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SERVICE MANUAL

PUMA 20/40

Summary of Contents for 20

Page 1: ...SERVICE MANUAL PUMA 20 40...

Page 2: ...eserves the right to changes and modifications The information provided is valid for the product in its standard version Handicare cannot be held liable for possible damage resulting from specificatio...

Page 3: ...nd modules Shark 22 4 4 Wiring and modules R net 24 4 5 Wiring and modules DX2 26 4 6 Wiring and modules VR 2 28 5 Service instructions 30 5 1 Maintenance plan 30 5 2 Assembly replacement and adjustme...

Page 4: ...Puma 20 40 4...

Page 5: ...ns are important when ordering parts Model Year of manufacture Colour Identification number Part number Name of the part concerned This information is provided on the identification plate See Identifi...

Page 6: ...ge to the wheelchair or the environment ATTENTION Suggestions and advice that help tasks or procedures involved to be carried out more easily Reference symbol The symbol refers to a separate user manu...

Page 7: ...burns If you do not use the wheelchair ensure that it is not exposed to direct sunlight for lengthy periods of time Certain parts of the wheelchair such as the seat the back and the armrests can beco...

Page 8: ...iately Decals and instructions on the wheelchair Decals and instructions on the wheelchair The signs symbols and instructions affixed to the wheelchair comprise part of the safety facilities They must...

Page 9: ...arious electronic settings Article numbers Description DX2 DX Shark Rnet Pilot VR 2 PC Hand Brand 1001893 Shark Programming adaptor DK ADAPT X X Dynamic 00355 0440 Hand Held Programmer DX HHP GDW X X...

Page 10: ...e part concerned cannot be purchased separately The part concerned is part of the assembly shown This assembly must be ordered as one piece It has to be replaced in its entirety Boxed position numbers...

Page 11: ...uspension arm and motors Puma 20 6 03 Suspension arm and motors Puma 40 7 04 Castor forks and wheels Puma 20 8 05 Castor forks and wheels Puma 40 9 06 Covers Puma 20 10 07 Covers Puma 40 11 08 Tilt an...

Page 12: ...53 Battery MK M24 12 Gel 74Ah C20 6a 6b 6c 6d 7 4 9005956 Battery spacer set universal 6a 6b 7 4 9005957 Battery spacer set MK 40 50A 6c 6d 7 4 9005958 Battery spacer set MK 60 74A 6 7 1 9005959 Batte...

Page 13: ...05938 Motor bracket left 28 33a 37 38 1 9005940 Motor right 6 Km h DX 28 32 33b 37 38 1 9005941 Motor left 6 Km h DX 28 32 34a 37 38 1 9005942 Motor right 6 Km h PG 28 32 34b 37 38 1 9005943 Motor lef...

Page 14: ...Km h DX left 35 39 40d 44b 1 9006784 Motor 4 pole Alpine 6 Km h DX right 35 39 41a 44a 1 9005951 Motor 6 Km h PG right 35 39 41b 44a 1 9005950 Motor 6 Km h PG left 35 39 41c 44b 1 9006785 Motor 4 pol...

Page 15: ...oor 2 80 2 50 4 punctureproof 8 11 12c 2 9005987 Castor wheel outdoor right 3 00 4 grey air 8 11 12d 2 9006820 Castor wheel outdoor left 3 00 4 grey air 8 11 12e 2 9005990 Castor wheel outdoor 3 00 4...

Page 16: ...10 14b 2 9006004 Castor wheel outdoor left 3 00 4 grey punctureproof 8 10 15a 2 9006002 Castor wheel outdoor 3 00 4 right black air 8 10 15b 2 9006001 Castor wheel outdoor 3 00 4 left black air 8 10...

Page 17: ...a 20 1 4 1 9005971 Battery cover black 3 4 1 9005972 Battery cover clips set 5 1 9004517 Battery access cover 6 7 1 9005973 Tube end covers dark grey set 8 1 9005970 Handicare logo Service 9 10 1 9005...

Page 18: ...cover dark grey 8a 16a 18a 19a 1 9005982 Deco covers green 8b 16b 18b 19b 1 9005983 Deco covers blue 8c 16c 18c 19c 1 9005984 Deco covers orange 8d 16d 18d 19d 1 9005985 Deco covers silver 9 1 9004517...

Page 19: ...0 Spare parts 19 08 Carrier and seat adjustments Tilt modules Puma 20 1 7 1 9006017 Electrical tilt 25 4 6 1 9006025 Til actuator mounting set 4 7 1 9006199 Tilt actuator 8 14 1 9006018 Electrical til...

