Invacare Typhoon II User manual

Category
Motor vehicle electronics
Type
User manual

Invacare Typhoon II is a reliable and innovative electric wheelchair designed to provide utmost comfort and mobility for its users. This advanced wheelchair boasts exceptional maneuverability, allowing you to navigate tight spaces and uneven terrains effortlessly. With its durable construction and user-friendly controls, the Invacare Typhoon II empowers you to maintain an active lifestyle and enjoy a greater sense of independence.

Invacare Typhoon II is a reliable and innovative electric wheelchair designed to provide utmost comfort and mobility for its users. This advanced wheelchair boasts exceptional maneuverability, allowing you to navigate tight spaces and uneven terrains effortlessly. With its durable construction and user-friendly controls, the Invacare Typhoon II empowers you to maintain an active lifestyle and enjoy a greater sense of independence.

Invacare® Typhoon II
SERVICE MANUAL
This document contains information on:
Troubleshooting
Maintenance
Repair
Version: 08.02.08
2
Mobitec Mobilitätshilfen GmbH
Herzog Odilostrasse 101
A-5310 Mondsee
Austria
+43 - 6232 - 55 35 0
Fax: +43 - 6232 - 55 35 4
WWW: www.mobitec-austria.com
Invacare® n.v.
Autobaan 22
B-8210 Loppem (Brugge)
Belgium
+32 - (0)50 - 83 10 10
Fax: +32 - (0)50 - 83 10 11
WWW: www.invacare.be
Mobitec Rehab AG
Benkenstraße 260
CH-4108 Witterswil
Switzerland
+41 - (0)61 - 48 77 08 0
Fax: +41 - (0)61 - 48 77 08 1
WWW: www.mobitec-rehab.ch
Invacare Aquatec
Alemannenstraße 10
88316 Isny
Deutschland
0 75 62 / 7 00 - 251
Fax 08 00 / 6 73 81 72
WWW: www.invacare-aquatec.de
Invacare® A/S
Sdr. Ringvej 39
DK-2605 Brøndby
Danmark
(Kundeservice): +45 - (0)36 - 90 00 00
Fax (Kundeservice): +45 - (0)36 - 90 00 01
WWW: www.invacare.dk
Invacare® SA
c/ Areny, s/n
Poligon Industrial de Celrà
17460 Celrà (Girona)
ESPAÑA
: +34 - (0)972 - 49 32 00
Fax: +34 - (0)972 - 49 32 20
WWW: www.invacare.es
Invacare® Poirier SAS
Route de St Roch
F-37230 Fondettes
France
: +33 - (0)247 - 62 64 66
Fax : +33 - (0)247 - 42 12 24
WWW: www.invacare.fr
Invacare® Ltd
South Road
Bridgend Industrial Estate
Mid Glamorgan - CF31-3PY
United Kingdom
(Customer Service): +44 - (0)1656 - 664 321
Fax (Customer Service): +44 - (0)1656 - 667 532
WWW: www.invacare.co.uk
Invacare Mecc San s.r.l.
Via Dei Pini, 62
I - 36016 Thiene (VI)
ITALIA
+39 - 0445 - 38 00 59
Fax: +39 - 0445 - 38 00 34
WWW: www.invacare.it
Invacare Ireland Ltd.
Unit 5 Seatown Business Campus
Seatown Rd, Swords
County Dublin
Ireland
+353 - 18 10 70 84
Fax: +353 - 18 10 70 85
Invacare® AS
Grensesvingen 9
Postboks 6230
N-0603 Oslo
Norge
(Kundeservice): +47 - (0)22 57 95 10
Fax (Kundeservice): +47 - (0)22 57 95 01
WWW: www.invacare.no
Invacare® B.V.
