm
19/32
15.0813
39/64
15.4781
5/8
15.8750
41/64
16.2719
21/32
16.6688
43/64
17.0656
11/16
17.4625
45/64
17.8594
23/32
18.2563
47/64
18.6531
3/4
19.0500
49/64
19.4469
25/32
19.8438
51/64
20.2406
13/16
20.6375
53/64
21.0344
27/32
21.4313
55/64
21.8281
7/8
22.2250
101532486-L
Testing
5Testing
5.1Testingmotor
•Phillipsscrewdriversize2
•Digitalmultimeterwithresistancemeasurement
1.Removerearshroudasdescribedin6.6.2Removingrear
shroud,page30.
2.
Disconnectmotorplug(3)frompowermodule.
3.Connectdigitalmultimetertomotorplugcontacts(3)
andmeasureresistancebetweencontacts.
Aresistanceofbetween0.5and5ohmsindicates
amotorreadyforoperation.Aresistance
ofbetween15ohmsandinnityindicatesa
defectivemotor.Highresistancesarenormally
causedbybadconnectionsorworncarbon
brushes.
5.2Testingmotorbrake
Thistestshouldonlybecarriedoutonmobility
devicewithconventionalmotor/gearboxunits.
•Size2Phillipsscrewdriver
•Digitalmultimeterwithresistancemeasurement
1.Removerearshroudasdescribedin6.6.2Removingrear
shroud,page30.
2.
Pullmotorplug(3)outofpowermodule.
3.Connectdigitalmultimetertocentralmotorplug
contacts(3)andmeasureresistancebetweencontacts.
4.Ifthereisadefect,replacemotorandsendittoInvacare
Serviceforinspectionorrepair .
Aresistanceofbetween40and80ohms
indicatesanintactbrake.Aresistanceof0ohms
oraveryhighresistance(mega-ohmsorinnity)
indicatesashort-circuit,abadconnectionora
defectivebrake.
CAUTION!
Riskofdamagetopowermoduleduetoshorts
inmotorbrake
–NEVERconnectamotorbrakewithashortto
anintactpowermodule.
–Alwaysreplaceshortedbrakesimmediately.
Adefectivemotorcandamagethepowermodule,
butnottheotherwayaround.
5.3Raintest
•Checktoensurethattheblackbatteryterminalcaps
aresecuredinplace,joystickbootisnottornor
crackedwherewatercanenterandthatallelectrical
connectionsaresecureatalltimes.
•Donotusethemobilitydeviceifthejoystickbootis
tornorcracked.Ifthejoystickbootbecomestornor
cracked,replaceimmediately.
5.4Fieldloadtest
Oldbatteriesloosetheirabilitytostoreandreleasepower
duetoincreasedinternalresistance.Inthisprocedure,
batteriesaretestedunderloadusingadigitalvoltmeterto
checkbatterychargelevelatthechargerconnector.The
chargerconnectorislocatedontheremote.Whenvoltage
attheoutputdrops1.0voltsunderload(2.0forapair),
replacethebatteries.
Readtheseinstructionscarefullyandthe
manufacturer’sinstructionsonthedigitalvoltmeter
beforeproceeding.
1.SwitchtheelectronicsOFFontheremote.
2.Makesurebatteryisfullycharged.Anextremely
dischargedbatterywillexhibitthesamesymptomsasa
badbattery.
3.Removethefootboard/legrestsfromthemobilitydevice.
4.
Connectthevoltmeterleadstothechargerconnector
Aonthemobilitydevice.MostdigitalvoltmetersB
arenotaffectedbypolarity.However,analogmeters
(meterswithswingingneedles)canbeandshouldbe
usedcarefully.
Agoodmeterreadingshouldbe25.5to26VDC
withthechairinneutral.
WARNING!
–Whenperformingtheremainingsteps,ensure
yourfeetareclearfromcastersandwall,
otherwiseinjurymayresult.
5.Runthemobilitydeviceinneutralforatleast2minutes.
6.Sitinmobilitydeviceandplaceyourfeetagainstadoor
jam,workbenchorotherstationaryobject.
1532486-L
11
Invacare®TDX®SP2Series
7.Carefullypushtheremoteforward,tryingtodrivethe
mobilitydevicethroughthestationaryobject.Theload
shoulddrawbetween30to40ampsfromthebatteries
for0.3seconds.