Page 20: ...odules Puma 40 1 3 4 7 8 11 1 9006020 Electrical lift with electrical tilt 45 4 6 1 9006025 Til actuator mounting set 4 7 1 9006023 Tilt actuator 8 10 1 9006024 Lift actuator mounting set 8 11 1 90060...

Page 21: ...Article number Description Puma 20 40 Spare parts 21 10 Carrier and seat adjustments Kerb climber Puma 20 40 1 16 1 9005740 Kerb climber 7 15 1 9003571 Kerb climber gas spring 16 1 9003520 Kerb climb...

Page 22: ...DK ACU service 8 1 9006030 Shark Attendant Remote DK ACU bracket service 9 1 1002945 Shark bus cable 1 5m 10 1 1003094 Shark ACU connection cable 1 5m 11 1 9006429 Shark bus extension cable 0 9m 12 1...

Page 23: ...P 60 30 86 60 WR VHDW 86 6HDW WR 30 DEOHORRP 60 30 86 60 WR VHDW 86 6HDW WR 30 DEOHORRP 60 30 86 60 WR VHDW 86 6HDW WR 30 DEOHORRP 60 30 86 60 WR VHDW 86 6HDW WR 30 DEOHORRP 60 30 86 60 WR VHDW 86 6HD...

Page 24: ...ervice 7 1 9002912 R net Seating Lighting Module ISM 6L 6Act Lights service 8 1 9006238 R net 4 way Connector Block service 9 1 9006434 R net Cable 2 5m 10 1 9002481 R net Cable 1 0m 11 1 9002482 R ne...

Page 25: ...ZD ZD 30 86 ZD WR 60 60 LIW 86 ZD WR 30 86 ZD WR 30 86 ZD WR 30 86 ZD WR 30 LJKWV 7LOW LIW DFN HJV 8 LJKWV FDEOHV 1LNV KRRVH 9HUVLRQ FWXDWRU FDEOH 3 7 7HUP RPELQHG 7LOW FWXDWRU DQG HHGEDFN FDEOH GHJU...

Page 26: ...10 1 9006028 DX 2 Attendant Remote ACU3 service 11 1 9006032 DX 2 Attendant Remote ACU3 bracket service 12 1 9006239 DX 2 BUS 4 Way Socket DX SKT X4 service 13 1 00355 0023 DX 2 bus cable 1 0 m 14 1...

Page 27: ...OH LJKWV FDEOH LJKWV 7LOW LIW DFN HJV 8 1LNV KRRVH 9HUVLRQ FWXDWRU FDEOH 7HUP RPELQHG 7LOW FWXDWRU DQG HHGEDFN FDEOH GHJUHHV GHJUHHV 1LNV 7 86 7 WR ZD RPELQHG LIW FWXDWRU DQG HHGEDFN FDEOH 1LNV FWXDWR...

Page 28: ...service 8 1 9006033 VR 2 Dual Attendant Module bracket service 9 1 9002305 VR 2 Extension Cable 0 5m 10 1 9006853 VR 2 Extension Cable 1m 11 1 9006854 VR 2 Extension Cable 1 5m 12 1 9006855 VR 2 Exten...

Page 29: ...FDEOH 30 86 6HDW WR 30 DEOHORRP 60 LQFO P FDEOH 30 86 6HDW WR 30 DEOHORRP 60 LQFO P FDEOH 30 86 6HDW WR 30 DEOHORRP 60 LQFO P FDEOH 30 86 6HDW WR 30 DEOHORRP 60 LQFO P FDEOH 30 86 6HDW WR 30 DEOHORRP...

Page 30: ...atteries x Inspecting the drive x Inspecting the mechanical parts x Inspecting the bearings x Inspecting the suspension x Checking the tyres x Checking all fastenings and bolts tighten if necessary x...

Page 31: ...o be replaced use only dry batteries 5 2 Assembly replacement and adjustment instructions This chapter covers illustrated assembly replacement and adjustment instructions Every separate visual instruc...

Page 32: ...ace and seating Reprogram the wheel chair Note The visual instructions show all actions only on one side Carry out all actions also on the other side of the carrier Notice Use a lifting device to rais...

Page 33: ...vice instructions 33 Service instructions 33 3 Conversion set for converting RWD to FWD 4 Tools required Step 2 Remove interface and seating 1 2 Note Lift the chair in case the wheel chair has an elec...

