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Invacare orion metro, Orion Pro User manual

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Orion
Orion
METRO
, Orion
PRO
enScooter
ServiceManual
DEALER:Keepthismanual.
TheproceduresinthismanualMUSTbeperformedbyaqualied
technician.
©2016Invacare®Corporation
Allrightsreserved.Republication,duplicationormodicationinwholeorinpartisprohibitedwithoutpriorwritten
permissionfromInvacare.Trademarksareidentiedby™and®.AlltrademarksareownedbyorlicensedtoInvacare
Corporationoritssubsidiariesunlessotherwisenoted.
Invacare®reservestherighttoalterproductspecicationswithoutfurthernotice.
Contents
1General.........................................4
1.1Generalinformation............................4
2Safety..........................................5
2.1Safetyandttinginstructions.....................5
3Hygiene.........................................6
3.1Handlingofreturnedusedproducts.................6
4Service..........................................7
4.1Generalsafetyinformationoninstallationwork........7
4.2Troubleshooting...............................7
4.2.1Operationalfaults...........................7
4.2.2Drivefaultdiagnosis..........................7
4.2.3Errorcodesanddiagnosticcodes................8
4.3Tighteningtorques.............................8
4.4Serviceplan(1xannually)........................9
4.5Controls.....................................10
4.5.1Replacingoperatingconsole....................10
4.5.2Replacingcircuitboard........................11
4.5.3Replacingpotentiometer......................11
4.5.4Replacingpowermodule......................12
4.5.5Setupsettings..............................13
4.6Shrouds.....................................17
4.6.1Removingshroud............................17
4.6.2Replacingfrontshroud........................17
4.7Lightingunit..................................17
4.7.1Replacingheadlight..........................17
4.7.2Replacingfrontdirectionindicators...............17
4.7.3Replacingcenterbrakelight....................18
4.7.4Replacingrearlights/directionindicators...........19
4.8Wheels......................................20
4.8.1Replacingwheelsuspension....................20
4.8.2Replacingshockabsorber......................20
4.8.3Replacingswingarm.........................21
4.8.4Replacingfrontaxle..........................21
4.8.5Replacingsteeringcolumn.....................22
4.8.6Replacingfork3–wheel.......................23
4.8.7Replacingfrontwheelsuspension4–wheel.........23
4.8.8Repairingtirepunctures.......................24
4.9Brakes.......................................25
4.9.1Replacinghandbrakes........................25
4.9.2Replacingbrakecable.........................25
4.9.3Replacingsteeringlink/couplingrod..............26
4.9.4Replacingcurvecontroldevice..................26
4.10Drivecomponents.............................27
4.10.1Replacingdriveunit.........................27
4.10.2Replacingcarbonbrushes.....................29
4.11Seatsystem..................................30
4.11.1Replacingseatsuspension/spring...............30
4.11.2Replacingseatsupporttube...................31
4.12Accessories..................................31
4.12.1Accessorieslist.............................31
Orion
1General
1.1Generalinformation
•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.
4
1608032-A
Safety
2Safety
2.1Safetyandttinginstructions
Thesesafetyinstructionsareintendedtopreventaccidents
atwork,anditisimperativethattheyareobserved.
Beforeanyinspectionorrepairwork
•Readandobservethisrepairmanualandtheassociated
usermanual.
•Observetheminimumrequirementsforcarryingoutthe
work(see1.1Generalinformation,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
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.
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.
1608032-A5
Orion
3Hygiene
3.1Handlingofreturnedusedproducts
Whenreconditioningorrepairingreturnedmobilitydevices:
•Takeprecautionsforyourselfandtheproduct.
•Useprotectionequipmentasspeciedlocally.
Beforetransport(accordingtoBiologicalAgentsOrdinance)
Treatproductaccordingtofollowingprocesssteps:
Processstep
Component
ApplicationConditioningtechniqueWorkstation
ManualcleaningSurfaceofuseddeviceBeforerepairor
reconditioning
Usesaturatedtowel
toapplycleaning
detergent“Nücosept
special”andremove
residuesafter5min
impact.
Cleaningand
disinfection
DisinfectionSurfaceofuseddeviceBeforerepairor
reconditioning
Usesaturated
disinfectantwipes
andclean*thedevice
surface.
