Invacare Kite Service Manual Download Page 60

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SERVICE MANUAL

Invacare

- Kite

Uninstalling the headlight bracket:

•

Loosen both Torx screws (2).

•

Remove the headlight bracket (1).

•

Replace the bracket.

Installing the headlight bracket:

•

Assemble all parts again in reverse order.

•

Tighten the screws hand-tight.

•

Check all vehicle functions.

Summary of Contents for Kite

Page 1: ...Edition 11 09 2013 Invacare Kite SERVICE MANUAL ...

Page 2: ...zerland 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...

Page 3: ...wn 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 norway invacare com 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...

Page 4: ...acare com 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...

Page 5: ...on about fitting removal 13 3 Tightening torques 15 4 Layout of components and componentry 16 4 1 Overview 16 4 2 Overview of the electronic modules ACS 2 system 17 4 2 1 ACS 2 70 ACS 2 70L ACS 2 90L electronic module 19 4 2 2 ACS 2 90LG electronic module 19 4 2 3 ACT actuator module 19 4 2 3 1 ACT 2 actuator module 19 4 2 3 2 ACT 4 actuator module 20 4 2 4 Lighting PCB 20 5 Service plan 1x annual...

Page 6: ...ing and replacing the main fuse 49 8 6 Checking the cables 51 8 7 Lighting system 52 8 7 1 Replacing front headlight completely LED lighting unit 52 8 7 2 Replacing the front bulb holder LED lighting unit 54 8 7 3 Replacing the rear light completely LED lighting unit 55 8 7 4 Replacing light bulbs in the front Conventional lighting system 56 8 7 5 Replacing the head lamps completely conventional l...

Page 7: ... 15 1 Replacing the tilt actuator 89 8 15 2 Replacing the tilt module 91 8 15 3 Replacing the lifter tilt module 93 8 16 Backrest unit 97 8 16 1 Replacing the standard backrest 97 8 16 2 Replacing a standard backrest with quick release 99 8 16 3 Replacing a Flex2 backrest 100 8 16 4 Adjusting backrest former 101 8 17 Seat system Modulite 102 8 17 1 Replacing the tilt actuator 102 8 17 2 Replacing ...

Page 8: ...lacing the connecting cable of the operating hours counter 122 9 4 Luggage carrier 124 9 5 Further accessories 125 10 Adjusting the seating position 126 10 1 Adjusting the lower leg length and seat depth 127 10 1 1 Adjusting the lower leg length 127 10 1 2 Adjusting the seat depth 127 10 2 Adjusting the seat angle 128 10 2 1 12 Adjusting the seat angle with Standard seat or Flex2 seat 129 10 2 2 2...

Page 9: ...y 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 o...

Page 10: ...e 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...

Page 11: ...ructions 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...

Page 12: ...acare Kite 12 1 5 Images in this manual The detailed images in this manual are given digits to identify various components Component numbers in text and operational instructions always relate to the image directly above ...

Page 13: ...s possible that battery acid can be discharged when working on defective batteries or when handling batteries improperly Always wear acid proof safety gloves when working on any defective or possibly defective batteries 2 3 General safety information and information about fitting removal WARNING Danger of crushing Various components such as the drive unit batteries seat etc are very heavy This res...

Page 14: ...l run at the end of your work CAUTION Danger of injury and damage to property if the maximum speed reduction on a wheelchair with a lifter does not function correctly The wheelchair s control unit must reduce the maximum possible speed as soon as the lifter is raised Test the maximum speed reduction for correct function after any maintenance work or modifications to the wheelchair Note Mark all cu...

Page 15: ...rmined All values assume dry and de greased 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 Damage can be caused to the mobility device due to improperly tightened screws nuts or plastic connections Always tighten screws nuts etc to the stated tightening torque Only tighten screws or nuts which are not listed here finger...

Page 16: ... 4 Layout of components and componentry 4 1 Overview Under the rear cover 1 G Trac sensor 2 Power module 3 Lighting PCB 4 Actuator module The electronic modules used are described in Chapter 4 2 Electric seat tilting 1 Actuator motor ...

Page 17: ...rman Road Traffic Act StVZO LED lighting Extension cable Actuator cable lifter Extension cable 10 11 12 13 14 15 16 End position switch lower position End position switch upper position Remotes ACS attendant control switchable Bus cables Bus cables ACT 17 18 19 A B C D E F G G Trac sensor Bus cables Power module To the motor M1 To the motor M2 To the tilt actuator To the lifter actuator To the lif...

Page 18: ... ACS 2 70 ACS 2 70L ACS 2 90L ACS 2 90L G ACS 2 wiith ACT actuator module See chapter 4 2 1 See chapter 4 2 1 See chapter 4 2 1 See chapter 4 2 2 See chapter 4 2 3 The actuator module is optional Actuator module ACT 2 ACT 4 See chapter 4 2 3 1 See chapter 4 2 3 2 The actuator module is optional Lighting PCB See chapter 4 2 4 The lighting PCB is optional G Trac sensor The G Trac sensor is optional ...

Page 19: ...or M2 4 2 3 ACT actuator module Different adjusting motors also known as actuators can be fitted to the mobility aid These actuators are either connected directly to the power module or to a separate actuator module The actuator module is connected to the power module via a bus cable 4 2 3 1 ACT 2 actuator module Connections 1 ACI 2 Bus cable ACT or power module 3 Bus cable ACT or power module 4 A...

Page 20: ...l 1 Rubber stoppers for free slots 1 Order number 1555701 2 3 Order number 1552876 4 to 7 Order number 1555700 The ACI connection is used for actuator limitation or speed reduction 4 2 4 Lighting PCB Connections 1 Driving light l h indicator 1 2 Driving light l h indicator 2 3 Power module 4 Driving light r h indicator 1 5 Driving light r h indicator 2 The lighting PCB connections are printed dire...