Celsiusstraat 46
NL-6716 BZ Ede
The Netherlands
: +31 - (0)318 - 69 57 57
Fax: +31 - (0)318 - 69 57 58
WWW: www.invacare.nl
3
Invacare® PORTUGAL Lda
Rua Senhora de Campanhã 105
P-4369-001 Porto
PORTUGAL
: +351-225105946
Fax: +351-225105739
WWW: www.invacare.pt
Återförsäljare:
Invacare® AB
Fagerstagatan 9
S-163 91 Spånga
Sverige
Tillverkare:
Invacare® Deutschland GmbH
Kleiststraße 49
D-32457 Porta Westfalica
Deutschland
(Kundtjänst): +46 - (0) 8 761 70 90
Fax (Kundtjänst): +46 - (0) 8 761 81 08
WWW: www.invacare.se
MÖLNDAL
+46 - (0) 31 – 86 36 00
Fax: +46 - (0) 31 – 86 36 06
LANDSKRONA
+46 - (0) 418 – 285 40
Fax: +46 - (0) 418 – 180 89
OSKARSHAMN
+46 - (0) 491 – 101 40
Fax: +46 - (0) 491 – 101 80
4
Table of Contents
Chapter Page
1 INTRODUCTION 6
1.1 General information 6
1.2 Notes on transport 6
1.3 Important symbols in this manual 6
2 SAFETY AND ASSEMBLY INSTRUCTIONS 8
2.1 Before any inspection or repair work 8
2.2 General safety information and notes on assembly / disassembly 8
3 TIGHTENING TORQUES 9
4 LAYOUT OF MODULES, COMPONENTS AND DISPLAYS AND CONTROLS 10
5 SERVICE PLAN (1X ANNUALLY) 11
6 OPERATIONAL FAULTS 13
6.1 Operational faults on electric wheelchair with ACS 13
6.1.1 Drive fault diagnosis 13
6.1.2 Fault diagnosis with electric actuator motors 15
6.1.3 REM24 Error Codes and Diagnostic Codes 16
7 REPAIR WORK 18
7.1 Replacing and calibrating drive motor 18
7.1.1 Replacing the motor 18
7.1.1.1 Removing wheel rim and tyres on vehicle with pneumatic tyres 20
7.1.1.2 Removing wheel rim and tyres on vehicle with puncture-proof tyres 21
7.1.1.3 Continuing dismounting the motor 21
7.1.1.4 Reassembling wheel rim and tyres on vehicle with pneumatic tyres 23
7.1.1.5 Reassembling wheel rim and tyres on vehicle with puncture-proof tyres 23
7.1.2 Calibration of GB motors 26
7.2 Replacing electronic components 28
7.3 Replacing batteries 30
7.4 Replacing the main fuse. 36
7.5 Checking the cables 38
5
7.6
Replacing the ACS Remote 39
7.7 Updating the software 41
7.8 Checking an actuator motor 42
7.9 Adjusting and replacing the speed reduction switch 43
7.10 Replacing the steering head bearings on the front and rear steering wheels 44
7.10.1 Front steering wheels 44
7.10.2 Rear steering wheels and 45
6
1 Introduction
1.1 General information
All maintenance and overhaul work must be carried out in accordance with these repair
instructions.
Please observe all safety instructions.
Information about operation or about general maintenance and care work should be taken
from the electric vehicle Operating Manual.
You can find information about ordering spare parts in the spare parts catalogue.
Use only genuine Invacare® spare parts. Using parts from any other source will void the
warranty!
We reserve the right to make any alterations on the grounds of technical improvements.
The electric vehicle may only be maintained and overhauled by qualified personnel.
The minimum requirement for service technicians is relevant training, such as in the cycle or
orthopaedic mechanics fields, or suitably long-term job experience.
- Experience and knowledge of electrical measuring devices (Multimeter)
is also a requirement.
- Special Invacare training sessions are recommended.
Alterations to the electric vehicle which occur as a result of incorrectly or improperly executed
maintenance or overhaul work lead to the exclusion of all liability on the part of INVACARE.
If you have any problems or questions please contact INVACARE SERVICE.
1.2 Notes on transport
If the electric vehicle has to be shipped back to the manufacturer for major repairs, you should
always use the original packaging for transport.
You should also include as accurate a fault description as possible.
1.3 Important symbols in this manual
WARNING!
This symbol warns you of danger!
Always follow the instructions to avoid injury to the user or damage to the product!
EXPLOSION HAZARD!
This symbol warns you of an explosion hazard, an example of which can be caused by
excessive tyre pressure in a pneumatic tyre!
Always follow the instructions to avoid injury to the user or damage to the product!
BURN HAZARD!
This symbol warns you of burns due, for example, to leaking battery acid!
