Invacare TDX SP2 series User manual

Brand: Invacare

Model: TDX SP2 series

Type: User manual

Invacare®TDX®SP2Series

enPowerWheelchair

ServiceManual

DEALER:Keepthismanual.

TheproceduresinthismanualMUSTbeperformedbyaqualied

technician.

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.

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

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

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

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

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.

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.

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.

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

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.

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

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.

Fig.6-4

LoosenandremovehandscrewAunderrearlightB

nearwheelD.

Fig.6-5

Ifmobilitydeviceisttedwithcableties,remove.

Wheninstalling,makesuretoreplacecableties.

LoosenandremovescrewA.

LoosenandremovescrewAovermudguardBunder

seatframeC.

6.Removebatteriesasdescribedin6.7.6Replacing

batteries,page33and6.7.9Replacingbatteries/replacing

batterycables,page35.

7.Removedrivewheelasdescribedin6.5.6Replacing

drivewheel,page26.

1532486-L

Service

Fig.6-6

LoosenscrewsBnearhubAandcastorDthatx

lowerbeamCtochassis.

Wheninstalling,usethreadlockingadhesive,for

example,Loctite242.

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.

LoosentwoscrewsBandremovetogetherwithwashers

5.LoosenandremovelocknutBofsettingscrewD.

6.RotatesettingscrewDtowardsbatterycaseuntilyou

canremoveitfromitsholderC.

Installingsettingscrew

•1/4”wrench

•Feelergaugewith2mm

1.ScrewnewsettingscrewDintoholderC.

InserttwoscrewsBtogetherwithwashersC.

3.Tightenscrews.

4.Removewoodenblockfromundermobilitydevice,so

thatallcastersareincontactwithoor.

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.

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

Invacare®TDX®SP2Series

5.RemovebottomwalkingbeamCfromaxle.

6.RemovespacerBfromaxle.

Installingbottomwalkingbeam

1.Installpartsinreverseorder.

2.TightennutsDto18Nm.

6.3.3Steeringheadfront

•5/16“Allenkey

•Torquewrench5-25Nm(orsimilar)

Removingsteeringheadfront

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.

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.

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

Page is loading ...

Invacare TDX SP2 series User manual

Invacare TDX SP2 series User manual

Invacare TDX SP2 series User manual

Related papers

Other documents