Cleaningand
disinfection
*Invacareusesdetergent"Nücoseptspecial"1.5%inwaterml/ml
Disinfectiontools
•Onewaywipes(eece)
•Brushestocleandifculttoaccessareas
Furtherinformation
FormoreinformationseeInvacareRANprocedureandInvacareRepairandHygieneguidelines,orcontactyourInvacare
Servicedepartment.
61608032-A
Service
4Service
4.1Generalsafetyinformationoninstallation
work
Riskofdamagetomobilitydevice
Collisionscanbecausedifshimringsareremoved
fromthedrivewheelsduringinstallationwork.
Shimringsarefrequentlyplacedbetweendrive
shaftandwheelhubtocompensatetolerances.
Collisionscanbecausediftheseshimringsare
removedandnotre-installed.
–Installallshimringsinexactlythesame
positionstheywereinbeforedismantling.
4.2Troubleshooting
4.2.1Operationalfaults
Proceedasfollowsifyouhaveanyproblems:
1.Firstassessthepossiblecauseoftheproblemusingthe
followingtable.
2.Checkoperatingconsolestatusdisplay.Evaluateash
code.
3.Carryoutnecessarychecksandrepairsasrecommended
inthefollowingtable.
4.2.2Drivefaultdiagnosis
ProblemOthersymptomsPossiblecauseSolution
Documentation
BatteriesdefectiveReplacebatteriesSeeusermanual
Completely
dischargedbattery
Pre-chargebatteries
Powersupplyto
operatingconsole
interrupted
CheckmainfuseSeeusermanualfor
mainfuseposition
Checkcablebetween
modulesforloose
connectionsor
damage
See4.5.4Replacing
powermodule,page
12
Statusdisplayon
operatingconsole
doesnotilluminate
Operatingconsole
defective
Replaceoperating
console
See4.5.1Replacing
operatingconsole,
page10
Scooterwillnotstart
Statusdisplayon
operatingconsole
ashing
Variouscauses
AssesserrorcodeSeecontrolsuser
manual
Drivemotor(s)
defective
Replacemotor(s)
See4.10.1Replacing
driveunit,page27
Scooterjuddersindrivemode
None
Drivelever
potentiometer
defective
Replace
potentiometer
See4.5.3Replacing
potentiometer,page
11
None
BatteriesdefectiveReplacebatteriesSeeusermanual Batteriesnotbeingcharged
LEDsashingon
charger
ChargerdefectiveReplacechargerSeechargeruser
manual
Operatingconsole
defective
Replaceoperating
console
See4.5.1Replacing
operatingconsole,
page10
Scooterrunstooslowly
None
BatteriesdefectiveReplacebatteriesSeeusermanual
Curvecontroldevice
forbendtravelnot
adjusted
Adjustcurvecontrol
device
Scooterdoesnotreducespeed
onbends
None
Curvecontroldevice
defective
Replacecurve
controldevice
See4.9.4Replacing
curvecontroldevice,
page26
1608032-A
7
Orion
4.2.3Errorcodesanddiagnosticcodes
FlashcodeFault
Consequenceforthe
scooterComments
1
Batteriesmustbe
charged
Continuestodrive•Thebatteriesaredischarged.Chargethebatteries
assoonaspossible.
2
BatteryvoltagetoolowStopsdriving•Thebatteriesaredepleted.Chargebatteries.
•Ifyouswitchthescooteroffforafewminutes,the
batteriescanoftenrecuperatetosuchastagethata
shortjourneyisstillpossible.Youshouldonlydothis
inanemergency,however,becausethiscausesthe
batteriestobecomeexcessivelydischarged.
3
BatteryvoltagetoohighStopsdriving•Thebatteryvoltageistoohigh.Ifthebatterycharger
isconnected,disconnectitfromthescooter.
•Theelectronicsystemchargesthebatterieswhen
runningdownhillandwhenbraking.Thisfaultis
causedwhenthebatteryvoltagebecomestoohigh
duringthisprocess.Switchthescooteroffandon
again.
