Invacare FDX User manual

Edition: 26.03.2014

Invacare

FDX

SERVICE MANUAL

SERVICE MANUAL Invacare®- FDX

These instructions contain information about:

Testing work

Repair Instructions

This manual is part of the instructions for use.

Service addresses

Invacare Austria GmbH

Herzog Odilostrasse 101

A-5310 Mondsee

Austria

(: +43 6232 5 53 50

Fax: +43 6232 5 53 54

@: info@invacare-austria.com

WWW: www.invacare.at

Invacare n.v.

Autobaan 22

B-8210 Loppem (Brugge)

Belgium

(: +32 (0)50 83 10 10

Fax: +32 (0)50 83 10 11

@: belgium@invacare.com

WWW: www.invacare.be

Invacare AG

Benkenstraße 260

CH-4108 Witterswil

Switzerland

(: +41 (0)61487 70 80

Fax: +41 (0)61487 70 81

@: switzerland@invacare.com

WWW: www.invacare.ch

Invacare Aquatec GmbH

Alemannenstraße 10

88316 Isny

Deutschland

(+49 (0)7562 70 00

Fax +49 (0)7562 7 00 66

@: info@invacare-aquatec.com

WWW: www.invacare-aquatec.de

Invacare A/S

Sdr. Ringvej 37

DK-2605 Brøndby

Danmark

((Kundeservice): +45 (0)36 90 00 00

Fax (Kundeservice): +45 (0)36 90 00 01

@: denmark@invacare.com

WWW: www.invacare.dk

Invacare® SA

c/ Areny s/n

Polígon Industrial de Celrà

E-17460 Celrà (Girona)

ESPAÑA

(: +34 (0)972 49 32 00

Fax: +34 (0)972 49 32 20

@: contactsp@invacare.com

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

@: contactfr@invacare.com

WWW: www.invacare.fr

Invacare® Ltd

Pencoed Technology Park

Pencoed

Bridgend CF35 5HZ

United Kingdom

((Customer services): +44 (0)1656 77 62 22

Fax (Customer services): +44 (0)1656 77 62 20

@: uk@invacare.com

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

@: italia@invacare.com

WWW: www.invacare.it

Invacare®- FDX SERVICE MANUAL

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

@: ireland@invacare.com

WWW: www.invacare.ie

Invacare® AS

Grensesvingen 9

Postboks 6230

Etterstad

N-0603 Oslo

Norge

((Kundeservice): +47 (0)22 57 95 00

Fax (Kundeservice): +47 (0)22 57 95 01

@: [email protected]

@: island@invacare.com

WWW: www.invacare.no

Invacare® B.V.

Celsiusstraat 46

NL-6716 BZ Ede

Nederland

(: +31 (0)318 69 57 57

Fax: +31 (0)318 69 57 58

@: [email protected]om

@: [email protected]

WWW: www.invacare.nl

Invacare Lda

Rua Estrada Velha, 949

P-4465-784 Leça do Balio

Portugal

(: +351 225 10 59 46

(: +351 225 10 59 47

Fax: +351 225 10 57 39

@: [email protected]om

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

@: [email protected]

@: finland@invacare.com

WWW: www.invacare.se

MÖLNDAL

(: +46 (0)31 86 36 00

Fax: +46 (0)31 86 36 06

@: ginvacare@invacare.com

LANDSKRONA

(: +46 (0)418 2 85 40

Fax: +46 (0)418 1 80 89

@: linvacare@invacare.com

OSKARSHAMN

(: +46 (0)491 1 01 40

Fax: +46 (0)491 1 01 80

@: oinvacare@invacare.com

Eastern

european

countries

European Distributor

Organisation (EDO)