Always follow the instructions to avoid injury to the user or damage to the product!
NOTE:
This symbol identifies general information which is intended to simplify working with your product
and which refers to special functions.
Requirements:
This symbol identifies a list of various tools, components and items which you will need in
order to carry out certain work.
7
8
2 Safety and assembly instructions
These safety instructions are intended to prevent accidents during work and it is imperative that
they are observed.
2.1 Before any inspection or repair work
Read and observe this repair manual and the associated operating manual!
Observe the minimum requirements for carrying out the work (see chapter entitled "General
information”)!
2.2 General safety information and notes on assembly / disassembly
Danger of injury by crushing!
Please note the heavy weight of some components. This applies especially to removal of
drive units and batteries!
Prop up the lifted electric vehicle with appropriate supports before starting the disassembly or
assembly!
Danger of fire and burns due to electrical short-circuit!
The electric vehicle must be switched off before removal of voltage-carrying components! To
do this, disconnect the batteries!
When making measurements on voltage-carrying components, avoid short-circuiting the
contacts. Danger of fire and combustion!
Danger of injury and damage to the vehicle can result from incorrect or incomplete
maintenance!
Only ever use tools which are undamaged in good condition!
Some moving parts have Teflon bushings! These parts must never be lubricated with grease!
Never use standard nuts instead of self-locking nuts!
Always use correctly dimensioned washers or spacers!
Cable binders which have been cut off during disassembly should be replaced with new ones
during reassembly!
After completing maintenance work and before operating the electric vehicle, make sure all
fixations are correctly secured! Check all parts for correct interlocking1
Only operate the electric vehicle with correct tyre pressure (see Technical Specifications)!
Check electrical components for correct functioning, incorrect polarity of cables can result in
damage to the electronics!
As a last check, always carry out a test-drive!
Notes
Mark all current settings for the electric vehicle (seat, armrests, backrest etc.), and the cable
connecting plugs associated, before any removals. This makes reassembly easier.
All plugs are fitted with mechanical safety devices which prevent release of the connecting plugs
during operation. To release the connecting plugs the safety devices must be pressed in. When
reassembling, ensure that these safety devices are correctly engaged.
WARNING: Any alteration to the drive programme can influence vehicle handling and the
tipping stability of the electric vehicle!
Alterations to the drive programme may only be carried out by trained Invacare® dealers!
Invacare® supplies all electric vehicles from the factory with a standard drive programme.
Invacare® can only assume a warranty for the safe vehicle handling of the electric vehicle –
in particular tipping stability - for this standard drive programme!
9
3 Tightening torques
The tightening torques stated in the following table are dependent on the thread diameters for the
nuts and bolts for which no special values are determined. All values apply to dry and grease-free
threads.
Thread
M4 M5 M6 M8 M10 M12 M14 M16
Tightening torque
in Nm ±10%
3 Nm 6 Nm 10 Nm 25 Nm 49 Nm 80 Nm 120 Nm 180 Nm
Caution: All other nuts or plastic connectors not noted here must be tightened
FINGERTIGHT!
10
4 Layout of modules, components and displays and
controls
The following figure shows the Typhoon II from behind with extended seat lifter and the rear
panelling removed.
1 Seat lean adjustment
2 Seat frames / rear panelling anti-collision
switch
3 Speed controller
4 Main module (power module)
5 Lighting/actuator module
The following figure shows the Typhoon II from front right with raised lifter.
1 Lifter servo motor
11
5 Service plan (1x annually)
Component Check Remedy Note
9
Armrests and side
panels
Armrest damage
and fastening
Side panel damage
and fixing
Tighten screws, replace
top surface if damaged
Tighten screws, replace
side panels if damaged
Seat unit /
adjustable seat
inclination
Top surface
Check adjustable
seat inclination
Replace cover /
upholstery if damaged.
Replace parts if damaged.
Mechanical backrest
Electrical backrest
Damage and
seams
Fixing
Check cable
Check function
Replace parts if damaged.