4
PowertimeexceededStopsdriving•Themaximumcurrentwasexceededovertoolonga
period,probablybecausethemotorwasoverloaded
orhasbeenworkingagainstanimmovableresistance.
Switchthescooteroff,waitafewminutesandthen
switchonagain.
•Theelectronicsystemhasdeterminedamotor
short-circuit.Checkthewiringharnessforshort-circuit
andcheckthemotor.
•ContactyourInvacareprovider.
5
BrakefailureStopsdriving•Ensurethatthedisengagingleverisintheengaged
position.
•Thereisadefectinthebrakingcoilorinthecabling.
Checkthemagneticbrakeandcablingforopen
orshort-circuitedcircuitry.ContactyourInvacare
provider .
6
Noneutralposition
whenswitchingscooter
on.
Stopsdriving•Driveleverisnotinneutralwhenthekeyswitchwas
turned.Putthedriveleverinneutral,turnthepower
offandthenturnonagain.
•Itmaybenecessarytoreplacethedrivelever .
ContactyourInvacareprovider.
7
Faultinspeed
potentiometer
Stopsdriving•Thedrivelevercontrolscouldbefaultyor
incorrectlyconnected.Checkthecablingforopen
orshort-circuitedcircuitry.
•Potentiometerisnotcorrectlyadjustedandmustbe
replaced.ContactyourInvacareprovider.
8
MotorvoltageerrorStopsdriving•Themotororitscablingisdefective.Checkthe
cablingforopenorshort-circuitedcircuitry.
9
Miscellaneousinternal
fault
Stopsdriving•ContactyourInvacareprovider.
10
Push/freewheelmode
error
Stopsmoving
•Thescooterhasexceededthepermissiblemaximum
speedduringpushingorfreewheeling.Switchthe
electronicssystemoffandonagain.
4.3Tighteningtorques
CAUTION!
Riskofdamagetomobilitydevicedueto
improperlytightenedscrews,nutsorplastic
connections.
–Alwaystightenscrews,nutsetc.tothestated
tighteningtorque.
–Onlytightenscrewsornutswhicharenotlisted
herengertight.
Thetighteningtorquesstatedinthefollowinglistarebased
onthethreaddiameterforthenutsandboltsforwhichno
specicvalueshavebeendetermined.Allvaluesassume
dryandde-greasedthreads.
ThreadTighteningtorquein
Nm±10%
M43Nm
M5
6Nm
81608032-A
Service
ThreadTighteningtorquein
Nm±10%
M610Nm
M825Nm
M1049Nm
ThreadTighteningtorquein
Nm±10%
M1280Nm
M14120Nm
M16180Nm
4.4Serviceplan(1xannually)
Component
CheckRemedy
Notes
Checkwelded
seams,xingsand
upholstery
Tightenscrews,
replacepartsif
damaged
Seat
Checkseat
suspension
Greasethespring
generously,replace
partsifdamaged
See4.11.1
Replacingseat
suspension/spring,
page30
Checkxings,
weldedseamsand
batterymounting
Frames(chassis)/batterymounting
Checkbatteryxing
straps
Tightenscrews,
replacepartsif
damaged
Checkdrivewheels
fortightt
Tightenhubnuts,
replaceifnecessary
Checkfrontwheels
fortightt,oat
andsideplay
Adjust/replace
Checkpneumatic
tire
Repairorreplaceif
damaged
Seeusermanual
Tightenscrews
Wheelsuspensionandwheels
Checktrackingand
steeringlink
Checktrackingand
steering
BrakeCheckbrake
functioninpushing
mode
Adjustorreplace
brake
ShockabsorberCheckshock
absorber
Adjustorreplace
shockabsorber
Checkfunctions
indriveandpush
modes
Replacemotorif
necessary
Driveunits,couplingmechanism
Checkclutch
mechanism
Tightenscrews/
nuts,adjustor
replace
Checkfunction Lighting
Checkcable/plug
connections
Replacelightbulbs
orcable
Checkbatteriesfor
damage
ReplacebatteriesSeeusermanual
Checkbattery
voltage
ChargebatteriesSeeusermanual
Batteries
Checkcontactsand
terminals
Cleancontactsand
terminals
1608032-A9
Orion
Component
CheckRemedy
Notes
Checkstatusdisplay
(ashing)
Evaluateashcode
CheckxingTightenorreplace
xing
Checkcable,
connectingplug
Replacecable,
connectingplug
Checkdrivelever
function
Replacedrivelever
Drivecontrols
CheckpowersupplyReplacecable,
connectingplug
orconsole
Driveprogram
Checkdrive
programversion.