Page 21: ...eplace seat lock Seat angle adjustment Tight seating of SL fuses Replace SL fuses if necessary Power backrest if fitted Damage to backrest Seams Fixing Check cable Check function Replace parts if damaged Tighten screws Replace cable motor if necessary Frames chassis battery mounting Check fixings welded seams and battery mounting Tighten screws Replace components if necessary Wheel suspension and ...

Page 22: ...batteries See operating manual Check contacts and terminals Clean contacts and terminals Please refer to the safety information in Chapter 8 4 for handling batteries Remote electronic module Remote status display blinking Evaluate error blink code Fixings Tighten fixings replace if necessary Cables and connecting plugs Tighten cables and connecting plugs replace if necessary Drive lever function R...

Page 23: ...e remote status display Evaluate the error code Carry out the necessary checks and repairs as recommended in the following table 6 1 Drive fault diagnosis PROBLEM OTHER SYMPTOMS POSSIBLE CAUSE SOLUTION Documentation Mobility device will not start The remote status display illuminates normally and does not show an error code Drive motors disengaged Engage drive motors See operating manual Remote st...

Page 24: ...arging unit See charging unit operating manual Mobility device runs too slowly None Remote defective Replace remote See chapter 8 2 5 Batteries defective Replace batteries See chapter 8 4 Electrical actuator does not respond Remote displays flashing E status diode on light actuator module does not extinguish even if the remote is shut down or disconnected Lighting actuat or module faulty Replace l...

Page 25: ...rror in motor M1 Connection loose faulty or motor faulty Check connection plug check motor See chapters 8 6 and 7 1 4 x blink Error in motor M2 Connection loose faulty or motor faulty Check connection plug check motor See chapters 8 6 and 7 1 5 x blink Fault brake fault in motor M1 Connection loose or faulty or motor faulty Check connection plug check motor See chapters 8 6 and 7 1 6 x blink Fault...

Page 26: ...of all cables and the sockets that they are connected to Mark the connectors and sockets or take a photograph with a digital camera Disconnect the motor plug 1 of the motor to be tested from the power module Connect the digital multimeter to the motor plug contacts 3 and measure the resistance between the contacts Note A resistance of between 0 5 and 5 ohms indicates a motor ready for operation A ...

Page 27: ... circuited brakes immediately Note A defective motor can damage the power module but a defective power module cannot camage the motor Requirements digital multimeter with resistance measurement Use the remote to identify which motor is possibly defective as described in chapter 6 2 Switch the electronics OFF on the remote Remove the rear cover as described in chapter 8 1 1 Take exact note of the p...

Page 28: ...istance between the contacts If there is a defect replace the motor and send it to Invacare Service for inspection or repair Note A resistance of between 40 and 80 ohms indicates an intact brake A resistance of 0 ohms or a very high resistance mega ohms or infinity indicates a short circuit a bad connection or a defective brake ...

Page 29: ...t they are connected to Mark the connectors and sockets or take a photograph with a digital camera Disconnect the motor plug 1 of the motor to be tested from the actuator module Check the electrical resistance at the plug 1 of the actuator The plug can have a different shape than show in the illustration If the resistance is close to infinity the motor is probably burnt out If the resistance is be...

Page 30: ...wheelchair 8 1 Covers 8 1 1 Rear cover Removing the rear cover Loosen and remove the left and right thumbscrews 1 on the rear cover 2 Carefully pull the rear cover backwards and off On models with LED lighting system tail lights in the rear cover Pull both of the tail light plugs off of the lighting circuit board Assembling the rear cover On models with LED lighting system Plug both of the tail li...

Page 31: ...ws 1 on the left and right sides of the wheelchair Pull the cover towards the rear and out of the wheelchair Assembling the middle cover Push the cover into the wheelchair from the rear Make sure that the cables that run from the battery box to the seat are lying in the recesses provided on the front edge of the cover Tighten both thumbscrews hand tight ...

Page 32: ...Kite 32 8 1 3 Side cover Requirements 4 mm Allen wrench Removing the side cover Use a 4 mm Allen wrench to loosen the hexagon socket head screw 1 Remove the cover 2 Installing the side cover Assemble the parts in reverse order ...

Page 33: ...rench 24 mm box wrench torque wrench 20 200 Nm wooden blocks Removing the front cover Disassemble the double bearing of the Dual Swing Technology D S T as described in chapter 8 13 Use a 4 mm Allen wrench to loosen both hexagon socket head screws Remove both hexagon socket head screws including the washers Remove the cover 2 towards the front Replace the cover Installing the front cover Assemble t...

Page 34: ...uirements 4 mm Allen wrench 24 mm socket wrench 24 mm open ended wrench Flat screwdriver Oblong wooden blocks at least 14 x 14 x 30 cm Medium strength thread locking adhesive for example Loctite 243 Heat gun Lift the wheelchair on one side and place a 14 cm high wooden block underneath it so that the front wheel is off the ground and can rotate freely Use proper lifting techniques Remove the front...

Page 35: ...o be fitted depending on the depth of the seat the width of the seat and the seat support plates used Removing the splash guard Loosen and remove the two Allen screws 2 incl the washers Remove the splash guard 1 from the transmission mounting 3 Replace the splash guard Refitting the splash guard Refit the parts in reverse order ...

Page 36: ...es to the drive program may only be carried out by trained Invacare specialist dealers Invacare can only give a warranty for safe mobility aid driving behaviour especially tipping stability for unaltered standard drive programs Note All power modules are delivered with a standard drive program If you have made any customer specific modifications to the drive program these must be adapted after the...

Page 37: ... guides Replace the power module Installing the power module Assemble the parts in reverse order Reconnect all cable connectors to their former positions Plug all free slots with a suitable rubber stopper see chapter 4 2 Select the driving program as described in chapter 8 2 6 Update the driving program if a new software version is available as described in chapter 8 3 Modify the driving program u...

Page 38: ...bles and the sockets that they are connected to Mark the connectors and sockets or take a photograph with a digital camera Disconnect the plugs 3 from the actuator module 2 Loosen both screws 1 with a Phillips screwdriver Replace the actuator module Installing the actuator module Assemble the parts in reverse order Reconnect all cable connectors to their former positions Plug all free slots with a...