Tighten screws
Replace cable or motor if
necessary
Frame (chassis) /
battery mounting
Check fixings,
welded seams and
battery mounting
Tighten screws, replace
components
Wheel suspension
and wheels
Check drive wheels
for tight fit and side
play
Adjust, replace wheel
hubs
See "Replacing
and calibrating
drive motor" on
page 18
Check steering
wheels for tight fit,
float and side play
Replace wheels, wheel
fork or wheel bearings
See "Replacing
the steering head
bearings on the
front and rear
steering wheels"
on page 44
Check drive wheel
pneumatic tyres
Repair or replace if
damaged
see operating
manual
Drive units, clutch
mechanism
Check functions in
drive and push
modes
Check clutch
mechanism
Replace motor if
necessary
Tighten screws / nuts,
adjust or replace if
necessary
Legrests
Check welded
seams, interlocking,
screws, footplates
Tighten, remove if
necessary
Electrical legrests
Check cable
Check contacts
check functions
Replace cable if
necessary
Lighting
Check cable
Check function
Replace bulbs or cable if
necessary
Batteries
Check batteries for
damage
Replace batteries if
necessary
See "Replacing "
on page 30
Check battery
voltage
charge batteries
See operating
manual
Check contacts and
terminals
Clean contacts and
terminals
See "Replacing "
on page 30 for
safety information
on handling
batteries
12
Component Check Remedy Note
9
Remote / drive
electronics
Remote, status
display blinking
Fixing
Cable, connecting
plug
Joystick function
Power supply
Evaluate blinking code
Tighten, replace
Replace
Replace joystick
Replace cable, connecting
plug or console
Lifter module
Check for correct
functioning
Check locking
device function.
Repair if necessary.
Drive program
Check drive
electronics program
version Newer
version available?
Update software
See "Updating the
software" on page
41
13
6 Operational faults
6.1 Operational faults on electric wheelchair with ACS
If you have problems with the wheelchair, please proceed as follows:
First assess the possible cause of the problem using the following table.
Check the status display on the remote. Evaluate the blink error code.
Carry out the necessary checks and repairs as recommended in the following table.
NOTE:
You can find more information about operational faults on electric wheelchairs with GB motors in
the document entitled “Dynamic DX-GB-AS Power Module - Assembly Instructions”, order no.
1441533
6.1.1 Drive fault diagnosis
PROBLEM OTHER
SYMPTOMS
POSSIBLE
CAUSE
SOLUTION Documentation
Wheelchair
will not
start
Remote
status display
illuminates
normally
without
showing an
error code
Drive motors
possibly
disengaged
Re-engage drive
motors
See operating manual
Remote
status display
does not
illuminate
Batteries
possibly
defective
Replace
batteries
See "Replacing " on
page 30
Batteries
possibly over-
discharged
Pre-charge
batteries
See operating manual
Power supply
to remote
possibly
interrupted
Check master
fuse
See "Replacing the
main fuse" on page 36
Check cable
between
modules for
loose
connections or
damage
See "Checking the
cables" on page 38
Remote
possibly
defective
Replace the
remote on the
wheelchair in
order to rule out
the possibility
that the remote
is causing the
fault.
See "Replacing the
ACS Remote" on page
39
Remote
status display
blinking
Various causes
Assess error
code
See "REM24 Error
Codes and Diagnostic
Codes" on page 16
14
PROBLEM OTHER
SYMPTOMS
POSSIBLE
CAUSE
SOLUTION Documentation
Status display
on remote
blinking 2x,
drive display
on "U"
Speed
controller on
lifter possibly
defective or not
connected
Replace cable
or switch
See "Adjusting and
replacing the speed
reduction switch" on
page 43
Wheelchair
judders in
drive mode
None Batteries
possibly
defective
(voltage
unstable)
Replace
batteries
See "Replacing " on
page 30
Drive motor(s)
possibly
defective
Replace
motor(s)
See "Replacing and
calibrating drive
motor" on pages 18
and "Replacing and
calibrating drive
motor" on page 18
Batteries
not being
charged
None Batteries
possibly
defective
Replace
batteries
See "Replacing " on
page 30
LEDs blinking
on charging
unit
Charging
device possibly
defective
Replace
charging unit
See charging unit
operating manual
Wheelchair
runs too
slowly
Status display
on remote
blinking 2x,
drive display
on "U"
Seat lifter is not
in drive position
(either too high
or too low) and
has activated
automatic
speed
regulation.