Newversion
available?
Updatesoftware
Checkcableand
connectingplug
Adjustorreplace
sensoroncurve
controldevice
Curvecontrolinbends
Checkfunction
Screws
Checkscrewsfor
tightt
Tightenscrewsif
necessary
4.5Controls
4.5.1Replacingoperatingconsole
CAUTION!
Riskofburnsifpowercableisshorted
–Turnoffthepowercompletelybeforeremoving
anypowersupplycomponentsofmobility
device.Thereforetakeoutbatteries.
–Avoidbridgingofcontactsduringmeasurements
onliveelectricalcomponents.
Riskofdamagetooperatingconsole/circuit
boardbyinstanthighcurrent/voltage
–Unplugbatterycablebeforeremoving/installing
operatingconsole.
–Makesureallpinsarecorrectlyconnected.
Theplugsontheoperatingconsolecannotbe
wronglyconnectedbecauseallplugshaveadifferent
sizeandonlytinonesocket.
•Phillipsscrewdriver
Settingbatterygaugeismandatorywhenretrotting
operatingconsole.
Settingwheeldiameterismandatorywhen
retrottingoperatingconsole.
1.Removeseat.
2.Removeshroud.
3.
DisconnectbatterycableA.
4.
RemovetopshroudAfromsteeringcolumnB.
101608032-A
Service
5.
RemovescrewsAbelowoperatingconsole.
6.Removeoperatingconsoleandfoldupwards.
7.RemovescrewsCondriveleverBandremovedrive
lever .
8.
LED
LCD
Disconnectplugfromoperatingconsolecircuitboard.
9.Replaceoperatingconsole.
10.Connectplugwithcircuitboardonnewoperating
console.
11.Installpartsinreverseorder .
12.Testallfunctions(trialrun).
4.5.2Replacingcircuitboard
CAUTION!
Riskofburningifpowercableisshorted
–Turnoffpowercompletelybeforeremovingany
powersupplycomponentsofmobilitydevice.
Thereforetakeoutbatteries.
–Avoidbridgingofcontactsduringmeasurements
onliveelectricalcomponents.
Riskofdamagetooperatingconsole/circuit
boardbyinstanthighcurrent/voltage
–Unplugbatterycablebeforeremoving/installing
circuitboard.
–Makesureallpinsarecorrectlyconnected.
1.Unplugbatteryconnector .
2.
Removeoperatingconsoleasdescribedinchapter4.5.1
Replacingoperatingconsole,page10.
3.Replacecircuitboard.
4.Makesureallpinsarecorrectlyconnected.
5.Pluginbatteryconnectors.
6.Installpartsinreverseorder.
7.Testcircuitboardfunction.
4.5.3Replacingpotentiometer
CAUTION!
Riskofburningifpowercableisshorted
–Turnoffthepowercompletelybeforeremoving
anypowersupplycomponentsofthemobility
device.Thereforetakeoutbatteries.
–Avoidbridgingofcontactsduringmeasurements
onliveelectricalcomponents.
Riskofdamagetooperatingconsolebyinstant
highcurrent/voltage
–Unplugbatterycablebeforeremoving/installing
operatingconsole.
–Makesureallpinsarecorrectlyconnected.
CAUTION!
Riskofaccident
Wrongpotentiometersettingcanresultin
dangerousdrivingsituations.
–Connectpotentiometertodrivelevermounting.
•Phillipsscrewdriver
•2mmAllenkey
•Digitalmultimeter
1.Removeseat.
2.Removeshroud.
3.
DisconnectbatterycableA.
1608032-A
11
Orion
4.
RemovetopshroudAfromsteeringcolumnB.
5.
RemovescrewsAbelowoperatingconsole.
6.Removeoperatingconsoleandfoldupwards.
7.RemovescrewsCondriveleverBandremovedrive
lever .
8.
