Invacare Pronto M41 Service Manual Download

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Contents

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

1.1 About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Notes on Shipping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Symbols in This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Images in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

2.1 Safety and Fitting Instructions . . . . . . . . . . . . . . . . . . . . . 5

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

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

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

4.1 Adjusting Seating Position . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Adjusting Lower Leg Length . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Adjusting Seat Depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.3.1 Adjusting Seat Position on Seat Base . . . . . . . . . . . . . 9

4.4 Adjusting Seat Height (Captain's Seat and Standard

Seat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.5 Adjusting Seat Height (Modulite) . . . . . . . . . . . . . . . . . . . 11
4.6 Adjusting Seat Angle (Modulite). . . . . . . . . . . . . . . . . . . . 12
4.7 Adjusting Centre of Gravity of Seat . . . . . . . . . . . . . . . . . 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 Imperial to metric conversion chart . . . . . . . . . . . . . . . . . 18
6.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

6.4.1 Operational Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.4.2 Drive Fault Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.4.3 Charging device fault diagnosis. . . . . . . . . . . . . . . . . . 22

6.5 Service Plan (Once a Year). . . . . . . . . . . . . . . . . . . . . . . . 23
6.6 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.7 Moving Seat into Service Position (Modulite) . . . . . . . . . . 25
6.8 Drive Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

6.8.1 Replacing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.8.2 Replacing Swingarm Assembly . . . . . . . . . . . . . . . . . . 26
6.8.3 Replacing Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.8.4 Replacing Forks and/or Castor Assemblies. . . . . . . . . . 27
6.8.5 Adjusting Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6.9 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6.9.1 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.9.2 Tyre Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.9.3 Tyre Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.9.4 Specific Tightening Torques . . . . . . . . . . . . . . . . . . . . 30
6.9.5 Overview of Power Wheelchair Models and Wheel

Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6.9.6 Replacing Drive Wheel (1-Bolt Installation) . . . . . . . . . 32
6.9.7 Replacing Castor Wheel on Double-Sided Fork . . . . . . 33

6.10 Shrouds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6.10.1 Replacing Top Shroud . . . . . . . . . . . . . . . . . . . . . . . . 36
6.10.2 Replacing Front Shroud . . . . . . . . . . . . . . . . . . . . . . 36
6.10.3 Replacing Rear Shroud . . . . . . . . . . . . . . . . . . . . . . . 37

6.11 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6.11.1 Replacing Power Module . . . . . . . . . . . . . . . . . . . . . 37
6.11.2 Checking Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.11.3 Updating Software . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.11.4 Drive Program Selection After Component

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6.11.5 Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.11.6 Checking Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6.12 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.12.1 General Instructions on Handling Batteries . . . . . . . . 40
6.12.2 Handling Damaged Batteries Correctly . . . . . . . . . . . 40
6.12.3 Using Proper Batteries . . . . . . . . . . . . . . . . . . . . . . . 41

6.12.4 Connecting/Disconnecting Battery Cables . . . . . . . . . 41
6.12.5 Replacing Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . 43

7 Seating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Summary of Contents for Pronto M41

Page 1: ...Invacare Pronto M41 Series en Power Wheelchair Service Manual PROVIDER Keep this manual The procedures in this manual MUST be performed by a qualified technician...

Page 2: ...ior written permission from Invacare Trademarks are identified by and All trademarks are owned by or licensed to Invacare Corporation or its subsidiaries unless otherwise noted Invacare reserves the r...

Page 3: ...8 2 Replacing Swingarm Assembly 26 6 8 3 Replacing Spring 27 6 8 4 Replacing Forks and or Castor Assemblies 27 6 8 5 Adjusting Forks 28 6 9 Wheels 29 6 9 1 Repair Instructions 29 6 9 2 Tyre Pressure 2...

Page 4: ...s is also a requirement Special Invacare training is recommended Alterations to the mobility device which occur as a result of incorrectly or improperly executed maintenance or overhaul work lead to t...

Page 5: ...a fire resulting in death serious injury or damage Mobility device occupants are at particular risk of death or serious injury from these fires and resulting fumes because they may not have the abilit...

Page 6: ...age 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 r...

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: ...blocked castors Always check seat depth settings for both forward and reverse movement Make sure that castors can rotate freely and have no contact to any fixed mobility device component Any changes t...