Run the seat
lifter to the drive
position
See operating manual
Speed
controller on
seat lifter may
be badly
adjusted.
Adjust regulator
See "Adjusting and
replacing the speed
reduction switch" on
page 43
None Remote
possibly
defective
Replace remote
See "Replacing the
ACS Remote" on page
39
Batteries
possibly
defective
Replace
batteries
See "Replacing " on
page 30
15
6.1.2 Fault diagnosis with electric actuator motors
Please use the following table to assess fault causes when using electric actuator motors.
PROBLEM OTHER
SYMPTOMS
POSSIBLE
CAUSE
SOLUTION Documentation
Electric
actuator
motor does
not react
Remote shows
blinking "E",
status diode on
lighting/actuator
module does not
go out even if
the remote is
switched off or
disconnected.
Lighting /
actuator
module
defective
Replace
lighting/actuator
module
See "Replacing
electronic
components" on page
28
None Cable
possibly
disconnected
or damaged
Check to
ensure that the
cable has not
been
disconnected
or damaged.
Replace cable
if necessary
See "Checking the
cables" on page 38
Electrical
actuator
motor
possibly
defective
Test actuator
motor
See "Checking an
actuator motor" on
page 42
Remote
possibly
defective
Replace the
remote on the
wheelchair in
order to rule
out the
possibility that
the remote is
causing the
fault.
See "Replacing the
ACS Remote" on page
39
16
6.1.3 REM24 Error Codes and Diagnostic Codes
The drive electronics are capable of rectifying some errors automatically. In this case the status
display will cease to flash. Please switch the remote on and off several times. Wait approx. 5
seconds each time before switching the remote on again. If this does not rectify the error, locate
the error using the flash codes shown below.
Flash code: Meaning: Solution: Notes
1 x flash
Module defective
Replace defective module
See "Replacing electronic
components" on page 28
2 x flashes
Accessory error
(e.g. actuator
short-circuit)
Check accessory
connections, check
accessories
See "Checking an
actuator motor" on page
42
Lifter raised or
lowered too far
(seat not at driving
height)
If lifter is raised, lower in
stages until the status
display stops flashing. If
lowered too far, raise lifter
in stages until the status
display stops flashing. If
at all possible, only drive
when the seat is at driving
height.
See User Manual
3 x flashes
Connection on the
left motor
loose/defective
Check plug-in
connections.
See "Checking the
cables" on page 38
Left motor
defective.
Check/replace motor
See "Replacing and
calibrating drive motor"
on page 18
4 x flashes
Connection on the
right motor
loose/defective
Check plug-in
connections.
See "Checking the
cables" on page 38
Right motor
defective.
Check/replace motor
See "Replacing and
calibrating drive motor"
on page 18
5 x flashes
Fault/brake fault
on left-hand motor.
Connection
loose/defective or
motor defective.
Check plug-in
connections.
See "Checking the
cables" on page 38
Left motor
disengaged (GB-
motors)
Engage motor. Shut
electronics down and then
switch on again.
See User Manual
Both motors
disengaged
(standard motors)
Engage motors. Shut
electronics down and then
switch on again.
See User Manual
6 x flashes
Fault/brake fault
on right-hand
motor. Connection
loose/defective or
motor defective.
Check plug-in
connections.
See "Checking the
cables" on page 38
Right motor
disengaged (GB-
motors)
Engage motor. Shut
electronics down and then
switch on again.
See User Manual
7 x flashes
Battery dead
Pre-charge battery
See User Manual
8 x flashes
Battery voltage too
high
Switch lights on to lower
battery voltage
Check battery charger
See User Manual of battery
charger
17
Flash code: Meaning: Solution: Notes
9 or 10 x
flashes
Faulty data
transmission
between modules
-
Remove all electronic
modules except the Power
Module and the Remote.
Re-attach modules one by
one to determine which one
is causing the fault.
See "Replacing electronic
components" on page 28
11 x flashes
Motors overloaded
/ overheated
Switch remote on and off /
wait if necessary
-
12 x flashes
Module used has
compatibility
problems
Remove incorrect module
See "Replacing electronic
components" on page 28
18
7 Repair Work
CAUTION: Risk of damage to the vehicle! Collisions can be caused if shim rings are
removed from the drive wheels during installation work!
