Invacare AVIVA RX Series Service Manual Download Page 3

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Contents

1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Symbols in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Images in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.1 Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Safety and Fitting Instructions . . . . . . . . . . . . . . . . . . . . . 5

3 Hygiene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.1 Handling of Returned Used Products . . . . . . . . . . . . . . . . 7

4 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.1 General information on setup . . . . . . . . . . . . . . . . . . . . . 8
4.2 Adjusting Seating Position . . . . . . . . . . . . . . . . . . . . . . . . 8

4.2.1 Adjusting Lower Leg Length . . . . . . . . . . . . . . . . . . . . 8
4.2.2 Adjusting Seat Depth . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2.3 Adjusting Centre of Gravity of Seat. . . . . . . . . . . . . . . 9

4.3 Adjusting Centre of Gravity — Ultra Low Maxx Seat . . . . . 9
4.4 Adjusting Centre of Gravity — Modulite Seat . . . . . . . . . . 12

4.4.1 Telescopic seat frame . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.5 Adjusting Seat Height . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.5.1 Adjusting Seat Height — Tilt with Fixed Pivot

Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.1 Testing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2 Testing Motor Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.3 Rain test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.4 Field Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.5 Checking Battery Charge Level . . . . . . . . . . . . . . . . . . . . . 16

6 Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

6.1 General Warning Information on Installation Work . . . . . . 18
6.2 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.3 Glossary of Frequently Used Mounting Hardware . . . . . . . 18
6.4 Overview Components . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

6.5.1 Operational Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.5.2 Drive Fault Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.5.3 Charging device fault diagnosis. . . . . . . . . . . . . . . . . . 22

6.6 Service Plan (Once a Year). . . . . . . . . . . . . . . . . . . . . . . . 22
6.7 Shrouds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

6.8 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6.8.1 Changing Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.8.2 Replacing Kerb Climber . . . . . . . . . . . . . . . . . . . . . . . 33
6.8.3 Replacing Rubber Foot . . . . . . . . . . . . . . . . . . . . . . . . 34
6.8.4 Replacing Tie-Down Points . . . . . . . . . . . . . . . . . . . . . 34
6.8.5 Replacing C.T.C. Suspension . . . . . . . . . . . . . . . . . . . . 35
6.8.6 Replacing and Adjusting Rear Suspension . . . . . . . . . . 36

6.9 Drive Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6.9.1 Replacing Motor-Gearbox Unit . . . . . . . . . . . . . . . . . . 37
6.9.2 Replacing or rotating motor/gearbox unit sealing

ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6.9.3 Replacing motor/gearbox clutch . . . . . . . . . . . . . . . . . 39
6.9.4 Replacing Engaging Turn Knob . . . . . . . . . . . . . . . . . . 40
6.9.5 Replacing Castor Fork. . . . . . . . . . . . . . . . . . . . . . . . . 41
6.9.6 Replacing Castor Lock. . . . . . . . . . . . . . . . . . . . . . . . . 43

6.10 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

6.10.1 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.10.2 Tyre Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.10.3 Tyre Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.10.4 Specific Tightening Torques. . . . . . . . . . . . . . . . . . . . 45

6.10.5 Overview of Power Wheelchair Models and

Wheel Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

6.10.6 Replacing Drive Wheel (5–Screw Installation) . . . . . . 48
6.10.7 Replacing Castor Wheel on Double-Sided Fork . . . . . 49
6.10.8 Replacing Castor Wheels on Single-Sided Fork. . . . . . 51
6.10.9 Replacing Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.10.10 Replacing drive wheel hub . . . . . . . . . . . . . . . . . . . 54

6.11 Electronics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

6.11.1 Replacing Power Module . . . . . . . . . . . . . . . . . . . . . 54
6.11.2 Replacing Bus Expansion Block (GLM-CONX4) . . . . . . 56
6.11.3 Replacing G-Trac Sensor . . . . . . . . . . . . . . . . . . . . . . 56
6.11.4 Replacing Operating Hour Counter/ Connecting

Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

6.11.5 Replacing Cable Harness. . . . . . . . . . . . . . . . . . . . . . 58
6.11.6 Updating Software . . . . . . . . . . . . . . . . . . . . . . . . . . 58

6.12 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

6.12.1 General Instructions on Handling Batteries . . . . . . . . 59
6.12.2 Handling Damaged Batteries Correctly . . . . . . . . . . . 59
6.12.3 Making Batteries Accessible . . . . . . . . . . . . . . . . . . . 59
6.12.4 Replacing Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.12.5 Replacing Circuit Breaker . . . . . . . . . . . . . . . . . . . . . 60
6.12.6 Checking Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

6.13 Lighting unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

6.13.1 Replacing Headlight . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.13.2 Replacing Headlight Holder. . . . . . . . . . . . . . . . . . . . 63
6.13.3 Replacing Rear Light . . . . . . . . . . . . . . . . . . . . . . . . . 64

6.14 Seating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

6.14.1 Replacing Actuator/Spindle — Tilt with Fixed Pivot

Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

6.14.2 Replacing Height Adjustment Bracket — Tilt and

Lifter-Tilt Modules . . . . . . . . . . . . . . . . . . . . . . . . . . 65

7 Mounting Dahl Docking System . . . . . . . . . . . . . . . . . . . . . . . 67

Summary of Contents for AVIVA RX Series

Page 1: ...Invacare AVIVA RX series AVIVA RX20 AVIVA RX40 AVIVA RX40HD en Power Wheelchair Service Manual PROVIDER Keep this manual The procedures in this manual MUST be performed by a qualified technician...

Page 2: ...whole or in part is prohibited without prior written permission from Invacare Trademarks are identified by and All trademarks are owned by or licensed to Invacare Corporation or its subsidiaries unles...

Page 3: ...32 6 8 1 Changing Wheelbase 32 6 8 2 Replacing Kerb Climber 33 6 8 3 Replacing Rubber Foot 34 6 8 4 Replacing Tie Down Points 34 6 8 5 Replacing C T C Suspension 35 6 8 6 Replacing and Adjusting Rear...

Page 4: ...ich have been approved by Invacare The product may only be maintained and overhauled by qualified personnel The minimum requirement for service technicians is suitable training such as in the cycle or...

Page 5: ...ive or possibly defective batteries Safety gloves It is possible that battery acid can be discharged when working on defective batteries or when handling batteries improperly Always wear acid proof sa...

Page 6: ...ll electrical components for correct function Note that incorrect polarity can result in damage to the control system Always carry out a trial run at the end of your work CAUTION Risk of injury and da...

Page 7: ...tation Manual cleaning Surface of used device Before repair or reconditioning Use saturated towel to apply cleaning detergent and remove residues after impact Cleaning and disinfection Disinfection Su...

Page 8: ...and reverse movement Make sure that steering wheels can rotate freely and have not contact to any fixed mobility device component WARNING Any changes to the drive program can affect the driving charac...

Page 9: ...choice of the centre of gravity CoG If the user is heavy and the seat depth is greater the focus should be the farther back For best possible driving characteristics of rear wheel drive mobility devi...

Page 10: ...rformance 530 mm 21 inch N A N A N A N A 555 mm 22 inch N A N A N A N A 490 mm 580 mm 23 inch N A N A N A N A 405 mm 16 inch 72 5 mm Performance considerations 72 5 mm Performance considerations 430 m...

Page 11: ...e 5 0 mm Performance considerations 530 mm 21 inch N A N A 5 0 mm Best performance 555 mm 22 inch N A N A 17 5 mm Best performance 520 mm 580 mm 23 inch N A N A 17 5 mm Best performance 405 mm 16 inch...

Page 12: ...me Fig 4 3 Variant narrow base Recommended positions of module Wheelbase Seat Depth Distance XX Comment 405 mm 16 inch N A N A 455 mm 18 inch N A N A 460 mm 505 mm 20 inch N A N A 405 mm 16 inch 50 0...