Page 34: ...Puma 20 40 34 Service instructions 34 Service instructions 4 5 6...

Page 35: ...or reuse at step 5 2 Step 3 Change the direction of drive wheels and the mudguards only Puma 40 1 Note Use a lifting device to provide a proper working platform Note Position the lift completely under...

Page 36: ...The Puma 40 has mudguards take them off Step 4 Replace the anti tip wheels and brackets 1 Note Replace the anti tip wheels and brackets FWD into RWD 2 Note Use top mounting holes for Indoor anti tip...

Page 37: ...the key is still in place Note Tighten the bolts of the drive wheels with 25 Nm 2 Step 6 Change the position of the castor wheels 1 2 Note Tighten the shaft and nut of the castor wheels with 25 Nm Cau...

Page 38: ...Puma 20 40 38 Service instructions 38 Service instructions Step 7 Remount the interface and seating 1 2 3 4...

Page 39: ...able 2 0 m 055 00121 000 DX 2 bus cable 2 5 m R net 9002481 R net Cable 1 0m 9002484 R net Cable 1 5m R net with Lift 9002482 R net Cable 2 0m 9006434 R net Cable 2 5m VR 2 9006853 VR 2 Extension Cabl...

Page 40: ...Puma 20 40 40 Service instructions 40 Service instructions Step 8 Reprogram the wheelchair 1 Note Program the correct standard RWD program to the wheelchair...

Page 41: ...ount the kerb climber Switch off the wheelchair via the remote control Remove the leg rests Mount the mounting bracket of the kerb climber on the castor arms Mount the kerb climber on the mounting bra...

Page 42: ...Puma 20 40 42 Service instructions 42 Service instructions 5...

Page 43: ...his can be done in one way only Screw the new plastic screw cap onto the carbon brush holder Mount the motor mudguard anti tip wheel and driving wheel on the carrier Check the tyre pressures Notice Us...

Page 44: ...Puma 20 40 44 Service instructions 44 Service instructions 3 4 5 6 7 8...

Page 45: ...Puma 20 40 Service instructions 45 Service instructions 45 9 10 11 Note Inspect the collector on the anchor of the motor if the collector is seriously worn replace the entire drive unit 12 13...

Page 46: ...0 40 46 Service instructions 46 Service instructions 14 15 Note Check the key is still in place Note Tighten the bolts of the drive wheels with 25 Nm Note Bolts are provided with Loctite thread locker...

Page 47: ...Puma 20 40 carrier Inflate the tube to the correct pressure See Technical specifications Relevant article numbers Puma 20 00000 1703 Lock nut M10 P20 9005992 Drive wheel Indoor 12 1 2 x 2 1 4 air 9005...

Page 48: ...20 40 48 Service instructions 48 Service instructions 3 4 5 6 7 Note Check the key is still in place Note Tighten the bolts of the drive wheels with 25 Nm Note Bolts are provided with Loctite thread l...

Page 49: ...Puma 20 40 Service instructions 49 Service instructions 49 8 9...

Page 50: ...l Allen bolts and remove the front of the rim half Remove the tyre and the tube replace a new tube and or tyre Replace the tyre and tube on the rim half Mount the front of the rim half Replace the dri...

Page 51: ...Puma 20 40 Service instructions 51 Service instructions 51 3 4 5 6 7 Caution Deflate the tyre first before you dismantle the wheel Follow the steps as shown...

Page 52: ...tioned on the rim Caution Make sure the tube is not jammed between the two rim halves Note Inflate the tube to the correct pressure See Technical specifications 9 Note Check the key is still in place...

Page 53: ...Puma 20 40 Service instructions 53 Service instructions 53 11...

Page 54: ...50 4 puncture proof 9005987 Castor wheel outdoor right 3 00 4 grey air 9006820 Castor wheel outdoor left 3 00 4 grey air 9005990 Castor wheel outdoor 3 00 4 grey puncture proof Puma 40 9005998 Castor...

Page 55: ...instructions 55 Service instructions 55 3 4 5 Note Tighten the shaft and nut of the castor wheels with 25 Nm Caution Place at the Puma 20 on both sides of the castor wheel an extra ring between the wh...

Page 56: ...ee instruction Replacing the castor wheel Hold the wheel tight and remove the shaft Take the castor wheel out of the fork Loosen all Allen bolts and remove the front of the rim half Remove the tyre an...