Performingthisstepputsaheavyloadon
thebatteriesastheytrytopushthroughthe
stationaryobject.Ifthewheelsspin,havetwo
individuals(oneoneacharm)applyasmuch
downwardpressureaspossibleonthearmsof
themobilitydevice.
8.Readthemeterwhilethemotorsarestrainingto
determinethevoltageunderload.
Ifthevoltagedropsmorethan2voltsfroma
pairoffullychargedbatteriesduringthe0.3
seconds,theyshouldbereplacedregardlessof
theunloadedvoltages.
5.5CheckingBatteryChargeLevel
Thefollowing“Dos”and“Don’ts”areprovidedforyour
convenienceandsafety.
DON’TDO
Don’tperformany
installationormaintenance
withoutrstreadingthis
manual.
Readandunderstand
thismanualandany
serviceinformationthat
accompaniesabatteryand
chargerbeforeoperating
thepersonaltransporter .
Don’tperforminstallation
ormaintenanceofbatteries
inanareathatcouldbe
damagedbybatteryspills.
Movethepersonal
transportertoaworkarea
beforecleaningterminals,
oropeningbatterybox.
Don’tmakeitahabitto
dischargebatteriestothe
lowestlevel.
Rechargeasfrequentlyas
possibletomaintainahigh
chargelevelandextend
batterylife.
Don’tusechargersor
batteriesthatarenot
appropriateforthechair.
Followrecommendationsin
thismanualwhenselecting
abatteryorcharger .
Don’tputnewbatteriesinto
servicebeforecharging.
Fullychargeanewbattery
beforeusing.
Don’ttiportiltbatteries.
Useacarryingstrapto
remove,moveorinstalla
battery.
Don’ttaponclampsand
terminalswithtools.
Pushbatteryclampsonthe
terminals.Spreadclamps
widerifnecessary.
12
1532486-L
Service
6Service
6.1Tighteningtorques
CAUTION!
Damagecanbecausedtothemobilitydevice
duetoimproperlytightenedscrews,nutsor
plasticconnections.
–Alwaystightenscrews,nutsetctothestated
tighteningtorque.
–Onlytightenscrewsornutswhicharenotlisted
herengertight.
Thetighteningtorquesstatedinthefollowinglistarebased
onthethreaddiameterforthenutsandboltsforwhichno
specicvalueshavebeendetermined.Allvaluesassume
dryandde-greasedthreads.
ThreadTighteningtorquein
Nm±10%
M43Nm
M5
6Nm
M610Nm
M825Nm
M1049Nm
M1280Nm
M14120Nm
M16180Nm
UNCThreadTighteningtorquein
Nm±10%
1/4”-20
11–7Nm
5/16”-20
22–14Nm
3/8”-16
41–25Nm
7/16”-14
67–40Nm
1/2”-13
100–60Nm
9/16”-12
150–90Nm
5/8”-11
210–130Nm
3/4”-1
370–230Nm
7/6”-9
600–370Nm
1”-8
900–550Nm
6.2Overviewmobilitydevice
ThisoverviewappliesforTDXSP2mobilitydeviceswith
ModuliteSeat.
Underneathseat
BatteriesbehindfrontshroudA
Fig.6-1
PowermodulebehindrearshroudA
Fig.6-2
Actuatormodules
Tiltactuator(optional)A
Actuatormodule(optional)B
Lifteractuator(optional)C
Fig.6-3
Lifter
ACTwithLifter
1532486-L13
Invacare®TDX®SP2Series
locatedundertheseat.
Centermountpoweredlegrestsandtiltmodule
G-Trac®Sensor
TheoptionalG-Trac-sensorislocatedbehindtherearshroud.
6.3Chassis
6.3.1Stabilitylock
Replacinggascylinder
CAUTION!
Riskofcrushing
Mobilitydeviceisveryheavy.Injuryhazardto
handsandfeet.
–Useproperliftingtechniques.
Riskofinjurybyuncontrolledmovementof
mobilitydevice
–Switchpowersupplyoff(ON/OFFkey).
–Engagedrive.
–Beforeraisingmobilitydevice,securewheelsby
blockingthemwithwedges.
•3/16”Allenkey
•5/16“wrenchwithextension
•3/4”wrench
•5/32“Allenkey
•7/16”socketwrench
•Phillipsscrewdriversize2
•Torquewrench5-25Nm(orsimilar)
•Twolongwoodenblocks,min.14x14x30cm
•Threadlockingadhesive,forexampleLoctite242
Removinggascylinder
1.Liftmobilitydeviceupononesideandplacea14cm
highwoodenblockunderbatterycasesothatwheels
areoffthegroundandcanrotatefreely.Useproper
liftingtechniques.