Kleiststraße 49

D-32457 Porta Westfalica

Deutschland

(+49 (0)5731 75 45 40

Fax +49 (0)5731 75 45 41

@: [email protected]om

WWW: www.invacare.de

SERVICE MANUAL Invacare®- FDX

Table of contents

Chapter Page

1INTRODUCTION 8

1.1 General information 8

1.2 Notes on transport 8

1.3 Definition and representation of information and safety information in this manual 9

1.4 Hazard symbols and symbols used 10

1.5 Images in this manual 11

2SAFETY AND FITTING INSTRUCTIONS 12

2.1 Before any inspection or repair work 12

2.2 Personal safety equipment 12

2.3 General safety information and information about fitting / removal 12

3TIGHTENING TORQUES 14

4ARRANGEMENT OF SUB-ASSEMBLIES AND COMPONENTS 15

4.1 Overview 15

4.2 Electronic modules 16

4.2.1 ACS 2 PMB70 / ACS 2 PMB70L electronic module 17

4.2.2 ACS 2 PMA90L electronic module 17

4.2.3 Actuator module ACT 17

4.2.3.1 Actuator module ACT2 17

4.2.3.2 Actuator module ACT 4 18

4.2.4 Lighting circuit board 18

4.3 Remotes 19

5MAINTENANCE PLAN (ONCE A YEAR) 21

6OPERATIONAL FAULTS 24

6.1 Drive fault diagnosis 25

6.2 REM remotes: Error codes and diagnostic codes 29

6.3 Diagnosis of charging device faults 31

Invacare®- FDX SERVICE MANUAL

7TEST PROCEDURES 32

7.1 Testing the motor 32

7.2 Testing the electro-mechanical parking brake 33

8REPAIR WORK 35

8.1 Covers 35

8.1.1 Open front cover 35

8.1.2 Opening the rear cover 36

8.1.3 Opening the lateral cover 37

8.1.4 Opening the cover of the rear wheel cantilever arm 40

8.2 Electronic modules 41

8.2.1 Replacing remotes 41

8.2.2 Replacing electronic modules 41

8.2.3 Replacing the G-Trac sensor 44

8.2.4 Drive program selection after component replacement 46

8.2.4.1 Profile selection with G90A remote 46

8.2.4.2 Profile selection with remote REM A or REM B 47

8.2.4.3 Profile selection with remote REM 550 48

8.3 Updating the driving program 49

8.4 Batteries, cables & battery chargers 50

8.4.1 Removing the batteries 50

8.4.2 Replacing batteries / replacing battery cables 53

8.4.3 How to handle damaged batteries correctly 55

8.4.4 Replacing the main fuse 55

8.4.5 Checking the cables 56

8.5 Replacing the battery boxes 58

8.6 Lighting system 59

8.6.1 Replacing light bulbs in the front (conventional lighting system) 59

8.6.2 Replacing the LEDs in the front (LED lighting system) 59

8.6.3 Replacing the complete head lamp assembly (conventional lighting system until 03/12) 60

8.6.4 Replacing headlamps completely (conventional lighting system starting 03/2012) 62

8.6.5 Replacing the head lamps completely (LED lighting system until 03/2012) 64

8.6.6 Replacing headlamps completely (LED lighting system starting 03/2012) 66

8.6.7 Replacing the head lamp bracket (conventional lighting system until 03/0212) 68

8.6.8 Replacing headlamp brackets (conventional lighting system starting 03/2012) 69

8.6.9 Replacing the front bulb holder (LED lighting system until 03/2012) 70

8.6.10 Replacing a light bulb in the rear (conventional lighting system) 71

8.6.11 Replacing the LEDs in the rear (LED lighting system) 71

8.6.12 Replacing the complete tail lamp assembly (conventional lighting system) 72

8.6.13 Replacing the tail lamp bracket (conventional lighting system) 74

8.6.14 Replacing the tail lamps completely (LED lighting system) 75

8.7 Rear wheels 76

8.7.1 Replacing a rear wheel 76

8.7.2 Replacing a rear wheel fork 77

8.7.3 Adjusting the wheel fork 79

8.8 Drive wheels 81

8.8.1 Replacing a drive wheel 81

8.8.2 Replacing a tyre 82

8.8.3 Replacing a drive wheel hub 83

SERVICE MANUAL Invacare®- FDX

8.9 Replacing the spring in the rear 85

8.10 Replacing the anti-tipper wheels 87

8.11 Drive unit 88

8.11.1 Replacing the motor / gearbox unit 88

8.11.2 Replacing or rotating the motor / gearbox unit sealing ring 90

8.11.3 Replacing the motor / gearbox coupling 91

8.11.4 Replacing the carbon brushes 93

8.11.5 Running the motor in 95

8.12 Replacing the motor / gearbox fixation and rear wheel cantilever arm 96

8.13 Seat adjustment standard 98

8.13.1 Seat / seat frame (without lifter) 98

8.13.2 Replacing the tilt module / lifter module 101

8.13.2.1 Replacing the tilt module (without lifter) 101

8.13.2.2 Replacing the lifter / tilt module 104

8.13.2.3 Replacing the tilt actuator 108

8.13.2.4 Replacing the lifter actuator 110

8.13.3 Seat frame 116

8.13.3.1 Adjusting the seat width 116

8.13.3.2 Adjusting the seat depth 118

8.14 Centre-mounted legrest (electric & manual) 122

8.14.1 Replacing the manually operated centre-mounted legrest 122

8.14.2 Replacing the electrically operated centre-mounted legrest 123

8.14.3 Replacing the electrically operated centre-mounted legrest LNX (Modulite seat) 125

8.14.4 Replacing an electric legrest actuator 126

8.14.5 Replacing the calf plate on the centre-mounted legrest (electric & manual) 128

8.14.6 Replacing the foot plate on the centre-mounted legrest (electric & manual) 129

8.15 Back unit 130

8.15.1 Replacing the standard back 130

8.15.2 Adjusting the belt back 131

8.15.3 Replacing the EasyAdapt back 132

8.15.4 Replacing / adjusting the universal backrest frame for the EasyAdapt backrest 133

8.16 Back unit with ergonomic length adjustment 136

8.16.1 Adjusting the width 136

8.16.2 Replacing the planetary gear 137

8.16.3 Replacing the servo motor 139

8.16.4 Replacing the microswitch 140

8.16.5 Fitting back plates to the base support of the back with ergonomic length adjustment 141

8.16.6 Fitting the handlebar 142

8.16.7 Replacing the travelling armrest 143

8.16.8 Replacing the arm support on the travelling armrest 144

8.16.9 Retrofitting a travelling armrest 145