Page 39: ...ors and sockets or take a photograph with a digital camera Disconnect the plug 3 of the G Trac sensor 1 from the power module 2 Loosen the M6 nut 4 and push the G Trac sensor upwards Pull the G Trac sensor backward and out Replace the G Trac sensor Installing the G Trac sensor Insert the square end piece into the slot provided for this purpose When installing the G Trac sensor make sure it is posi...

Page 40: ...e of the positions of all cables and the sockets that they are connected to Mark the connectors and sockets or take a photograph with a digital camera Disconnect the plug 2 from the lighting circuit board 1 Loosen and remove both screws on the lighting circuit board 3 Replace the lighting circuit board Installing the lighting circuit board Assemble the parts in reverse order Reconnect all cable co...

Page 41: ... installation manual available from Invacare Note All electronic modules are supplied with a standard drive programme If you have performed customer specific modifications to the drive programme then these will need to be recreated manually after installing the new electronic module WARNING Every alteration to the drive programme can influence vehicle handling and the tipping stability of the whee...

Page 42: ...he profile is selected afterwards 8 2 6 1 Profile selection with remote REM A or REM B Insert the plug into the remote or into the power module respectively Switch the remote on LEDs 1 and 4 blink Use the bottom rocker switch 5 to select where the required controller profile is saved LED 1 power module LED 4 remote Only LED 1 or 4 blinks now depending on the selection Press the Horn 2 and 3 button...

Page 43: ...ile Use the bottom rocker switch 3 to select where the required controller profile is saved I remote II power module The display shows which profile you have selected Press the Horn 4 and 1 buttons on the speed selection and hold them down for 3 seconds to confirm the selection The system will switch itself off and restart automatically In the process the selected profile is saved in the remote an...

Page 44: ...ration to the drive program can influence vehicle handling and the tipping stability of the wheelchair Alterations to the drive program must only be carried out by trained Invacare dealers Invacare can only assume a warranty for the safe vehicle handling of the wheelchair in particular tipping stability for unaltered standard drive programs Pre requisites Dynamic Wizard software User manual for th...

Page 45: ...The batteries are extremely heavy This results in injury hazards to your hands Bear in mind that the batteries are sometimes very heavy Please handle the batteries with care WARNING BURN HAZARD Injury hazard due to discharged acid Always wear acid proof protective gloves when handling batteries Always wear protective goggles when handling batteries What to do if acid is discharged Always take clot...

Page 46: ...tery cable from the electronic module Loosen and remove both of the knurled head screws 4 Loosen and remove the knurled head screws 2 Turn the rear cover 1 down along with the electronic modules Pull foam rubber block 3 backwards out of the battery box ...

Page 47: ... cable Pull the battery 3 out onto the rear cover by its belt 4 Remove the battery Pull the second battery towards you by its belt and repeat the previous steps Installing batteries Install the batteries in reverse order Make sure the battery box sockets and plugs are correctly installed A diagram showing how to connect the battery terminals correctly can be found in the rear cover ...

Page 48: ...act with eyes is made Rinse the affected eye under running water for several minutes You should also consult an eye specialist immediately afterwards Requirements protective goggles acid proof gloves acid proof transport container If handling damaged batteries always wear suitable protective clothing Always deposit damaged batteries in suitable acid proof containers immediately after removal Only ...

Page 49: ...ighten the nuts with 3 3 or 3 5 Nm 1 Strip fuse 2 Spade terminal 3 DIN 6923 nut Requirements 8 mm socket wrench 11 mm socket wrench 80 A strip fuse Note If the fuseholder is damaged you can replace this complete with the battery cables Dismantling the main fuse Switch the electronics OFF on the remote Remove the rear battery as described in chapter 8 4 The fuse holder is located on top of the rear...

Page 50: ...may only be replaced once the fault has been rectified Remove the strip fuse nuts 3 with an 8 mm socket spanner Replace the strip fuse Fitting the main fuse Refit all the parts again in reverse order To conclude check all the mobility aid functions ...

Page 51: ...he plug must not come out of its socket when pulled on lightly If a plug is loose apply slight pressure to push the plug into the socket The plug must snap in place securely Check that the plug is firmly attached to its socket Remove the batteries as described in chapter 8 4 Check the battery cables for visible damage crushing points or abrasion points Replace damaged cables Assemble all parts aga...

Page 52: ...binder Uninstalling head lamps Switch the electronics OFF on the remote Remove the rear and the middle covers as described in chapter 8 1 1 und 8 1 2 Take exact note of the positions of all cables and the sockets that they are connected to Mark the connectors and sockets or take a photograph with a digital camera Disconnect the plug 2 of the appropriate headlight from the lighting circuit board 1 ...

Page 53: ...ug from the lighting PCB Free the cable or remove any cable ties Loosen the nut 2 with a 7 mm jaw spanner and a 3 mm Allen key Remove the front headlight 1 from the lamp holder 3 Reassembly takes place in the reverse order To complete check all vehicle functions ...

Page 54: ...blique pliers cable binder Loosen the nut 2 with a 7 mm jaw spanner and a 3 mm Allen key and remove Remove the front headlight 1 from the lamp holder 3 and place it carefully to the side Undo and remove the two screws 4 with a TX25 torx screwdriver Replace the lamp holder 3 Reassembly takes place in the reverse order To complete check all vehicle functions ...

Page 55: ...lens 1 together slightly Pull the tail light lens carefully off of the rear cover 4 Disconnect the plug of the tail light 2 and of the turn signal 3 from the tail light cable 5 Press the clips of the tail light lens or the turn signal together slightly Pull the corresponding light towards the rear and out of the rear cover Replace the faulty part Installing the tail light Re assembly is done in re...

Page 56: ...ghting system Requirements Phillips screwdriver size 2 Loosen the concealed Phillips head screw 1 on the back of the head lamp turn indicator combination Remove the transparent plastic cover Replace the defective light bulb Reposition the cap and tighten the Phillips head screw hand tight ...