2.Repeatsameprocedureonothersideofmobilitydevice.
3.
Fig.6-4
LoosenandremovehandscrewAunderrearlightB
nearwheelD.
4.
Fig.6-5
Ifmobilitydeviceisttedwithcableties,remove.
Wheninstalling,makesuretoreplacecableties.
LoosenandremovescrewA.
5.
LoosenandremovescrewAovermudguardBunder
seatframeC.
6.Removebatteriesasdescribedin6.7.6Replacing
batteries,page33and6.7.9Replacingbatteries/replacing
batterycables,page35.
7.Removedrivewheelasdescribedin6.5.6Replacing
drivewheel,page26.
14
1532486-L
Service
8.
Fig.6-6
LoosenscrewsBnearhubAandcastorDthatx
lowerbeamCtochassis.
Wheninstalling,usethreadlockingadhesive,for
example,Loctite242.
9.
RotatetopwalkingbeamEsothatyoucanreachthe
screwDonthegascylinderthroughthedrillholeC
inbatterybox.
10.
Fig.6-7
RemovenutConupperbeamB,DonmudguardA.
Holdscrewinplace.
11.
RemovenutF.Holdscrewinplace.
12.PushscrewDtowardsbatteryboxsothatgascylinder
Aisseparatedfromwalkingbeam.
13.Pushgascylinderagainstbatterybox.
14.Raiserearaxlesothatgascylinderisactivatedandthen
retractcylinder.
15.Pushgascylindertotherearandpullitoffbatterybox.
Installinggascylinder
1.Installpartsinreverseorder.
Replacingsettingscrew
•1/4“wrench
•Twolongwoodenblocks,min.14x14x30cm
•Feelergaugewith2mm
1532486-L15
Invacare®TDX®SP2Series
Invacarerecommendsalwaysreplacingbothsetting
screwssimultaneouslytoensurethatthemobility
deviceworksperfectly.
Removingsettingscrew
1.Liftthemobilitydeviceupononesideandplacea14
cmhighwoodenblockunderthebatterycasesothat
thewheelsareoffthegroundandcanrotatefreely.Use
properliftingtechniques.
2.Repeatsameprocedureonothersideofmobilitydevice.
3.Removebothanti-tipsystemprotectivecaps.The
protectivecapsonanti-tipsystemwilleitherbeheld
usingascreworacabletiedependingonthemobility
device'sdateofmanufacture.
4.
LoosentwoscrewsBandremovetogetherwithwashers
C.
5.LoosenandremovelocknutBofsettingscrewD.
6.RotatesettingscrewDtowardsbatterycaseuntilyou
canremoveitfromitsholderC.
Installingsettingscrew
•1/4”wrench
•Feelergaugewith2mm
1.ScrewnewsettingscrewDintoholderC.
2.
InserttwoscrewsBtogetherwithwashersC.
3.Tightenscrews.
4.Removewoodenblockfromundermobilitydevice,so
thatallcastersareincontactwithoor.
5.
RotatesettingscrewCuntilthereisaspaceof2mm
(1)betweenitandthegascylinderD.
6.InstalllocknutBandtighten.
7.Installtwoprotectivecaps.
Adjustingsettingscrew
•1/4“wrench
•Feelergaugewith2.0mm
1.Removebothprotectivecapsofstabilitylocksystem.
Theyareheldusingascreworacabletiedependingon
themobilitydevice’sdateofmanufacture.
2.Ensurethatmobilitydeviceiscontactingoorwithall
itswheelsandcasters.
3.LoosenandremovelocknutB.
4.RotatesettingscrewCuntilthereisaspaceof2.0mm
(1)betweenitandgascylinderD.
5.InstalllocknutBandtighten.
6.Repeatforothersettingscrew.
7.Installtwoprotectivecaps.
161532486-L
Service
6.3.2WalkingBeams
Removingtopwalkingbeam
•5/8“Allenkey
•7/8“Allenkey
•5/16“Allenkey
•Size2Phillipsscrewdriver
•1/2“wrench
•1/4“wrench
•Torquewrench5-25Nm(orsimilar)
•Twolongwoodenblocks,min.14x14x30cm
1.Removebatteriesasdescribedin6.7.5Makingbatteries
accessible,page32and6.7.6Replacingbatteries,page
33/6.7.9Replacingbatteries/replacingbatterycables,
page35
2.Ensureyounotethecableroutingcarefully.Ifnecessary,
takephotoswithadigitalcamera.