Page 13: ...NOT remove 3 Shift position of seat 4 Tighten screws 5 Install seat plate or sling seat 4 5 Adjusting Seat Height How you adjust the seat height depends on the seating system and the tilt mechanism M...

Page 14: ...ween seat and chassis or lower seat carefully to the chassis 1 Remove SL retainer clip D and pin E on top fixation of actuator Hold seat in position 2 Adjust seat height on top fixation according to t...

Page 15: ...s immediately A defective motor can damage the power module but a defective power module cannot damage the motor Phillips screwdriver size 2 Digital multimeter with resistance measurement 1 Remove shr...

Page 16: ...2 minutes 8 Sit in mobility device and place your feet against a door jam workbench or other stationary object 9 Carefully give forward command trying to drive the mobility device through the station...

Page 17: ...ecting a battery or charger Don t put new batteries into service before charging Fully charge a new battery before using Don t tip or tilt batteries Use a carrying strap to remove move or install a ba...

Page 18: ...screws nuts etc to the stated tightening torque Only tighten screws or nuts which are not listed here fingertight The tightening torques stated in the following list are based on the thread diameter...

Page 19: ...ries page 58 Completely discharged battery Pre charge batteries See user manual Check status of circuit breaker See user manual Power supply to remote interrupted Check cables between modules for loos...

Page 20: ...se power while driving None Bad connections Turn off electronics wait 10 seconds turn on electronics Check all cabling See 6 12 6 Checking Cables page 62 Clutch es defective Replace clutch See 6 9 1 R...

Page 21: ...e gearbox See 6 9 1 Replacing Motor Gearbox Unit page 37 and 6 9 3 Replacing motor gearbox clutch page 39 Gearbox makes clicking noise None Drive wheel loose Tighten drive wheel secure bolts with thre...

Page 22: ...se Battery charger not connected to mobility device Ensure that the battery charger has been connected to the mobility device No mains supply Check the mains supply with a voltmeter Defective mains su...

Page 23: ...play Replace wheels castor forks or wheel bearings See 6 10 Wheels page 44 Tyres Repair or replace if damaged See 6 10 Wheels page 44 Check suspension Repair or replace if damaged See 6 10 Wheels pag...

Page 24: ...ecessary Cables and connecting plugs Replace damaged cables and tighten connecting plugs if necessary Replace joystick knob if necessary Joystick function Replace remote if necessary Remote power modu...

Page 25: ...mobility device 2 Remove both power module shrouds See 6 7 1 Power Module Shrouds page 24 3 Unplug motor cable 4 Remove drive wheel See 6 10 6 Replacing Drive Wheel 5 Screw Installation page 48 5 Remo...

Page 26: ...es Fig 6 4 Parts of main frame shrouds A Front shroud B Middle shroud C Rear Shroud Removing Front Shroud 1 Loosen and remove hand screw D on bottom side of frame 2 Pull shroud A upwards Remove shroud...

Page 27: ...hroud 1 Loosen and remove screw G 2 Remove shroud C Fig 6 7 Installing Shrouds 1 Install middle shroud Make sure to install pins on rear side within corresponding holes E and F 2 Install remaining par...

Page 28: ...t may be necessary to remove tie wrap before installing cables to notch Install parts in reverse order Make sure that cables are correctly installed to notch of shroud 9 Remove tie wrap 10 Plug in all...

Page 29: ...nstall parts in reverse order 2 Install labels 3 Test all functions 6 7 6 Replacing Fender 1 Press in snap in element on inner side of fender A and pull fender upwards Remove fender 2 Replace fender m...

Page 30: ...ly ON OFF key Engage drive Before raising mobility device secure wheels by blocking them with wedges Prevent the mobility device tipping by propping it up on a wooden block which is long and wide enou...

Page 31: ...obility device tipping by propping it up on a wooden block which is long and wide enough under the battery case If the wooden block is too short or too high the mobility device can still tip TX40 Torx...