Page 57: ...on the remote Remove the rear and the middle covers as described in chapter 8 1 1 und 8 1 2 Take exact note of the positions of all cables and the sockets that they are connected to Mark the connectors and sockets or take a photograph with a digital camera Disconnect the plug 2 of the appropriate headlight from the lighting circuit board 1 Pull the headlight cable out of the wheelchair If necessar...

Page 58: ...s Assemble all parts again in reverse order Install the cables carefully and secure them with cable ties Tighten the screws hand tight Check all vehicle functions Perform an approximate adjustment of the headlight using the ratchet plate as a guide The final adjustment can be performed by the user according to the instructions found in the User Guide ...

Page 59: ...ements TX25 Torx wrench Phillips screwdriver size 2 If the headlight does not need to be replaced Loosen both Phillips screws 1 Detach the headlight 2 from its holder Carefully put the headlight aside on its cable If the headlight does need to be replaced Remove the headlight as described in chapter 8 7 5 ...

Page 60: ...talling the headlight bracket Loosen both Torx screws 2 Remove the headlight bracket 1 Replace the bracket Installing the headlight bracket Assemble all parts again in reverse order Tighten the screws hand tight Check all vehicle functions ...

Page 61: ...nal lighting unit Requirements Phillips screwdriver size 2 Undo the Phillips screw in the transparent cover over the rear light indicator combination Remove the transparent plastic cover Replace the defective bulb Close the cover and tighten the Phillips screw finger tight ...

Page 62: ...s and the sockets that they are connected to Mark the connectors and sockets or take a photograph with a digital camera Disconnect the cable of the affected tail light from the lighting circuit board Remove both plastic covers 1 Use the 8 mm socket wrench to loosen both nuts 2 Remove the nut and the washers 3 Pull the tail light 5 towards the rear and off and remove both bushings 4 Installing the ...

Page 63: ...7 8 Loosen the screw on the seat frame that goes through the drill hole of the light bracket using a 5 mm Allen wrench Remove the hexagon socket head screw Pay attention to the distance washer 1 Use a 4 mm Allen wrench to loosen the hexagon socket head screw 6 Remove the hexagon socket head screw Pay attention to the distance washer 5 and the distance tube 3 Replace the lamp bracket 4 Installing t...

Page 64: ...ncorrect reassembly can damage the bearings and cause the steering wheels to fall out The single row angular ball bearing rings are not identical on both sides There is only one correct way to insert them Follow the assembly instructions precisely Requirements open ended spanner 19 mm Torque wrench large screwdriver flat wooden block approx 12 x 12x 30 cm for propping up vehicle Note When disassem...

Page 65: ...emoved Pull the steering head shaft upwards out of the steering head tube Take the washers out of the tube Take the ball bearing out of the tube The adjacent figure shows an overview of the individual parts 1 Plastic cap 2 Ball bearing 3 19 mm nut Reassembly takes place in reverse order to disassembly Ensure that you insert the ball bearings exactly as described below Also ensure that the washers ...

Page 66: ...e facing each other inside The steering head bolts and nuts must always be pressing against the wide outside border of the ball bearings Otherwise the bearings will be pressed apart and damaged by the bolts The illustrations show the wide border of the ball bearing on the outside of the ball race A and the narrow ball bearing edge on the inside B After assembly the steering wheels should rotate fr...

Page 67: ...y by placing wedges under the wheels Requirements 24 mm socket wrench 24 mm open ended wrench Flat screwdriver Oblong wooden blocks at least 14 x 14 x 30 cm Medium strength thread locking adhesive for example Loctite 243 Heat gun Removing the wheel Prop up the wheelchair on multiple wooden blocks Use proper lifting techniques Use a Phillips screwdriver to remove the plastic cap 5 Heat up the nut 4...

Page 68: ...er 3 Take the wheel 1 off the axle 2 Refitting the wheel Refit the parts in reverse order When installing the wheel pay attention to the correct direction of rotation Apply medium strength thread locking adhesive to the nut 4 when re positioning it ...

Page 69: ... against rolling away by placing wedges under the wheels Requirements 5 mm Allen key 13 mm open ended wrench Oblong wooden blocks at least 14 x 14 x 30 cm Removing the wheel Prop up the wheelchair on multiple wooden blocks Use proper lifting techniques Counter the axle 3 using an open end wrench Loosen and remove the hexagon socket head screw 5 Pay attention to the washer 4 Pull the axle out of th...

Page 70: ...vehicle against rolling away by placing wedges under the wheels Requirements 6 mm Allen key Long wooden blocks min 14 x 14 x 30 cm Removing the drive wheel Lift the wheelchair on one side and place a 14 cm high wooden block underneath it so that the drive wheel is off the ground and can rotate freely Use proper lifting techniques Loosen the four or five 6 mm Allen screws 1 Take the wheel 2 off the...

Page 71: ...aps puncture proof tyres have no valves Please proceed in accordance with the appropriate chapter Replacing pneumatic tyres see user manual Replacing puncture protected tyres see chapter 8 9 2 1 Replacing puncture proof tyres see chapter 8 9 2 2 8 9 2 1 Replacing puncture protected tyres Note Pneumatic tyres have black valve caps Puncture protected tyres have red valve caps Requirements 6 mm Allen...

Page 72: ... air from the tyre Undo the five 6 mm Allen screws 4 on the inside of the wheel Remove the inner 3 and outer 6 ring of the rim from the tyre 1 Replace any defective or worn parts Refitting the tyres Refit the inner tube in the tyre Note If the old inner tube is to be repaired and re used and has become wet during repair you can make replacement easier by sprinkling the inner tube with a little tal...

Page 73: ...xpected discharge with three joiner s clamps When doing so ensure that you do not scratch the rims Undo the five 6 mm Allen screws 2 on the inside of the wheel Now loosen the joiner s clamps carefully and alternately until you can remove the rim rings without danger Remove the inner 3 and outer 1 ring of the rim from the tyre 4 Replace any defective or worn parts Refitting the tyres Refit the tyre...