3.Removedrivewheelasdescribedin6.5.6Replacing
drivewheel,page26.
4.Removefrontsteeringheadasdescribedin6.3.3
Steeringheadfront,page18.
5.Removerubberstopperasdescribedin6.3.8Replacing
rubberstopper,page20.
6.Pullmotorplugoffpowermodule.
7.Notecarefullyhowmotorcableisrouted.
8.Ifnecessary,removeanyexistingcabletieswhichare
xingmotorcable.
9.
RotatetopwalkingbeamKuntilAllenscrewEisin
linewithopeningCinbatterycaseD.
10.RemovenutJ,whichsecuresscrewE.
11.PushscrewEtowardsbatterycaseuntilgascylinderis
freeoftopwalkingbeam.
12.Fixgascylinderinplacewithacabletieorsuitable
adhesivetape.
13.RemovenutHandwasherI.
14.Removetopwalkingbeamincludingmotor/gearboxunit
fromaxle.
15.RemovewasherAfromaxle.
Installingtopwalkingbeam
•5/8“Allenkey
•7/8“Allenkey
•5/16“Allenkey
•Phillipsscrewdriversize2
•1/2“wrench
•1/4“wrench
•Torquewrench5-25Nm(orsimilar)
•Twolongwoodenblocks,min.14x14x30cm
1.PlacewasherAonbatterycaseDrearaxle.
2.PushtopwalkingbeamKincludingmotor/gearboxunit
ontoaxle.
3.InstallwasherIandnutH.
4.TightennutHto18Nm.
5.RotatenutHbackby1/4turn.
6.RaiserearwheelsuspensiontofreegascylinderB.
7.PositiongascylindersothatscrewEisinlinewith
openingCinbatterycaseD.
8.RotatetopwalkingbeamKuntildrillholeforscrewEis
inlinewithopeningCinbatterycaseD.
9.PushscrewEthroughgascylinderandtopwalking
beam.
10.InstallnutJonscrewEandtightento8.5Nm.
11.Installrubberstopperasdescribedin6.3.8Replacing
rubberstopper,page20.
12.Installfrontsteeringheadasdescribedin6.3.3Steering
headfront,page18.
13.Installbatteriesasdescribedin6.7.5Makingbatteries
accessible,page32and6.7.6Replacingbatteries,page
33/6.7.9Replacingbatteries/replacingbatterycables,
page35.
14.Installrearshroudasdescribedin6.6.2Removingrear
shroud,page30.
15.Installfrontshroudasdescribedin6.6.1Removingfront
shroud,page30.
16.Installdrivewheelasdescribed6.5.6Replacingdrive
wheel,page26.
Bottomwalkingbeam
•5/8“Allenkey
•5/16“Allenkey
•Phillipsscrewdriversize2
•1/2“wrench
•Torquewrench5-25Nm(orsimilar)
•Twolongwoodenblocks,min.14x14x30cm
Removingbottomwalkingbeam
1.Removedrivewheelasdescribedin6.5.6Replacing
drivewheel,page26
2.Removefrontsteeringheadasdescribedin6.3.3
Steeringheadfront,page18.
3.RemovenutD.
4.RemovewasherA.
1532486-L
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Invacare®TDX®SP2Series
5.RemovebottomwalkingbeamCfromaxle.
6.RemovespacerBfromaxle.
Installingbottomwalkingbeam
1.Installpartsinreverseorder.
2.TightennutsDto18Nm.
6.3.3Steeringheadfront
•5/16“Allenkey
•Torquewrench5-25Nm(orsimilar)
Removingsteeringheadfront
1.
RemovetwoAllenscrewsA.
2.RemovetwowashersB.
3.RemovesteeringheadEfromtopwalkingbeamCand
bottomwalkingbeamD.
Installingsteeringheadfront
1.Installpartsinreverseorder.
2.Tightenscrewsaccordingtofollowingsequence:
•Tightenallscrewsto18Nm.
•Turnscrewsbackby1/8turn.
6.3.4Removingrearsprings
Invacarerecommendsalwaysreplacingbothsprings
simultaneouslytoensurethatthemobilitydevice
worksperfectly.