LCDLED
DisconnectpotentiometerplugAfromoperating
console.
9.
RemovescrewsAonpotentiometer .
10.Replacepotentiometer.
11.
LCDLED
ReconnectpotentiometerplugAwithoperatingconsole.
12.
ConnectpotentiometerAanddrivelevermountingB:
•TightenscrewC.
13.Installpartsinreverseorder .
14.Testallfunctions(trialrun).
4.5.4Replacingpowermodule
CAUTION!
Riskofaccident
Whenparkingmobilitydeviceonantitippersitis
nolongerslowedbymotorbrake.Mobilitydevice
canrollawayoutofcontrol.
–Placemobilitydevice’srearframeona
supportingwoodenblockbeforeyouremove
wheels.
CAUTION!
Riskofburningifpowercableisshorted
–Turnoffthepowercompletelybeforeremoving
anypowersupplycomponentsofthemobility
device.Thereforetakeoutbatteries.
–Avoidbridgingofcontactsduringmeasurements
onliveelectricalcomponents.
CAUTION!
Anychangestothedriveprogramcanaffectthe
drivingcharacteristicsandthetippingstability
ofthemobilitydevice
–Changestothedriveprogrammayonlybe
carriedoutbytrainedInvacare®specialist
providers.
–Invacare®canonlygiveawarrantyforsafe
mobilitydevicedrivingbehavior-especially
tippingstability-forunalteredstandarddrive
programs.
CAUTION!
Riskofaccident
Accidentalrollingcanleadtoaccidents.
–Securemobilitydeviceagainstrollingaway.
12
1608032-A
Service
Thecontrolssystemissuppliedwithastandarddrive
program.Ifyouhavecarriedoutcustomer-specic
modicationstothedriveprogram,youwillhaveto
makethesechangesagainafterinstallingthenew
powermodule.
Whendisassembling,notepositionofsmallparts
suchasscrewsandwashers.Putsmallpartsdown
sothattheycanbereassembledinrightsequence.
Theplugsontheelectronicmodulecannotbe
wronglyconnectedbecauseallplugshaveadifferent
sizeandonlytinonesocket.
•10mmwrench
•17mmwrench
•Rubberhammer
•Phillipsscrewdriver
•Supportingwoodenblock
•Toadaptthedriveprogram:programming
softwareorhandprogrammingdeviceand
electronicsysteminstallationmanual,available
fromInvacare.
1.Securemobilitydeviceagainstrollingaway.
2.Placesupportingwoodenblockunderframesatbattery
holderheight.
3.Removeseat.
4.Removeshroud.
5.
Disconnectbatterycable(1).
6.Loosenandremoverearwheelxingscrews.
7.Removerearwheels.
8.Removedriveunit.See4.10.1Replacingdriveunit,page
27
.
9.Removescrews(1)onpowermodule(2).
•Rhino1:
DS72KB01/DS112KB02
•Rhino2:
DS90/DS120:
10.
Replacepowermodule(2).
11.Installpartsinreverseorder .
12.Loaddriveprogramontopowermodule.Seecontrols
softwaredescription.
13.Testallfunctions(trialrun).
4.5.5Setupsettings
Operatingconsole(LEDversion)
Arrangement
1608032-A13
Orion
A
Statusdisplay
B
Switchingon/offcurvecontrol(reductionofspeed
whendrivinginacurve)
C
Hazardlights
D
Horn
E
Left-handdirectionindicator(switchesitselfoff
automaticallyafter30seconds)
F
Speedcontroldial
G
Right-handdirectionindicator(switchesitselfoff
automaticallyafter30seconds)
H
Lighting
I
Lowspeedmode
J
Drivelever
Statusdisplay
TheON/OFFdiode(1)isusedasafaultdisplay
(statusdisplay).Itwillashifthereisaproblem
withthescooter.Thenumberofashesindicates
thetypeoferror.Referto4.2.3Errorcodesand
diagnosticcodes,page8.
Batteryindicationgauge
Lowbatteryindication:Everytimethescooteris
activatedoratworkwhenbatterycapacityislower
than25%,theelectronicsystemwillbeepthree
times.