Page 32: ...tall rim cap with notch positioned at valve Position cap straight on rim and carefully push on outer edges for initial fixation Ensure not to damage fixation pins on rear side while installing to rim...

Page 33: ...sen and remove screw D and washer E on both sides 5 Move main frame G to desired position A B or C Fig 6 18 6 Install parts in reverse order 7 Adjust seat depth to meet requirements of user See user m...

Page 34: ...all functions 6 8 3 Replacing Rubber Foot 1 Pull front part of old rubber foot B off kerb climber A in forward direction 2 Place rear part of new rubber foot over kerb climber 3 Push front part of new...

Page 35: ...wooden blocks at least 7 5 cm x 7 5 cm x 30 cm Removing Main Frame 1 Place wooden block underneath mobility device and prop up mobility device 2 Remove seat 3 Loosen and remove screws A and washers B...

Page 36: ...Suspension 8 mm Allen key 17 mm wrench 19 mm wrench Water pump pliers Oblong wooden block at least 7 cm x 7 cm x 30 cm 2 wooden blocks at least 4 cm x 4 cm x 8 cm 1 Place wooden block underneath mobi...

Page 37: ...3 Tilt seat including main frame I forwards Place wooden block between carrier J and main frame I 4 Loosen suspension G 5 Move suspension to desired position A C or D according to table If required in...

Page 38: ...uts D and washers E 6 If fitted remove mounts for wheel lock G and fender F 7 Pull off unit H of bolts J Fig 6 26 8 If fitted remove adapter I Installing Unit 1 Check that sealing ring and unit are co...

Page 39: ...lling sealing ring 1 Install sealing ring so square hole for carriage screw is on inside of mobility device 2 Insert carriage screw through sealing ring 3 Install washer and self locking nut 4 Do not...

Page 40: ...to position of groove in axle of gearbox If necessary rotate motor and gearbox to correct position 4 Insert carriage bolt through locking ring Do not forget spacer sleeve 2 5 Install washer and self l...

Page 41: ...tion clockwise and drive position counterclockwise 6 9 5 Replacing Castor Fork Various forks can be installed to the mobility device The following instructions show a single sided fork as an example T...

Page 42: ...are not identical on both sides There is only one correct way to insert them Bearings must always be installed so that narrow borders of the ball bearings are facing each other inside Steering head bo...

Page 43: ...ee 6 7 3 Main Frame Shrouds page 25 3 Loosen and remove screw A washer B and locking device C Fig 6 35 4 Install parts in reverse order Make sure to install screw including washer to correct mounting...

Page 44: ...ructions on maintenance and repairs that can be performed by the user For the specifications of spare parts please see Technical Data or consult the service manual available from Invacare in this conn...

Page 45: ...replacement 6 10 6 Replacing Drive Wheel 5 Screw Installation page 48 Replacing Drive Wheel 1 Bolt Installation 6 10 7 Replacing Castor Wheel on Double Sided Fork page 49 6 10 8 Replacing Castor Whee...

Page 46: ...s indicate three tyre types pneumatic black valve cap puncture protected red valve cap puncture proof no valve Drive wheels 10 x 3 12 1 2 x 2 1 4 14 Models 4 Spoke Rim 1 Bolt Installa tion 3 Spoke Rim...

Page 47: ...ion 5 Spoke Rim 5 Screw Installa tion 5 Spoke Rim for True Track Solid Rim 5 screw installa tion Dragon Pronto M41 AVIVA RX For wheelchair specific mounting instruction see respective manual Castor Wh...

Page 48: ...ce Pay attention to hand and feet Use proper lifting techniques CAUTION Risk of Uncontrolled Movement of Mobility Device Turn off power supply ON OFF key Engage drive Before raising mobility device se...

Page 49: ...ays use new screws with undamaged coating Tighten screws to prescribed torque when mounting drive wheels Install parts in reverse order 6 When installing wheel pay attention to correct direction of ro...

Page 50: ...at least 14 x 14 x 30 cm Removing Wheel 1 Loosen and remove bolts A 2 Fig 6 39 Pull wheel C including axle D and bushing B out of fork E Installing Wheel CAUTION Risk of injury from wheels coming loo...