•5/6“Allenkey
•5/32“Allenkey
•Phillipsscrewdriversize2
•Flatscrewdriver
•1/4“wrench
•5/16“wrench
•Torquewrench0-20Nm(orsimilar)
•Obliquepliers
•Cableties
•M8washer
•Twolongwoodenblocks,min.14x14x30cm
1.Liftmobilitydeviceupononesideandplacea14cm
highwoodenblockunderbatterycasesothatwheels
areoffthegroundandcanrotatefreely.Useproper
liftingtechniques.
2.Repeatsameprocedureonothersideofmobilitydevice.
3.Removerearshroudasdescribedin6.6.2Removingrear
shroud,page30.
4.Makesureyounotecableroutingcarefully.Ifnecessary,
takephotoswithadigitalcamera.
5.Removeallcablesandcabletieswhicharexedtowheel
suspensionorwhichcouldgetinthewayduringwork.
6.Removebothprotectivecapsofstabilitylocksystem.
Theyareeitherheldusingascreworacabletie
dependingonthemobilitydevicedateofmanufacture.
7.
MakesurerearspringsGarecompressed:
•Blockmethod
–RaisesuspensionarmsFandplacewooden
blocksunderneathtoremovestopperD.
•Clampmethod
–LoosenbothscrewsCandremoveincluding
spacerB.
–MakesuresuspensionarmsFareloweredas
muchaspossible.
–RemoverubbercapsE.
–Compressspringswithjoiner'sclamptoremove
stopperD.
8.Loosenbothnutsonstopperwithwrenchandremove
nuts,washersandstopper .Ifnecessary,useaat
screwdrivertoloosenstopper .
9.Removewoodenblocksorjoiner'sclampstorelease
springs.
10.Removesprings.
6.3.5Installingrearsprings
Invacarerecommendsalwaysreplacingbothsprings
simultaneouslytomakesurethatthemobilitydevice
worksperfectly.
CAUTION!
Riskofcrushing
Mobilitydeviceisveryheavy.Riskofinjuryto
handsandfeet.
–Useproperliftingtechniques.
Riskofinjurycausedbyuncontrolledmovement
ofthemobilitydevice
–Turnoffpower(ON/OFFkey).
–Engagedrive.Beforeproppingupmobility
device,securewheelsbyblockingthemwith
wedges.
181532486-L
Service
•5/6“Allenkey
•5/32“Allenkey
•Phillipsscrewdriversize2
•Flatscrewdriver
•1/4“wrench
•5/16“wrench
•Torquewrench0-20Nm(orsimilar)
•Obliquepliers
•Cableties
•M8washer
•Twolongwoodenblocks,min.14x14x30cm
1.PutspringsGintopositionbetweensuspensionarm
FandstopA.
2.Makesurerearspringsarecompressed:
•Blockmethod
–Raisesuspensionarmsandreplacewoodenblocks
underneaththemuntilspringsarecompressed.
•Clampmethod
–Pressspringstogetherwithjoiner'sclampor
similarsuitableclampuntilnylonspacerBcan
bettedintorecessesprovidedinsuspensionF.
–FittwoscrewsCincludingspacerB.
–Tightenscrewsto8.5Nm.
3.InstalltwostoppersD.
4.Fitwasherandnutstosecurestoppers.
5.Tightennutsto8.5Nm.
6.Removewoodenblocksorjoiner'sclampscarefullyso
thatspringsarereleased.
7.Reinsertallnecessaryplugsandxcableswithcableties
aspreviously.Seealso6.7.16Cablerouting,page38.
8.Installrearshroudasdescribedin6.6.2Removingrear
shroud,page30.
9.Liftmobilitydeviceoffwoodenblocks.
10.Checkallmobilitydevicefunctions.
11.Ifnecessary,carryoutadjustmentstosettingscrewon
stabilitylocksystemasdescribedinAdjustingsetting
screw,page16.
12.Fitbothprotectivecapsofthestabilitylocksystem.
Theyareheldusingascreworacabletiedependingon
mobilitydevice’sdateofmanufacture.
6.3.6Replacingbatterytray
•Phillipsscrewdriversize2
•5/8“Allenkey
•5/32“Allenkey
TDXSP2Low-Riderdoesnothaveabatterytray.
Removebatteriesmanually.
Removingbatterytray
1.Makebatteriesaccessibleasdescribedin6.7.5Making
batteriesaccessible,page32.
2.Removebatteriesasdescribedinchapter6.7.6Replacing
batteries,page33/6.7.9Replacingbatteries/replacing
batterycables,page35/6.7.8Replacingbatteries
(Poweredsimpletilt20°),page34.