Page 9: ...mbly see 4 3 1 Adjusting Seat Position on Seat Base page 9 6 Reinstall seat Min seat depth 16 inch 406 4 mm Middle seat depth 17 inch 431 8 mm Fig 4 2 Detail A Max seat depth 18 inch 457 2 mm Modulite...

Page 10: ...n 9 Standard seat position 10 1 inch 25 4 mm forward seat position1 5 Align mounting holes on seat pivot with mounting holes on seat base 6 Secure seat base to seat assembly using four mounting screws...

Page 11: ...post mounting positions 1 see 4 3 Adjusting Seat Depth page 8 For users over 220 lbs 100 kg the mounting holes 3 4 and 5 must be used with the seat in the 1 inch 25 4 mm back position See 4 3 1 Adjus...

Page 12: ...3 Adjust seat frame 2 to desired mounting position a b or c See table Seat Height for different seat height values 4 Refit screws and self locking nuts 5 Install seat plate or sling seat Fig 4 8 Seat...

Page 13: ...frame farther towards the front or the rear on the seat The seating system of the mobility device is delivered ex works with an optimally adjusted centre of gravity Any change in this adjustment setti...

Page 14: ...Invacare Pronto M41 Series Fig 4 12 For best possible driving characteristics of rear wheel drive wheelchairs the weight to be distributed 30 40 front and 60 70 rear 14 1568396 C...

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: ...t 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 statio...

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: ...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 for the...

Page 19: ...11 32 8 7313 23 64 9 1281 3 8 9 5250 25 64 9 9219 13 32 10 3188 27 64 10 7156 7 16 11 1125 29 64 11 5094 15 32 11 9063 31 64 12 3031 1 2 12 7000 33 64 13 0969 17 32 13 4938 35 64 13 8906 9 16 14 2875...

Page 20: ...agnosis Problem Other Symptoms Possible Cause Solution Documentation Mobility device will not start The remote status display illuminates normally and shows an error code Drive motors disengaged Engag...

Page 21: ...6 11 1 Replacing Power Module page 37 Motors lose power while driving None Bad connections Turn off electronics wait 10 seconds turn on electronics Check cabling See 6 11 6 Checking Cables page 39 Mot...

Page 22: ...g Batteries page 43 6 4 3 Charging device fault diagnosis Symptom Possible cause Solution No LEDs illuminating on battery charger Charging device not connected to mains supply Ensure that the battery...

Page 23: ...nction Replace parts if damaged Tighten screws Replace cable or actuator if necessary Frames chassis battery mounting Check fixings welded seams and battery mounting Tighten screws Replace components...

Page 24: ...s page 40 Remote status LED flashing Evaluate error flash code See 6 4 Troubleshooting page 20 Fixings Tighten fixings replace if necessary Cables and connecting plugs Replace damaged cables and tight...

Page 25: ...the wheelchair Switch the vehicle s power system off ON OFF key Engage the drive motors Secure the vehicle against rolling away by pressing the parking brake down CAUTION Risk of crushing The seat has...

Page 26: ...e rear shroud refer to 6 10 3 Replacing Rear Shroud page 37 8 Disconnect motor lead connectors from power module 9 Unhook spring from frame and bracket refer to 6 8 3 Replacing Spring page 27 10 Remov...

Page 27: ...5 Remove four screws 1 that secure swingarm 4 assembly to motor 6 Remove locknut 2 and spacer 3 that secure swingarm 4 assembly and bracket 8 to frame 9 Fig 6 6 7 Install parts in reverse order 8 Tes...

Page 28: ...refer to 6 9 7 Replacing Castor Wheel on Double Sided Fork page 33 5 Replace headtube cap 1 6 8 5 Adjusting Forks Tools Ratchet with 15 16 inch socket 1 Remove headtube cap 1 2 To properly tighten ca...

Page 29: ...if the mobility device is accidentally set into motion during repairs Switch the power off ON OFF Button Engage the motors Secure the mobility device against rolling away by placing wedges under the w...

Page 30: ...d rim halves are listed in 6 9 4 Specific Tightening Torques page 30 6 9 4 Specific Tightening Torques Drive Wheels 10 x 3 12 1 2 x 2 1 4 14 Wheel Fixation 70 Nm 70 Nm 33 Nm 35 Nm 70 Nm 33 Nm 60 Nm 25...