Page 51: ...lacing Castor Wheels on Single Sided Fork 24 mm wrench Oblong wooden block at least 14 x 14 x 30 cm Removing Wheel 1 Place wooden block underneath mobility device and prop up mobility device 2 Remove...

Page 52: ...d cause serious injury Do not inflate tyre if one or more rim threads are damaged Immediately replace rim with damaged threads WARNING Risk of Explosion There is considerable pressure in the tyre Risk...

Page 53: ...e that inner tube is not clamped between wheel rim halves 12 Make sure that tyre is contacting wheel rim directly 13 Inflate tyre to prescribed pressure 14 Make sure that tyre is still closely contact...

Page 54: ...3 Install wheel as described in respective chapter in this manual 6 10 10 Replacing drive wheel hub 19 mm wrench Removing drive wheel hub 1 Loosen and remove nut 7 2 Remove washer 6 3 Remove distance...

Page 55: ...downwards direction 2 Swivel module to bottom latch C Make sure that module is correctly installed on inner sides of latches see figure on right side Fig 6 45 3 Ensure to install lock washer D alongsi...

Page 56: ...cable from power module 3 Loosen and remove nut E and washer D 4 Remove bolt B and sensor C Installing sensor CAUTION Risk of injury and damage due to uncontrolled movement of mobility device An incor...

Page 57: ...d minus wires are connected wrong way it will damage electronic components of operating hour counter Make sure cable is connected correctly 1 Plug in blue wire to pin 2 and brown wire to pin 1 on coun...

Page 58: ...s CAUTION Fire and burns hazard if battery terminal is bypassed Take great care to ensure that the battery terminals are never short circuited with tools or mechanical mobility device parts Ensure tha...

Page 59: ...ician Always wear safety goggles and appropriate safety clothing when handling damaged batteries Place damaged batteries in an acid resistant receptacle immediately after removing them Only ever trans...

Page 60: ...attery 7 If necessary replace inlays Fig 6 52 Positive terminal serves as an example Installing Batteries A 52 Ah 60 Ah battery B 73 5 Ah battery 1 Install batteries in reverse order 2 Make sure that...

Page 61: ...ect negative terminal first then positive terminal a Remove tie wraps not shown b Remove terminal caps A c Loosen and remove terminal screws B together with washers C and cable lug from terminal Fig 6...

Page 62: ...t position See below 3 Plug in battery cable on power module 4 Install shrouds 5 Test all functions Adjusting Mounting Position of Holder 7 mm wrench 1 Loosen nut E 2 Move holder and circuit breaker t...

Page 63: ...me Shrouds page 25 2 Unplug cable and cut tie wraps from headlight affected 3 Pull cable out of guidance 4 Loosen and remove nut A and washer B 5 Remove bolt D washer B and headlight C 6 Replace headl...

Page 64: ...mponents between the base of the mobility device and the corresponding seating system For detailed instructions on the seating system see the service manual of the corresponding seating system 6 14 1...

Page 65: ...ight adjustment brackets for a seat with tilt or lifter tilt module Replacing the brackets by other variants see spare parts catalogue allows to retrofit another seat height to the mobility device CAU...

Page 66: ...t on wooden blocks Fig 6 61 5 Loosen and remove screws D on both sides 6 Replace brackets C on both sides 7 Re install screws Tighten screws Fig 6 62 8 Place seat including brackets on chassis 9 Chang...

Page 67: ...re not strong enough in the event of a collision Tighten screws 16 18 Nm 4 Mark where to cut screws 5 Remove screws lock plate and spacer 6 Cut screw It is very important to check correct length of sc...

Page 68: ...53 1 810 7085 ireland invacare com www invacare ie New Zealand Invacare New Zealand Ltd 4 Westfield Place Mt Wellington 1060 New Zealand Phone 0800 468 222 Fax 0800 807 788 sales invacare co nz www in...

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