3.
RemovetwostopboltsA.
4.PullbatterytrayBoutofbatterybox.
Installingbatterytray
1.Installpartsinreverseorder.
6.3.7Replacingbatterybox
•5/6“Allenkey
•5/32“Allenkey
•Phillipsscrewdriversize2
•Flatscrewdriver
•1/4“wrench
•5/16“wrench
•Torquewrench0-20Nm(orsimilar)
•Torquewrench5-25Nm(orsimilar)
•Torquewrench20-80Nm(orsimilar)
•Obliquepliers
•Cableties
•M8washer
•Twolongwoodenblocks,min.14x14x30cm
Removingbatterybox
1.Removeseatincludingseatsupportasdescribedin
“Seating”andinModuliteservicemanual.
2.Removeshroudsasdescribedin6.6Shrouds,page30.
3.Removebatteriesasdescribedin6.7.5Makingbatteries
accessible,page32and6.7.6Replacingbatteries,page
33/6.7.9Replacingbatteries/replacingbatterycables,
page35.
4.Removebatterysupportasdescribed6.3.6Replacing
batterytray,page19.
5.Removeheadlightsandrearlightsdependingonversion
(includingholder)asdescribedin6.8Lightingunit,page
38.
6.Removepowermoduleasdescribedin6.7.1Replacing
powermodule,page31.Seecorrespondingservice
manual:
-ForLinX,seeLiNXservicemanual.
-ForDX2,seerevision11ofTDXSP2servicemanual.
1532486-L19
Invacare®TDX®SP2Series
7.RemovebottomwalkingbeamsasdescribedinBottom
walkingbeam,page17.
8.RemovetopwalkingbeamsasdescribedinRemoving
topwalkingbeam,page17.
9.RemovegascylinderasdescribedinReplacinggas
cylinder,page14.
10.Removerearwheelsuspensionasdescribedin6.5
Wheels,page24.
11.Removefrontandrearbulbholdersdependingon
versionasdescribedin6.8Lightingunit,page38.
12.Removerubberstopperasdescribedin6.3.8Replacing
rubberstopper,page20.
13.Removebatterybox.
Installingbatterybox
1.Installrubberstopperasdescribedin6.3.8Replacing
rubberstopper,page20.
2.Installfrontandrearlampholderdependingonversion
asdescribedin6.8Lightingunit,page38.
3.Installrearwheelsuspensionasdescribedin6.5Wheels,
page24.
4.InstallgascylinderasdescribedinReplacinggascylinder,
page14.
5.InstalltopwalkingbeamsasdescribedinInstallingtop
walkingbeam,page17.
6.InstallbottomwalkingbeamsasdescribedinBottom
walkingbeam,page17.
7.Installpowermoduleasdescribedin6.7.1Replacing
powermodule,page31.
8.Installbatterysupportasdescribedin6.3.6Replacing
batterytray,page19.
9.Installbatteriesintheircorrectlocationasdescribed
in6.7.6Replacingbatteries,page33/6.7.9Replacing
batteries/replacingbatterycables,page35and6.7.5
Makingbatteriesaccessible,page32.
10.Installshroudsasdescribedin6.6Shrouds,page30.
11.Installseatincludingseatsupportasdescribedin6.9
Seating,page41andModuliteservicemanual.
12.Adjustsettingscrewonanti-tipsystemasdescribedin
Adjustingsettingscrew,page16.
13.Toconclude,carryoutanextensivedrivingandfunction
testwithmobilitydevice.
6.3.8Replacingrubberstopper
Invacarerecommendsthatyoureplaceallrubber
stoppersassoonasoneneedsreplacing.
•5/16“wrench
•7/8“Allenkey
•Twolongwoodenblocks,min.14x14x30cm
•Torquewrench5-25Nm(orsimilar)
Removingrubberstopper
1.Removedrivewheelasdescribedin6.5.6Replacing
drivewheel,page26.
2.LoosenandremovenutC.
3.RemovewasherB.
4.RemoverubberstopperA.
Installingrubberstopper
1.Installpartsinreverseorder.
6.4Drivecomponents
6.4.1Overviewmotor
Speed-TorqueCombinations
AGearBox18:123:123:1
10km/h/
6.25mph
8km/h/
5mph
6km/h
/3mph
(onlyEU)
BMotor
High
Speed
High
Speed
Low
Speed
Fordescriptionofoldmotorsandcomponents,see
earlierrevisionofservicemanual.
201532486-L
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