Overdischargeprotection:afteracertaindrivetime
onreservebatterypowertheelectronicsystem
switchesthedriveoffautomaticallyandbringsthe
scootertoastandstill.Ifyoudonotdriveyour
scooterforawhilethebatterieswill"recuperate"
andallowafurther,butshort,journey.However,
afteraverybriefjourneythebatteryreservesymbol
willilluminateagainandtheelectronicsystemwill
beepthreetimes.Thisprocedureleadstobattery
damageandshouldbeavoidedifpossible!
Batterycapacity:
<25%
Reduceddrivingrange.
Rechargethebatteriesattheend
ofyourjourney.
Batterycapacity:
<20%
Batteryreserve=severely
restricteddrivingrange.
Rechargebatteriesimmediately!
(2)(3)(4)(5)(6)(7)(8)
Batterycapacity
>80%
<80%
<65%
<50%
<35%
<25%
<20%
Operatingconsole(LCDversion)
Arrangement
A
Statusdisplay
B
Switchingon/offcurvecontrol(reductionofspeed
whendrivinginacurve)
C
Hazardlights
D
Horn
E
Left-handdirectionindicator(switchesitselfoff
automaticallyafter30seconds)
F
Speedcontroldial
G
Right-handdirectionindicator(switchesitselfoff
automaticallyafter30seconds)
H
Lighting
I
Lowspeedmode
J
Setting
K
Drivelever
Statusdisplay
A
Speedindication
B
Faultindication
C
Curvecontrolindication
D
Maintenanceindication
1
14
1608032-A
Service
E
Headlightindication
F
Leftturnindication
G
Settingsshown:ODO,TRIP ,TEMP ,TIME
H
Rightturnindication
I
Batterystatus
J
Lowspeedselectionindication
1
Ifthissymbolstartsashingforoneminuteeverytime
thescooterisswitchedon,contactyourprovider .
Batteryindicationgauge
Lowbatteryindication:Everytimethescooteris
activatedoratworkwhenbatterycapacityislower
than25%,theelectronicsystemwillbeepthree
times.
Overdischargeprotection:afteracertaindrivetime
onreservebatterypowertheelectronicsystem
switchesthedriveoffautomaticallyandbringsthe
scootertoastandstill.Ifyoudonotdriveyour
scooterforawhilethebatterieswill"recuperate"
andallowafurther,butshort,journey.However,
afteraverybriefjourneythebatteryreservesymbol
willilluminateagainandtheelectronicsystemwill
beepthreetimes.Thisprocedureleadstobattery
damageandshouldbeavoidedifpossible!
Batterycapacity:
<25%
Reduceddrivingrange.
Rechargethebatteriesattheend
ofyourjourney.
Batterycapacity:
<20%
Batteryreserve=severely
restricteddrivingrange.
Rechargebatteriesimmediately!
>80%<80%<65%<50%<35%<25%<20%
Enteringsetup(LCDDisplay)
ThischapterappliesformobilitydeviceswithLCD
display.
1.Turnkeytoswitchmobilitydeviceoff.
2.
Pressandholdkeys.
3.Turnkeytoswitchmobilitydeviceon.
Mobilitydeviceenterssetupmodeaftertwoseconds.
Enternextdisplaywith
key.
Enternextdisplaywith
key.
Enternextdisplaywith
key.
Settingcounter
ThischapterappliesformobilitydeviceswithLCD
display.
1.EntersetupsettingsasdescribedinEnteringsetup(LCD
Display),page15.
Defaultsettingis0.Youcansetakmvalueas
serviceinterval.
Ifcountervalueisgreaterthansetvalue,symbol
willashforoneminute,whenkeyisswitchedon.
+
0(OFF)+500+1000
+1500+2000..........
+9500+9999(max)
-
9999–9500–9000–
8500–8000.........–
500–0(OFF)
2.
Pressandholdkeyfor2sec.toerasecounter .
3.
Presskeytoincreasevalue.
1608032-A15
Orion
4.
Presskeytodecreasevalue.
5.
Presskeytosaveandenternextpage.
Settingbatterygauge
ThischapterappliesformobilitydeviceswithLCD
display.
Settingbatterygaugeismandatorywhenretrotting
operatingconsole.