Page 57: ...the tyre first before you dismantle the wheel Follow the steps as shown 6 Caution Ensure tube and tyre are properly positioned on the rim Caution Make sure the tube is not jammed between the two rim h...

Page 58: ...Puma 20 40 58 Service instructions 58 Service instructions 7 Caution Deflate the tyre first before you dismantle the wheel Follow the steps as shown 8...

Page 59: ...ll head cover and loosen the bolt washers and shaft that hold the castor fork in the castor arm Take the castor fork out of the castor arm Remove the fender from the castor fork only Puma 40 Replace t...

Page 60: ...Apply Loctite 243 to the bolt of the castor fork Note Tighten the bolt of the castor fork with 7 Nm 9 Note Tighten the shaft and nut of the castor wheels with 25 Nm Caution Place at the Puma 20 on bot...

Page 61: ...move the batteries from the battery tray Disconnect all connections from the batteries Replace the new batteries in reverse order Info Some parts need to be replaced this is indicated by a symbol Cont...

Page 62: ...A battery tray with batteries is a heavy load Be careful at the moment you undock the battery tray from the battery box Caution Undockthebatterytrayslowlyfromprojectioninthebatterybox 7 8 Caution Dis...

Page 63: ...tructions 63 9a Note Insert the battery spacer set correctly as shown in the next diagrams 9b Note Insert the battery spacer set correctly as shown in the next diagrams 10 Caution Dock the battery tra...

Page 64: ...Puma 20 40 64 Service instructions 64 Service instructions 11 12...

Page 65: ...replace the new power module in the reverse order Info Use a lifting device to raise the wheelchair Puma 20 40 carrier Some parts need to be replaced this is indicated by a symbol Always remove the f...

Page 66: ...Puma 20 40 66 Service instructions 66 Service instructions 3 4 5 6 Caution Dispose of the power module has to be done in accordance with local regulations 7...

Page 67: ...Puma 20 40 Service instructions 67 Service instructions 67 8...

Page 68: ...or without brackets With brackets Turn the drive wheel in the correct position Loosen through the rim the 2 bolts of the mudguard brackets on the motor arm Remove the mudguards with brackets Tighten t...

Page 69: ...Puma 20 40 Service instructions 69 Service instructions 69 3 4 5 6...

Page 70: ...ld cover and click back the new cover Deco ring motor arm set Take away the old cover and click back the new cover Deco strip under the suspension bridge cover Take away the old cover Click the new co...

Page 71: ...Puma 20 40 Service instructions 71 Service instructions 71 5 6 7...

Page 72: ...r of the lift supports Adjust the height of lift support 5 height adjustments are possible 0 25 50 75 100 Is the lift support in the lowest position Mount also the battery cover in the lowest position...

Page 73: ...Puma 20 40 Service instructions 73 Service instructions 73 3 Note Lift the chair in case the wheelchair has a lift 4 5 6...

Page 74: ...Puma 20 40 74 Service instructions 74 Service instructions 7 Note Keep the spacers for reuse for rebuilding the wheelchair 8 Caution Two people are needed to carry out this operation 9...

Page 75: ...Puma 20 40 Service instructions 75 Service instructions 75 10 11 Caution Two people are needed to carry out this operation...

Page 76: ...Puma 20 40 76 Service instructions 76 Service instructions 12 Note Reuse the spacers 13 Note Fasten the cables with tie wraps 14...

Page 77: ...Puma 20 40 Service instructions 77 Service instructions 77 15...

Page 78: ...ect position Remount the 4 bolts Replace the leg rests Notice Changing the wheelchair s centre of gravity may negatively influence the wheelchair s driving characteristics and or its dynamic stability...

Page 79: ...Puma 20 40 Service instructions 79 Service instructions 79 5 6 7...

Page 80: ...Puma 20 40 80 Service instructions 80 Service instructions 8...

Page 81: ...ma 20 40 front wheel drive FWD to rear wheel drive RWD Step 2 Remove interface and seating Loosen the 2 bolts in the interface frame Move the upper part of the interface in the desired position two ot...

Page 82: ...uma 20 40 82 Service instructions 82 Service instructions 3 Caution Changing the wheelchair s tilt position may negatively influence the wheelchair s driving characteristics Please read the user manua...

Page 83: ...ke m1 connection is faulty or loose Correct the connection The left hand parking brake m1 is defective Replace the parking brake ON OFF light flashes 6 times The right parking brake m2 connection is f...