Page 31: ...lt In stallation 5 Spoke Rim 1 Bolt In stallation 5 Spoke Rim 5 Screw Installa tion 5 Spoke Rim for True Track TDX SP2 Storm4 Series Kite Bora Fox Stream Mirage Dragon Pronto M41 For wheelchair specif...

Page 32: ...isk of Crushing to Hands and Feet by Weight of Mobility Device Pay attention to hand and feet Use proper lifting techniques CAUTION Risk of Uncontrolled Movement of Mobility Device Turn off power supp...

Page 33: ...e shaft Installing Wheel 1 Apply anti seize compound to drive shaft D and keystock E Do not apply more than one inch 25 4 mm in length thin film of anti seize compound to the drive shaft Applying more...

Page 34: ...Wheel 1 Place wooden block underneath mobility device and prop up mobility device 2 Remove end caps from bolt and nut if applicable 3 Fig 6 12 Remove nut from bolt A 4 Remove bolt and wheel from fork...

Page 35: ...ys use new nuts and bolts with an undamaged coating 1 Install parts in reverse order Pay attention to correct direction of rotation when installing wheels 2 Test all functions Replacing Castor Wheel 6...

Page 36: ...Shroud 1 Pull joystick cable through center hole in top shroud 5 2 Place top shroud 5 on base frame Pull cover forward to clear motor release levers 3 Install two screws 2 that secure top shroud 5 to...

Page 37: ...ogram Selection After Component Replacement page 39 Different combinations of power modules and remotes can be fitted to the mobility device Power modules are described in earlier revisions of this se...

Page 38: ...vailable refer to Updating Software Select driving program refer to 6 11 4 Drive Program Selection After Component Replacement page 39 4 Plug all free slots with suitable covering cap 5 Adapt drive pr...

Page 39: ...wheelchair Motors not shown for clarity The motor cables are routed out the hole located at the back of the battery box Route the joystick cable two battery cables and the motor cable beneath the shro...

Page 40: ...diately afterwards When removing take care of small parts such as screws and washers Put all small parts down so that they can be installed in correct sequence 6 12 1 General Instructions on Handling...

Page 41: ...POSITIVE battery cable mounting screw To replace the fuse obtain and replace battery harness with fuse The POSITIVE battery cable MUST connect to the POSITIVE battery terminal otherwise serious damag...

Page 42: ...l be reduced Disconnecting Battery Cables DANGER Risk of damage and injuries Serious personal injury or damage may occur in case of an electrical short The use of rubber gloves is recommended when wor...

Page 43: ...ine source of contamination Never install reinstall a battery with a cracked or otherwise damaged case 1 Seat service position Modulite only Standard or Captain s Seat 2 Shroud 3 Batteries 4 Battery t...

Page 44: ...sition right battery 7 in battery tray 4 3 Position left battery 5 in battery tray Ensure that both batteries are properly seated and resting on battery tray 4 Connect battery cables See 6 12 4 Connec...

Page 45: ...oystick is in the OFF position Removing Seat Assembly 1 Disconnect joystick 2 Pull release lever to fold down seat back 1 3 Pull seat lever 5 up and lift seat assembly 2 up and away from seat post 4 F...

Page 46: ...olts 4 including nuts and washers on the left hand and right hand side 4 Remove backrest tube 1 from backrest holders 2 If Backrest Holders also need to be replaced 5 Loosen and remove Allen screws 5...

Page 47: ...ed between the two washers 2 and 4 as a spacer so that the belt mounting can rotate freely 5 mm Allen key 13 mm socket wrench 1 Remove plastic cap 5 2 Loosen bolt 3 and associated nut covered by plast...

Page 48: ...y 4 from wheelchair frame Fig 7 9 Installing Footboard Assembly Make sure the detent balls 3 of the quick release pin 2 are fully released beyond the outer edge of the tube 5 before operating the whee...

Page 49: ...Notes...

Page 50: ...Notes...

Page 51: ...Notes...

Page 52: ...x 0800 807 788 sales invacare co nz www invacare co nz United Kingdom Invacare Limited Pencoed Technology Park Pencoed Bridgend CF35 5AQ Tel 44 0 1656 776 222 Fax 44 0 1656 776 220 uk invacare com www...

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