Adjusttheparameterinbatterygaugetosuitdifferenttypes
andsizesofbatteries.
AGMbatteryGelbattery
(1)bigsize
batteries(>
50A)
(2)small
sizebatteries
(<50A,
default)
(3)smallsize
batteries(<
50A)
(4)bigsize
batteries(>
50A)
1.
Presskeytoincreasevalue.
2.
Presskeytodecreasevalue.
3.
Presskeytosaveandenternextpage.
Settingwheeldiameter
ThischapterappliestomobilitydeviceswithLCD
display.
Settingwheeldiameterismandatorywhen
retrottingoperatingconsole.
Setvalueaccordingtowheeldiameter11”,12”,13”,14”or
15”forcorrectdisplayofspeed.
1.
Presskeytoincreasevalue.
2.
Presskeytodecreasevalue.
3.
Presskeytosaveandleavesetupsettings.
Enteringsetup(LEDDisplay)
ThischapterappliesformobilitydeviceswithLED
display.
1.Turnkeytoswitchmobilitydeviceoff.
2.
Pressandholdkeys.
3.Turnkeytoswitchmobilitydeviceon.
Mobilitydeviceenterssetupmodeaftertwoseconds.
LED2andLED8willash.
4.
Releasekeystoentersetupsettings.
Settingbatterygauge
ThischapterappliesformobilitydeviceswithLED
display.
Settingbatterygaugeismandatorywhenretrotting
operatingconsole.
Adjusttheparameterinbatterygaugetosuitdifferenttypes
andsizesofbatteries.
AGMbatteryGelbattery
(1)bigsize
batteries(>
50A)
(2)small
sizebatteries
(<50A,
default)
(3)smallsize
batteries(<
50A)
(4)bigsize
batteries(>
50A)
161608032-A
Service
1.
Presskeytochangesettings.
2.Savesettingsbywaitingfor10secondsorpressingany
otherkeysexceptkeysabove.
4.6Shrouds
4.6.1Removingshroud
CAUTION!
Riskofdamagetoshroud
–Donotpullshroudstraightuptoremove.
–Followinstructionsbelow.
1.
Placeonehandatthefront,theotherattherearof
theshroudA.
2.Liftshroudupfromfront.
3.
Placehandsonleftandrightsideofshroud.
4.Twistandlifttoremoveshroudcompletely.
4.6.2Replacingfrontshroud
•10mmsocketwrench
•Phillipsscrewdriver
1.Removeshroud.See4.6.1Removingshroud,page17.
2.
RemovefourcapsA.
3.LoosenandremovescrewsB.
4.Takeofffrontshroud.
5.Installpartsinreverseorder.
4.7Lightingunit
4.7.1Replacingheadlight
•Phillipsscrewdriver
1.Removeseat.
2.Removeshroud.
3.
DisconnectbatterycableA.
4.
Removescrew(1)orAonheadlightunderfrontshroud.
5.Removeheadlight.
6.Disconnectcablefromwiringharness.
7.
Removescrews(1)onheadlightglass.
8.Removeheadlightglass.
9.Replacebulb(s)inheadlight.
10.Testfunction.
4.7.2Replacingfrontdirectionindicators
•Phillipsscrewdriver
1608032-A
17
Orion
1.Removeseat.
2.Removeshroud.
3.
DisconnectbatterycableA.
3-wheelversion
1.
Removedirectionindicatorscrew(1).
2.Disconnectdirectionindicatorcable(2)fromwiring
harness.
3.Replacedirectionindicator.
4.Installdirectionindicatorsinreverseorder.
5.Testfunction.
4-wheelversion
1.Removesteeringcolumnshroudandsteeringcolumn.
See4.8.5Replacingsteeringcolumn,page22
.
2.Removechassisboltsandfoldchassisupwards.
3.
RemovedirectionindicatorscrewAonchassis.
4.DisconnectdirectionindicatorcableBfromwiring
harness.
5.
Removescrews(3)onglass.
6.Removeglass.
7.Loosenscrews(4)onorange-coloredcap(5)andremove
cap.
8.Replacelightbulb.
9.Installpartsinreverseorder.
10.Testfunction.
4.7.3Replacingcenterbrakelight
CAUTION!