Page 74: ...ed and not replaced again collisions can be caused Always replace the adjusting washers exactly as they were before you started dismantling Requirements 19 mm socket spanner Uninstalling a drive wheel hub Use the 19 mm socket wrench to loosen and remove the nuts 7 Remove the washer 6 Remove the distance ring 5 Pull the wheel hub 4 off of the axle 2 Remove the shim ring 3 Remove the feather key 1 f...

Page 75: ...g wedges under the wheels ATTENTION Danger of crushing The motor gearbox unit is extremely heavy Injury hazards to hands Please note the high weight Requirements 6 mm Allen key 19 mm socket spanner long wooden blocks min 14 x 14 x 30 cm Removing the motor transmission unit Switch the electronics OFF on the remote Remove the rear battery box cover as described in chapter 8 1 1 Pull the motor plug o...

Page 76: ...ing ring is correctly mounted The sealing ring securely attaches the motor and the gearbox The ring must be installed such that the self locking nut is located on the outside If the sealing ring is incorrectly installed rotate it around as described in chapter 8 10 2 Install the motor gearbox unit in reverse order Use the scale to align the motor to the centre axis 1 2 pole motors Left 200 Right 2...

Page 77: ... 10 1 Use the 10 mm socket wrench to loosen and remove the self securing nuts 4 including the washers Remove the carriage bolt which secures the sealing ring 2 Carefully bend the sealing ring apart and remove it Installing the sealing ring Install the sealing ring so that the square hole for the carriage bolt is on the inside of the wheelchair Insert the carriage bolt through the sealing ring Inst...

Page 78: ...x unit as described in chapter 8 10 1 Use the 10 mm socket wrench to loosen and remove the self securing nut 4 Remove the carriage bolt which secures the sealing ring 2 Carefully bend the sealing ring apart and remove it WARNING Danger of damage to the wheelchair if the coupling is not serviced correctly Be careful not to damage the coupling mechanism during maintenance work Carefully pull the mot...

Page 79: ... the gearbox Pay attention to the position of the groove in the axle of the gearbox If necessary rotate the motor and gearbox to the correct position Insert the carriage bolt through the locking ring Do not forget the spacer sleeve 2 Install the washer and the self locking nut Do not tighten the self locking nut completely as the motor orientation must be adjusted during installation Install the m...

Page 80: ...chair Pay attention to the hand and feet Use proper lifting techniques Requirements 6 mm Allen key 10 mm socket spanner blade screwdriver long wooden blocks min 14 x 14 x 30 cm Removing the carbon brushes Switch off the mobility aid Remove the drive wheels as described in chapter 8 9 1 Disengage the motor 1 by setting the engaging lever to Push Note In the case of the SSD motor you can unto the bo...

Page 81: ...he motor round in position so that the engaging lever can be set both to the Push and the Travel position Now retighten the bolt 5 fingertight Refit the drive wheels as described in chapter 8 9 1 Note The following procedure is necessary to run the carbon brushes in after replacement and thus guarantee maximum performance WARNING Risk of accidents Hazards to workers surroundings and mobility devic...

Page 82: ... the weight of the wheelchair Pay attention to the maximum load capacity of the crane and the breaking strength of the belts Never position yourself under heavy objects suspended in the air by cranes or pulleys Uninstalling rubber shock absorbers Remove the rear and the middle battery box covers as described in chapter 8 1 1 und 8 1 2 Use the 13 mm socket wrench to loosen and remove the self secur...

Page 83: ...Invacare Kite SERVICE MANUAL 83 Installing rubber shock absorbers Assemble the parts in reverse order Tighten the rubber shock absorbers and nuts hand tight ...

Page 84: ...ter 8 15 2 Remove both tail light brackets as described in chapter 8 7 9 Remove both rubber shock absorbers as described in chapter 8 11 Remove both front forks as described in chapter 8 8 2 WARNING Risk of damage to the tube frame You should counter the bearing bolt against slippage but do not turn it Secure the bearing bolt 1 against slippage using a second 24 mm open end wrench Use a 19 mm box ...

Page 85: ...Invacare Kite SERVICE MANUAL 85 Assembling the tube frame Assemble the parts in reverse order Tighten the self locking nuts 4 to a torque of 120 Nm ...

Page 86: ...vers as described in chapter 8 1 3 Remove all cables that run from the electronic modules on the battery box to the seat for example to the remote or actuators or to the tube frame for example to the lighting system Place wooden blocks under the battery box so that it is secured in its present position Loosen the lower screws on both rubber shock absorbers as described in chapter 8 11 WARNING Risk...

Page 87: ...ve the hexagon socket head screw together with the Nord Lock washer 6 and the spacer ring 2 Pull the double bearing 3 off of the bearing bolt Remove and inspect the floating bearings 4 5 Replace the bearings if they are damaged or worn Replace the double bearing Assembling the double bearing of the Dual Swing Technology D S T Assemble the parts in reverse order Tighten the hexagon socket head scre...

Page 88: ... Take exact note of the positions of all cables and the sockets that they are connected to Mark the connectors and sockets or take a photograph with a digital camera Remove all electronic modules as described in chapter 8 1 58 4 and its subchapters Remove both batteries as described in chapter 8 4 Remove both drive wheels as described in chapter 8 9 1 Remove both motor gear box units as described ...

Page 89: ... OFF on the remote Remove the rear and the middle covers as described in chapter 8 1 1 und 8 1 2 Take exact note of the positions of all cables and the sockets that they are connected to Mark the connectors and sockets or take a photograph with a digital camera Disconnect the plug 1 of the actuator to be tested from the actuator module Pull the actuator cable out of the wheelchair If necessary als...

Page 90: ...he adjustment spindle out together with the actuator Insert the new adjustment spindle with the actuator Reinsert the fixing bolts and SL fuses Fix the SL fuses securely to the fixing bolt with the hammer Connect the plug of the actuator to the electronic module Fasten the actuator cable to the frame with new cable ties Position the cable such that it does not get abraded or pinched To complete ch...