Page 84: ...to the control system If the trip is still present after the above checks have been made then the Power Module may be defective M1 Motor Error 3B00 This occurs when the control system detects that a m...

Page 85: ...s most likely to be an indicator bulb failure Check the indicator bulbs cables and connections to the control system If the trip is still present after the above checks have been made then the ISM may...

Page 86: ...ram settings Check all parameter settings and re program the control system using the R net PC Programmer Make a note of the current parameter settings and then reset the control system to default set...

Page 87: ...the healthcare professional Gone to Sleep This occurs when the control system has been left inactive for a time greater than the parameter Sleep Timer An entry is made in the system log each time this...

Page 88: ...FF light flashes four times The right hand motor m2 connection is faulty or loose Check the connection and secure it The right hand motor m2 is defective Replace this motor Short circuit in the right...

Page 89: ...e weight distribution of the chair ON OFF light flashes 12 times System does not fit System modules are not compatible Program the entire drive system for the relevant wheelchair with the aid of the D...

Page 90: ...nd the cables Batteries may be empty charge the batteries Batteries may be damaged replace the batteries Batteries may be overcharged if driving downhill slow down 03 Actuator 00 01 02 03 Internal cur...

Page 91: ...Remote FC according to fault detected by Remote Actuator System Configuration Faults Module ID Collision 2 modules with same ID FC6 No DX BUS communication Actuator system will be missing None ACT Mo...

Page 92: ...p 7104 7 Joystick Trip refer to Type 7 Possible Joystick Trip 7147 User Dual Joystick Displaced Refer to Joystick Displaced at Power up 7902 Refer to High Temperature All Other Codes 7 or 8 Possible C...

Page 93: ...check the joystick cable and if you have authorization the joystick ribbon cable connections and mating sockets 7101 Loss of comms to the joystick check the joystick cable and if you have authorizatio...

Page 94: ...tches connected to Inhibit 2 If these appear to be in working order then the Power Module may be defective Refer to Section 5 Inhibit 3 Active This occurs when the Inhibit 3 Input is active The Inhibi...

Page 95: ...equirements as described in ISO 7176 19 2008 75 kg 7 2 Technical information Batteries Max Unit Maximum battery dimensions 2 260 x 172 x 210 10 25 x 6 75 x 8 25 mm inch Battery capacity 40 60 74 GEL 5...

Page 96: ...h mm inch 610 24 655 25 8 Total weight without batteries Batteries 40 Ah C20 set of two Batteries 50 Ah C20 set of two Batteries 60 Ah C20 set of two Batteries 74 Ah C20 set of two Electrical tilt adj...

Page 97: ...nformation 97 7 3 Electrical diagram Shark drive only To determine the correct remote control power module bus and cables for the Shark system in all possible models please follow the questionary in t...

Page 98: ...al product information Shark drive and lights To determine the correct remote control power module bus and cables for the Shark system in all possible models please follow the questionary in the Shark...

Page 99: ...roduct information 99 Shark drive lights seats To determine the correct remote control power module bus and cables for the Shark system in all possible models please follow the questionary in the Shar...

Page 100: ...100 Technical product information DX2 To determine the correct remote control power module bus and cables for the DX2 system in all possible models please follow the questionary in the DX2 flowchart...

Page 101: ...chnical product information 101 R net To determine the correct remote control power module bus and cables for the R net system in all possible models please follow the questionary in the R net flowcha...

Page 102: ...chnical product information VR 2 drive only To determine the correct remote control power module bus and cables for the VR 2 system in all possible models please follow the questionary in the VR 2 flo...

Page 103: ...al product information 103 VR 2 drive lights To determine the correct remote control power module bus and cables for the VR 2 system in all possible models please follow the questionary in the VR 2 fl...

Page 104: ...cal product information VR 2 drive lights seats To determine the correct remote control power module bus and cables for the VR 2 system in all possible models please follow the questionary in the VR 2...

Page 105: ...y that are demonstrably the direct consequence of material or manufacturing errors A fault or non functioning of the battery as a result of normal wear is not covered by the warranty as referred to in...

Page 106: ...andicare shall only accept liability for loss due to death or physical injury that is the result of a defect in the product for which Handicare is responsible and for damage to another object that is...

Page 107: ...numbers 1007080 9006237 00000 4042 and 00000 4035 position 14a 14d socket head screws 13 02 Added article numbers 9002784 9006360 and 9006452 position 32 37 and 38 14 03 Added article numbers 9006781...

Page 108: ...108 Puma 20 40...

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