8.17 Seat adjustment Modulite 146

8.17.1 Seat / seat frame Modulite (without lifter) 146

8.17.2 Replacing the tilt actuator 149

8.17.3 Replacing the lifter actuator 150

8.17.4 Replacing the lifter / seat angle adjustment module 151

8.17.5 Replacing the backrest actuator 154

8.18 Backrest Modulite 155

8.18.1 Replacing the standard backrest 155

8.18.2 Replacing the backrest mounting bracket 156

8.18.3 Replacing the backrest mounting bracket for SB 53 157

Invacare®- FDX SERVICE MANUAL

8.18.4 Adjusting the seat width/ backrest width 158

8.18.4.1 Adjusting the seat width 158

8.18.4.2 Adjusting the seat width (legrest LNX) 160

8.18.4.3 Adjusting the backrest width 162

8.18.4.4 Adjusting the Flex3 backrest 164

8.19 Fixation rings 165

8.19.1 Replacing a front fixation ring 165

8.19.2 Replacing a rear fixation ring 166

9INSTALLING ACCESSORIES 167

9.1 Replacing the restraining belt 167

9.2 Replacing the harness belt 168

9.3 Replacing seat belts (Modulite seat) 170

9.3.1 Installation on the backrest mounting bracket (simple backrest) 170

9.3.2 Installation on the backrest mounting bracket (adjustable seat) 171

9.3.3 Installation on the seat frame profile (adjustable seat) 172

9.3.4 Replacing the harness belt (adjustable seat) 173

9.3.5 Replacing the harness belt (simple seat) 175

9.4 DAHL Docking Station 177

9.5 Fitting the stick holder 180

9.6 Further accessories 181

SERVICE MANUAL Invacare®- FDX

1 Introduction

1.1 General information

●Service and maintenance work must be carried out taking this service manual into account.

●It is imperative that you observe safety information.

●Information about operation or about general maintenance and care work on the mobility aid

should be taken from the operating manual.

●You can find information about ordering spare parts in the spare parts catalogue.

●Only use original Invacare® spare parts. The guarantee will become invalid if other spare parts

are used!

●We reserve the right to make any alterations on the grounds of technical improvements.

●The mobility aid may only be maintained and overhauled by qualified personnel.

●The minimum requirement for service technicians is suitable training, such as in the cycle or

orthopaedic mechanics fields, or sufficiently long-term job experience.

- Experience in the use of electrical measuring equipment (multimeters) is also a requirement.

- Special Invacare® training is recommended.

●Alterations to the mobility aid which occur as a result of incorrectly or improperly executed

maintenance or overhaul work lead to the exclusion of all liability on the side of INVACARE.

●If you have any problems or questions please contact Invacare® Service.

1.2 Notes on transport

●If the mobility aid has to be shipped back to the manufacturer for major repairs, you should

always use the original packaging for transport.

●Please attach a precise description of the fault.

Invacare®- FDX SERVICE MANUAL

1.3 Definition and representation of information and safety

information in this manual

Different types of information and signal words are used throughout this manual.

HAZARD!

The signal word "HAZARD!" refers to immediate hazards.

●The following lines in italics refer to actions which serve to avoid such hazards.

WARNING!

The signal word "WARNING!" refers to possibly-occurring hazards which can lead to

death or serious injuries if they are not avoided.

●The following lines in italics refer to actions which serve to avoid such hazards.

ATTENTION!

The signal word " ATTENTION!" refers to possibly-occurring hazards which can lead to

minor injuries and/or material damage if they are not avoided.

●The following lines in italics refer to actions which serve to avoid such hazards.

CAUTION!

The signal word "CAUTION!" refers to hazards which could lead to material damage if

they are not avoided.

●The following lines in italics refer to actions which serve to avoid such hazards.

Note

The signal word "Note" is used to denote general information which simplifies the handling of

your product and refers to special functions.

SERVICE MANUAL Invacare®- FDX

1.4 Hazard symbols and symbols used

Different types of hazard symbols and symbols are used throughout this manual.

General hazards

This symbol warns you of general hazards!

●Always follow the instructions to avoid injury to the user or damage to the product!

BURN HAZARD!

This symbol warns you of the danger of chemical burns, for example due to the discharge

of battery acids!

●Always follow the instructions to avoid injury to the user or damage to the product!

DANGER OF CRUSHING!

This symbol warns you of crushing hazards due to inattentive working with heavy

components.

●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, 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!

Wear safety shoes

The symbol refers to the requirement for wearing safety shoes.

●Wear standardised safety shoes during all work.

Wear eye protection

This symbol refers to the requirement for wearing eye protection, for example when

working with batteries.

●Wear eye protection when this symbol is shown.

Wear safety gloves

This symbol refers to the requirement for wearing safety gloves, for example when

working with batteries.

●Wear safety gloves when this symbol is shown.

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. Please do not attempt to carry out the work if you do not have

the listed tools available.

Always dispose used or damaged batteries correctly

The symbol refers to information for the correct disposal of used or damaged batteries.

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