Page 91: ...ies Remove the legrests If possible tilt the seat back as far as it will go Switch the electronics OFF on the remote Remove the rear and the middle covers as described in chapter 8 1 1 und 8 1 2 Take exact note of the positions of all cables and the sockets that they are connected to Mark the connectors and sockets or take a photograph with a digital camera Disconnect the plug 1 of the actuator to...

Page 92: ...front and a 13 mm open end wrench for the two in the back Remove the seat support 1 from the tilt module 3 Use the 10 mm Allen wrench to loosen and remove both screws 1 Use the 24 mm open end wrench and the 24 mm box wrench to loosen and remove both screws 2 Remove the lifter from the vehicle frame and replace it Re assembly is done in reverse order Test all functions of the vehicle ...

Page 93: ...ote of the exact position of the seat Mark the position it is mounted in the angle and so on If necessary make photographs with a digital camera Any modification of the adjustment of the seat affects the centre of gravity of the wheelchair Uninstalling the lifter tilt module If possible raise the lifter to the highest position If possible tip the wheelchair with the tilt module as far backwards as...

Page 94: ...ies that secure the cable at the ends of the power supply chain Pull the cable out of the power supply chain Use the Phillips screwdriver to loosen the screws 1 Remove the power supply chain 2 Use the Phillips screwdriver to loosen the screws 4 Additionally the sensor 5 is secured with nuts Loosen the nuts while holding a 6 mm wrench against Remove the magnet 3 Remove the sensor 5 ...

Page 95: ...nds and feet Use proper lifting techniques Loosen the four screws 1 that attach the seat to the lifter tilt module using a 5 mm Allen key Lift the seat up off of the lifter module tilt module Use proper lifting techniques Disconnect the plug 1 from the actuator module Free up all cables so that you can lift the seat off ...

Page 96: ... 5 Tighten the connecting screws of the seat tilt mounting brackets and the seat frame mounting brackets to 18 Nm When installing the cables again make sure that they are placed in such a way that they cannot be crushed or damaged in any position of the tilt module ATTENTION Danger of crushing The seat is very heavy Danger of injury to hands and feet Use proper lifting techniques Install the seat ...

Page 97: ...d remove the handwheels 3 Use two 13 mm socket spanners to undo the bolts 4 including the nuts and washers on the left hand and right hand side of the chair Remove the backrest tube 1 from the backrest holders 2 If the backrest holders also need to be replaced Undo and remove the Allen screws 5 including the nuts and washers on the left hand and right hand side of the chair To do this use a 5 mm A...

Page 98: ...SERVICE MANUAL Invacare Kite 98 Refitting the backrest unit Replace the parts in the reverse order To conclude you should always carry out a trial run to test the vehicle functions ...

Page 99: ... right hand side of the chair Pull the quick release cord 5 to unlock the backrest tube Remove the backrest tube 1 from the backrest holders 2 If the backrest fixations are to be replaced also Loosen and remove the hexagon socket head screws 3 including the nuts and washers on the left and right side of the chair Use a 5 mm Allen key and a 10 mm socket wrench for this purpose Refitting the backres...

Page 100: ... Remove the backrest tube 1 from the backrest mounting bracket 2 Loosen and remove the screws 3 including the sleeve and washers with a Torx Bit TX40 wrench on the left and right side of the chair Remove the backrest mounting bracket 2 Refitting the backrest unit Replace the parts in the reverse order To conclude you should always carry out a trial run to test the vehicle functions ...

Page 101: ... user s back shape Pull the front and rear faces of the backrest upholstery 1 apart and remove The backrest upholstery front and rear faces are held together using Velcro fastenings Open the backrest belt 2 Velcro fastenings and adjust to the required length Reattach the backrest upholstery and fix with Velcro fastenings ...

Page 102: ...ixing bolt 2 secured with snap rings 1 Remove a snap ring using a screwdriver and remove the bolt Pull the actuator out Insert a new actuator Reassembly takes place in the reverse order Connect the actuator cable to the cable harness To complete check all seat tilting function Variant seat angle adjustment actuator in the lifter seat angle adjustment module Bottom fixing bolt 3 with slot Loosen th...

Page 103: ...cured with snap rings Remove a snap ring using a screwdriver and remove the bolt Top fixing bolt 3 with slot Loosen the fixing bolt with a screwdriver Remove the bolt Replace actuator Reassembly of the actuator takes place in the reverse order Connect the plug of the actuator cable to the actuator To complete check all seat tilting function If the lifter cannot be raised a cover can be removed fro...

Page 104: ...e cutting pliers Cable ties Remove legrests Tilt the seat tilting completely to the rear if possible Switch the electronics OFF on the remote Remove the backrest cushion Loosen and remove the screws which secure the middle seat plate A with a 3 mm Allen key Remove the middle seat plate B Loosen and remove the screws on both sides which secure the lateral seat plates C with a 3 mm Allen key Remove ...

Page 105: ...Invacare Kite SERVICE MANUAL 105 Remove the seat frame by removing the screws 1 with a T40 Torx wrench Disconnect the actuator cable and microswitch cable from the cable harness ...

Page 106: ...oosen and remove the screws 2 incl the washers with a 5 mm Allen key Lift the module of the seat angle adjustment 1 from the adapter and replace it Reassembly takes place in the reverse order To complete check all seat tilting function ...

Page 107: ... cable off directly where it is connected to the actuator 1 Detach the bracket of the actuator at the top and bottom to do this slide the bolts 3 to the side using the lever 4 and tilt the actuator 1 out of the backrest clamp 2 Replace actuator Refitting the backrest actuator Assemble the parts in the reverse order ...

Page 108: ... cushion Loosen the fixation lever 2 of the backrest tube Remove the backrest tube Use the Allen key to loosen and remove the hexagon socket head screws 3 including the nuts and washers on the left and right side of the chair Refitting the backrest unit Replace the parts in the reverse order To conclude you should always carry out a trial run to test the vehicle functions ...