Riskofburningifpowercableisshorted
–Turnoffthepowercompletelybeforeremoving
anypowersupplycomponentsofthemobility
device.Thereforetakeoutthebatteries.
–Avoidbridgingofcontactsduringmeasurements
onliveelectricalcomponents.
Whendisassembling,notethepositionofsmallparts
suchasscrewsandwashers.Putsmallpartsdownso
thattheycanbereassembledintherightsequence.
•Phillipsscrewdriver
1.Removeseat.
2.Removeshroud.
3.
DisconnectbatterycableA.
181608032-A
Service
4.
Disconnectplug(4).
5.
Removebolts(1)onrearshroud.
6.Lifttherearshroudupwards.
7.
Removescrews(1)onbrakelight.
8.Replacebrakelight.
9.Installpartsinreverseorder.
10.Testfunctions(trialrun).
4.7.4Replacingrearlights/directionindicators
CAUTION!
Riskofburningifpowercableisshorted
–Turnoffpowercompletelybeforeremovingany
powersupplycomponentsofmobilitydevice.
Thereforetakeoutbatteries.
–Avoidbridgingofcontactsduringmeasurements
onliveelectricalcomponents.
Whendisassembling,notethepositionofsmallparts
suchasscrewsandwashers.Putsmallpartsdownso
thattheycanbereassembledintherightsequence.
•Phillipsscrewdriver
1.Removeseat.
2.Removeshroud.
3.
DisconnectbatterycableA.
4.
Removebolts(1)onrearshroud.
5.Liftrearshroudupwards.
6.
Removescrews(1)onrearlight.
7.Removerearlight.
8.
Removescrews(1)onglass.
1608032-A19
Orion
9.
Removeglass(1).
10.Replacelightbulbs(2).
11.Installpartsinreverseorder .
12.Testfunction.
4.8Wheels
4.8.1Replacingwheelsuspension
CAUTION!
Riskofaccident
Accidentalrollingcanleadtoaccidents.
–Securemobilitydeviceagainstrollingaway.
Whendisassembling,notepositionofsmallparts
suchasscrewsandwashers.Putsmallpartsdown
sothattheycanbereassembledinrightsequence.
•10mmwrench
•12mmwrench
•13mmwrench
•32mmwrench
•Phillipsscrewdriver
•Supportingwoodenblock
1.Removeseat.
2.Removeshroud.
3.
DisconnectbatterycableA.
4.Removefrontsteering:
•3–wheelversion
–Dismantlechassisandsteeringcolumn.See4.8.5
Replacingsteeringcolumn,page22.
•4–wheelversion
–Dismantlesteeringlinkandcouplingrod.See
4.9.3Replacingsteeringlink/couplingrod,page
26.
5.
Loosenwheelsuspensionscrew(1).
6.Loosenscrew(2).
7.Replacewheelsuspension.
8.Installpartsinreverseorder.
Tightenscrew(1)to25Nm.
9.Adjustcamber.See4.9.3Replacingsteeringlink/coupling
rod,page26.
10.Testfunction(trialrun).
4.8.2Replacingshockabsorber
CAUTION!
Riskofaccident
Whenparkingmobilitydeviceonantitippersitis
nolongerslowedbymotorbrake.Themobility
devicecanrollawayoutofcontrol.
–Placemobilitydevicerearframeonasupporting
woodenblockbeforeyouremovewheels.
CAUTION!
Riskofaccident
Accidentalrollingcanleadtoaccidents.
–Securethescooteragainstrollingaway.
Whendisassembling,notepositionofsmallparts
suchasscrewsandwashers.Putsmallpartsdown
sothattheycanbereassembledinrightsequence.
Drivemotorneedstoberemovedbeforeyoucan
replaceleft-handshockabsorber.Ifright-handshock
absorberistobereplaced,youdonotneedto
removedrivemotor.
•10mmwrench
•17mmwrench
•Obliquepliers
•Rubberhammer
•Phillipsscrewdriver
•5mmAllenkeys(2x)
•Supportingwoodenblock
Replacingrearshockabsorber
1.Removewheel.Seeusermanual.
2.Removemudguard.See4.10.1Replacingdriveunit,
page27
.
201608032-A
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