Shim rings are frequently placed between the drive shaft and the wheel hub to compensate
tolerances. Collisions can be caused if these shim rings are removed and not re-installed!
Please install all shim rings in exactly the same positions they were in before dismantling.
7.1 Replacing and calibrating drive motor
The following two sections describe how a GB motor is replaced and a new motor is calibrated. We
recommend that you read these instructions completely through before commencing work.
GUIDELINE – First find out whether the vehicle is fitted with puncture-proof tyres or
pneumatic tyres!
The course of action during disassembly is different depending on whether the vehicle is fitted
with puncture-proof tyres or standard pneumatic tyres ! You can recognise puncture-proof tyres
by the fact that they do not have a valve !
7.1.1 Replacing the motor
CAUTION! Danger because wheelchair can tip or roll away !
Prevent the wheelchair from tipping by inserting a wooden block which is long and wide
enough under the battery case! If the wooden block is too short or too narrow the wheelchair
can still tip!
Switch the wheelchair off at the remote!
EXPLOSION HAZARD!
If the wheelchair is fitted with pneumatic tyres, the wheel can explode if the air is not
released from the tyre before removing the wheel !
Always release the air from the wheel before it is removed (depress the small tappet in the
centre of the valve) !
CAUTION! If the wheelchair is fitted with
puncture-proof tyres, the liquid in the tyres
can block the valve when air is released if
the valve is at the bottom ! The air cannot
then be released!
Before releasing air from the wheel, always
turn the wheel so that the valve is at the top
!
Injury hazard! The wheelchair will drive in an uncontrolled manner if the GB motors are
not calibrated after being fitted new !
Ensure that the GB motors have been calibrated after being fitted!
19
Injury hazard! If the bolts which secure the wheel are not tightened firmly enough, or if the
threaded holes in the casing are damaged by being tightened too much, the wheel can
come loose during travel !
Always position the nuts manually in their holes when fitting the drive wheels.
Never use electrical or pneumatic screwdrivers !
Tighten the Allen screws with a torque of 25 Nm !
The Nordlock washers must be fitted exactly as they were before removal !
NOTES REGARDING GB MOTOR GUARANTEE:
If motors become defective within their guarantee period, they will either be replaced or repaired
on Invacare's decision. This guarantee does not cover pay for working hours. We also accept no
liability for physical injuries or unauthorised repairs. Invacare's sole obligation and its exclusive
remedy during this guarantee is limited to such repair and/or replacement measures.
Required parts/tools:
wooden block to support vehicle
Allen key 4 mm
Allen key 5 mm
Allen key 6m
Allen key 10 mm
circIip pliers
jaw spanner 10 mm
Torque wrench
Additional parts/tools for fitting puncture-proof tyres
tyre fitting paste (soap-based)
3 bolts M8 x 30mm (for provisional positioning of wheel rim during fitting)
NOTE:
Take note of small parts and the sequence in which components have been fitted. Arrange these
in a tidy sequence so that they are easier to refit in the correct sequence.
Loosen the fixing bolts (1) on the dirt
arrester using the 4 mm open-ended
spanner and remove them.
20
Support the wheelchair with wooden blocks.
Loosen the bolt (1) and disconnect the motor
cable plug.
7.1.1.1 Removing wheel rim and tyres on vehicle with pneumatic tyres
EXPLOSION HAZARD!
If the wheelchair is fitted with pneumatic tyres, the wheel can explode if the air is not
released from the tyre before removing the wheel !
Always release the air from the wheel before it is removed (depress the small tappet in the
centre of the valve) !
Unscrew valve cap.
Reduce the air pressure in the tyre by
depressing the valve tappet (1).
Loosen the five bolts (2) using the 6 mm
Allen key.
Remove the wheel rim halves and the inner
tube from the wheel.
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Invacare Typhoon II User manual

Category
Motor vehicle electronics
Type
User manual

Invacare Typhoon II is a reliable and innovative electric wheelchair designed to provide utmost comfort and mobility for its users. This advanced wheelchair boasts exceptional maneuverability, allowing you to navigate tight spaces and uneven terrains effortlessly. With its durable construction and user-friendly controls, the Invacare Typhoon II empowers you to maintain an active lifestyle and enjoy a greater sense of independence.

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