Page 109: ...krest tube 1 depending on the version There are two versions 2 for the manual backrest 3 for the electrically adjustable backrest Remove the backrest tube Loosen and remove the two hexagon socket head screws 4 to the sliding block 5 on the left and right side of the chair Refitting the backrest unit Replace the parts in the reverse order To conclude you should always carry out a trial run to test ...

Page 110: ...g backrest tube 1 depending on the version There are two versions 2 for the manual backrest 3 for the electrically adjustable backrest Remove the backrest tube Loosen and remove the two hexagon socket head screws 4 to the sliding block 5 on the left and right side of the chair Refitting the backrest unit Replace the parts in the reverse order To conclude you should always carry out a trial run to ...

Page 111: ...apter 8 19 2 Requirements 3 mm Allen key 5 mm Allen key 13 mm open ended spanner T25 Torx wrench T40 Torx wrench Remove the backrest cushion Remove the backrest from the backrest mounting bracket See chapter 8 18 Loosen and remove the screws which secure the middle seat plate A with a 3 mm Allen key Remove the middle seat plate B Loosen and remove the screws on both sides which secure the lateral ...

Page 112: ...desired width according to the following illustrations and tables Seat frame Screw position Seat width A 530 mm B 480 mm C 430 mm D 380 mm Leg supports connection Screw position Seat width A 380 mm B 430 mm C 480 mm D 530 mm Note When switching from 430 mm to 480 mm and the other way around the fixation of the legrests must be replaced Reposition the screws and tighten them again Install the seat ...

Page 113: ... 16 4 Flex3 backrest as described in chapter 8 19 3 Replace the backrest cushion these are available in various widths When modifying the backrest width the seat width must also be correspondingly adapted Please see chapter 8 19 1 Requirements 3 mm Allen key 5 mm Allen key 13 mm Open ended spanner The screw position for the backrest width refer to the table Screw position Seat width A 530 mm B 480...

Page 114: ...n both sides Adjust the backrest fixation 6 for the new backrest width according to the table on page 113 Insert the screws 2 through the cover of the actuator fixation bracket and the corresponding holes of the backrest fixation to the actuator fixation Fasten these with the nuts 4 Reposition the cover of the actuator fixation bracket Insert and tighten the screws 5 again Adjust the straps of the...

Page 115: ... screws 3 Remove both Phillips screws A on the middle plate Shift the position of the rear plate halves three settings are possible using the drill holes Before pulling the Flex3 backrest apart a 1 will be visible in the small rectangular cut out After pulling the Flex3 backrest apart a 2 will be visible in the small rectangular cut out Re insert the two screws A into the middle plate Fasten the f...

Page 116: ...nd 4 as a spacer so that the belt mounting can rotate freely Remove the plastic cap 5 Loosen the bolt 3 and the associated nut in the figure this is covered by the plastic cap with a 5 mm Allen key and a 13 mm socket spanner Remove the nut Remove the bolt including safety belt and flat washers 2 and 4 Remove the flat washers 4 Replace the safety belt 1 Refit the parts in the reverse order ...

Page 117: ...s Modulite seat 9 2 1 Installation on the backrest mounting bracket simple backrest Requirements Socket spanner 13 mm 5 mm Allen key The seat belts are attached via the drill hole 1 at the top right The installation of seat belts is described in chapter 9 1 ...

Page 118: ...ng bracket adjustable seat Requirements 5 mm Allen key Loosen the screw 1 with a 5 mm Allen key Remove the screw 1 the corresponding washer 2 and the seat belt and belt winder 3 from the backrest mounting bracket 4 Replace the safety belt Refit the parts in the reverse order ...

Page 119: ...ofile adjustable seat Requirements 5 mm Allen key Loosen the screw 1 with a 5 mm Allen key Remove the screw 1 the washer 2 the seat belt the sliding bushing 3 and the sliding block 4 from the seat frame profile 5 Replace the safety belt Refit the parts in the reverse order ...

Page 120: ...in chapter 8 1 3 Detach the operating hours counter from the side cover Disconnect the plugs Remove the nut 4 including the locking washer Pull the operating hours counter 6 forwards out of the casing 1 Pay attention to the mounting bracket 5 and the retaining frame 7 Replace the operating hours counter CAUTION Property damage can result if the counter is wrongly connected If the plus and minus wi...

Page 121: ...act of the operating hours counter which is marked with a 2 The blue wire is additionally marked with a minus symbol Connect the plug of the brown wire to the plug contact of the operating hours counter which is marked with a 1 The blue wire is additionally marked with a sleeve which has a plus symbol on it Assemble all remaining parts again in reverse order ...

Page 122: ...onnection of the operating hours counter from the drive motor Remove the side cover as described in chapter 8 1 3 Detach the operating hours counter from the side cover Turn the operating hours counter around Loosen and remove the four Phillips screws of the housing Disconnect the plugs Remove the cable ties 4 Carefully pull the connecting cable 2 of the operating hours counter out of the casing 1...

Page 123: ...s counter is carried out in the reverse order Protect the cable from tension using a cable tie 3 Connect the plug of the blue wire to the plug contact of the operating hours counter which is marked with a 2 The blue wire is additionally marked with a minus symbol Connect the plug of the brown wire to the plug contact of the operating hours counter which is marked with a 1 The blue wire is addition...

Page 124: ...r sleeve etc Also see chapter 8 7 9 Install the luggage carrier fixation bracket 3 If a conventional lighting system is present Install the light bracket Also see chapter 8 7 9 Install both hexagon socket head screws 4 together with the washers spacer sleeve etc Repeat these work steps on the other side of the wheelchair Open the clamping levers 5 of the luggage carrier fixation bracket Push the b...

Page 125: ...tilt to any setting If collisions can occur Open the clamping levers of the luggage carrier fixation bracket Push the luggage carrier slightly towards the rear Close the clamping levers of the luggage carrier fixation bracket 9 5 Further accessories Note The installation instructions for additional accessories are available at your Invacare specialist supplier or directly from Invacare ...

Page 126: ...cessary WARNING Danger of injury hazard after tilting of mobility caused by blocked steering wheels Always check the seat depth settings for both forward and reverse movement Make sure that steering wheels can rotate freely and have not contact to any fixed mobility device component CAUTION Any changes to the drive program can affect the driving characteristics and the tipping stability of the veh...

Page 127: ...ange of legrests which can be adjusted individually See operation manual 10 1 2 Adjusting the seat depth A Seat depth B Center of gravity of the seat seat position Standard seat The Seat depth is adjusted by moving the seat back The backrest holders see Section 8 16 can be mounted in 3 different positions on the seat plate see Section 10 3 1 ...

Page 128: ...th proceed as follows Loosen screws 3 Push the front seat section forwards or backwards Retighten the screws 3 Modulite seat The seat depth is adjusted by shifting the position of the backrest See User Manual 10 2 Adjusting the seat angle The seat height is adjusted via the seat angle and the actuator holder There are two kinds of the seat angle adjustment A 12 Seat angle adjustment Standard seat ...

Page 129: ...ION Danger of crushing The seat is very heavy Danger of injury to hands and feet Use proper lifting techniques Overview of the fixations points depending on the desired seat height and the seat which is installed Seat height in cm 12 tilt with standard seat Actuator holder A B C D a b c d 42 X X 44 X X 46 X X 48 X X Seat height in cm 12 tilt with Flex2 seat Actuator holder A B C D a b c d 46 X X 4...

Page 130: ...ding bolt Adjust the actuator with holding bolt to the desired height according to the table S 129 Secure the holding bolt with the SL retainer Use the open end wrench to loosen and remove the self securing nut 1 Pay attention to the washer while doing so Place a support under the seat Pull the screw 2 Pay attention to the washers while doing so Adjust the seat with the screw 2 to the desired heig...

Page 131: ...xation points depending on desired seat height Seat height in cm 20 tilt with Flex2 seat Actuator holder B C D b c d 46 X X 48 X X 50 X X Adjusting the actuator holder on the chassis Detailed instructions on the actuator can be found in chapter 8 15 1 Use the screwdriver to remove the SL retainer 1 of the lower holding bolt Place a support under the seat Pull the holding bolt Adjust the actuator w...

Page 132: ...Place a support under the seat Use the Allen wrench to loosen the screw 1 and remove Pay attention to the washer while doing so Adjust the seat with the screw 1 to the desired height according to the table S 131 Tighten the screw 1 Modulite seat ...

Page 133: ...f the electric wheelchair is delivered ex works with an optimally adjusted center of gravity Any change in this adjustment setting can negatively influence the stability of the electric wheelchair You must perform an individual risk analysis every time you change the center of gravity of the seating position in order to ensure the safety and stability of the electric wheelchair A Seat depth B Cent...

Page 134: ...ics of rear wheel drive wheelchairs the weight to be distributed 30 40 front and 60 70 rear WARNING Danger of damage due to collisions of the legrests with other parts of the wheelchair Set the legrests to the smallest angle before adjusting the seat center of gravity Pay attention with adjusting the seat center of gravity that the legrests do not touch any other parts of the wheelchair This ensur...

Page 135: ...le 1 Screw fixation positions of the standard seat 2 Screw fixation positions of the Flex2 A Screw fixation variations Flex2 see details below 20 tilt module 2 Screw fixation positions of the Flex2 A Screw fixation variations Flex2 see details below Screw fixation variations Flex2 1 Rear 2 Middle 3 Front ...

Page 136: ... Invacare Kite 136 20 tilt module Modulite Because of the oblong holes 1 there is no fixed screw fixation position at the modulite The seat angle adjustment depends on the measurements as described in chapter 10 3 3 ...

Page 137: ...ON Danger of crushing The seat is very heavy Danger of injury to hands and feet Use proper lifting techniques The pictures show the standard seat without seat covering from above A and below B Rear bolts 1 Front bolts 2 Seat plate 3 Seat frame 4 The seat plate can be fixed in three different positions on the seat frame Front fixing V Centre fixing M Rear fixing H ...

Page 138: ...eat frame can only be fixed in one position on the base frame 10 3 2 Flex2 seat Requirements 4 mm Allen wrench 5 mm Allen wrench 13 mm open ended wrench Flat screwdriver Smal hammer ATTENTION Danger of crushing The seat is very heavy Danger of injury to hands and feet Use proper lifting techniques The illustration shows the Flex2 seat from above without seat covering ...

Page 139: ...Invacare Kite SERVICE MANUAL 139 Loosen the fixation screws at the appropriate positions 2 12 tilt 20 tilt ...

Page 140: ...eplace the fixation screws and tighten Re install all seat components CAUTION Danger of injury and damage to property If the castor wheels collide with parts of the wheelchair the castor wheels can become jammed causing the wheelchair to tip After adjusting the seat depth always check that the castor wheels can move freely during forward and backward driving and do not touch static parts of the wh...

Page 141: ...ty via the lateral profiles as described in chapter 10 3 3 1 Simple seat Adjustment of the center of gravity via the oblong holes of the seat adaptor as described in chapter 10 3 3 2 CAUTION Increased danger of tipping over if the center of gravity is shifted too far towards the rear There must ALWAYS be at least 46 mm clearance between the backrest and the rear axle ...

Page 142: ...of the seat frame profile should be located 15 to 17 mm in front of the steering heads of the castors If you decrease this value make sure that you decrease the seat depth by the same value and there are no collisions between the legrests and the castors ...

Page 143: ...uirements 6 mm Allen key Remove the seat plate or sling seat 1 see chapter 8 19 1 Loosen the socket head screws 2 in the front and rear left and right DO NOT remove Shift the position of the seat Re tighten the screws Install the seat plate or the sling seat again ...

Page 144: ...quirements 6 mm Allen key Remove the seat plate 1 or the sling seat see chapter 8 19 1 Loosen the socket head screws 2 in the front and rear left and right DO NOT remove Shift the position of the seat frame Re tighten the screws Install the seat plate again ...

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Invacare Kite, Service Manual

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