Manuals+

Invacare Colibri Mobility Scooter

Maintenance and Service Manual

Supplier Note

Supplier: Keep this manual. The procedures described in this manual MUST be performed by a qualified technician.

General Information

1.1 Introduction

This document provides important information regarding the assembly, adjustment, and in-depth maintenance of the product. To ensure safe handling of the product, carefully read this document and the user manual, and follow the safety instructions.

Consult the user manual on the Invacare website or contact an Invacare representative. Refer to the addresses indicated at the end of this document.

Invacare reserves the right to modify product features without prior notice.

Before reading this document, ensure you have the latest version. This version is available in PDF format on the Invacare website.

Previous versions of the product may not be described in the current revision of this manual. If you need assistance, please contact Invacare.

Consult the user manual for more information and before any purchase.

For more information about the product, such as safety notices or product recalls, contact your local Invacare representative. Refer to the addresses indicated at the end of this document.

1.2 General Information

Perform maintenance and service tasks with this manual in mind.

Please note that some sections of this document may not apply to your product, as the document covers all models available (as of the print date). Unless otherwise stated, each section of this document applies to all product models.

Models and configurations available in your country are listed in country-specific sales documents.

You must strictly adhere to the safety regulations.

For information concerning the operation or general maintenance and service tasks on the product, refer to the service manual.

The assembly of accessories/options may not be described in this document. Refer to the manual provided with the accessory/option. Additional manuals can be ordered from Invacare. Refer to the addresses indicated at the end of this document.

All information regarding spare parts ordering can be found in the spare parts catalog.

Spare parts must correspond to original Invacare parts. Use exclusively Invacare-approved spare parts.

Only qualified personnel may service and overhaul the product.

Adequate training, for example in orthopedic or mechanical engineering, or sufficient work experience is a minimum requirement for service technicians. Experience in using electrical measuring equipment (multimeters) is also required. Special Invacare training is recommended.

Alterations to the scooter resulting from incorrectly executed maintenance or repair work will void Invacare's liability.

In case of problems or questions, contact your supplier.

1.3 Transport Notes

1.4 Symbols in this Manual

The warning symbols and words used in this document apply to risks or dangerous practices that could cause injury or material damage. This document is printed in grayscale. For your information, safety messages use the following color coding in accordance with ANSI Z535.6: Danger (Red), Warning (Orange), Caution (Yellow), and Note (Blue). Refer to the information below for the definition of the warning symbols.

[DANGER] Indicates a dangerous situation which, if not avoided, will likely result in serious injury or death.

[WARNING] Indicates a dangerous situation which, if not avoided, is likely to result in serious injury or death.

[CAUTION] Indicates a potentially dangerous situation which may result in minor injury.

[NOTE] Indicates a dangerous situation which, if not avoided, could result in material damage.

[Tips] Provides useful advice, recommendations, and information for efficient and trouble-free use.

[Tools] Identifies the tools, components, and other items required to perform specific tasks.

1.5 Images in this Manual

Numbers are associated with detailed images in this manual to identify different components. The component numbers in the text and operating instructions always correspond to the image directly above.

Safety

2.1 Safety Information

[WARNING] Injury or material damage risk from improper handling of batteries. Pay attention to the warnings on the batteries. Use exclusively the battery type specified in the technical characteristics.

[WARNING] Risk of fire and burns from battery terminal short circuits. Take all necessary precautions to ensure that the battery terminals are never short-circuited by tools or mechanical components of the scooter. Ensure that the protective caps are reinstalled on the battery terminals when not working on them.

[WARNING] Risk of pinching. Batteries can be extremely heavy. You could injure your hands. Handle them with care. Be careful not to drop batteries on the floor when removing them from the chassis. Be careful with your hands. Use appropriate lifting techniques.

When disassembling, be careful not to misplace small parts like screws and washers. Place them correctly for reassembly in the correct order.

2.2 Safety and Assembly Instructions

To avoid accidents during procedures, you must strictly follow these safety instructions.

Before any inspection or repair task

Personal Protective Equipment

Safety Shoes

The scooter and some of its components are very heavy. You could injure your feet if these parts fall on them.

Eye Protection

When working on defective batteries or handling batteries incorrectly, acid can escape from the battery.

Safety Gloves

When working on defective batteries or handling batteries incorrectly, acid can escape from the battery.

General Safety Information and Information Regarding Assembly/Disassembly

[DANGER] Risk of material damage or serious injury, possibly fatal. Cigarette embers falling on upholstered seating can ignite a fire, potentially causing material damage or serious injury. Scooter occupants are particularly exposed to the risk of serious or fatal injury from these fires and resulting smoke, as they may not always be able to move away from the scooter. -- DO NOT smoke while using this scooter.

[WARNING] Risk of material damage or serious injury. Storing or using the scooter near an open flame or combustible materials can lead to material damage or serious injury. Avoid storing or using the scooter near an open flame or combustible materials.

[CAUTION] Risk of pinching. Many components, such as the motor unit, batteries, seat, etc., are very heavy. You could injure your hands. Note the high weight of certain components. This is particularly true when removing the motor units, batteries, and seat.

[CAUTION] Risk of injury if the scooter accidentally moves during repair. -- Turn off the power (ON/OFF button). -- Engage the motor. -- Before lifting the scooter, secure it with chocks to block the wheels.

[CAUTION] Risk of fire and burns due to electrical short circuit. -- You must completely stop the scooter before removing live components! To do this, remove the batteries. -- Avoid short-circuiting contacts when taking measurements on live components.

[CAUTION] Risk of burns from hot surfaces. -- Allow motors to cool down before working on them.

[CAUTION] Risk of injury and damage to the scooter due to incorrect or incomplete maintenance. -- Use only undamaged tools in good condition. -- Some moving parts are mounted in sockets with a PTFE (Teflon™) coating. Never lubricate these sockets! -- Never use "normal" nuts instead of self-locking nuts. -- Always use correctly dimensioned washers and spacers. -- When reassembling, always replace cable ties that were cut during disassembly. -- Once the task is completed/before restarting the scooter, check all connections to ensure they are tight. -- Once the task is completed/before restarting the scooter, check that all parts are securely locked. -- The scooter must not operate if the approved tire pressures are not met (consult the technical data in the user manual). -- Check that all electrical components function correctly. Note that incorrect polarity can damage the control system. -- Always perform a test run at the end of your work.

[CAUTION] Any modification to the driving program may alter the scooter's driving characteristics and stability. -- Only specialized Invacare suppliers are authorized to make modifications to the driving program. -- Invacare provides all scooters with a standard driving program ex-factory. Invacare guarantees the safe operation of the scooter, particularly regarding stability, only for this standard driving program.

[CAUTION] Risk of injury. Modifications made to the scooter can affect its performance. -- For modifications made with third-party products, these operations are only permitted under a valid partnership agreement. -- The maximum values and restrictions of both products must be observed. -- It is forbidden to machine, bend, weld, or reinforce any safety-critical component.

Mark all existing scooter settings (seat, armrests, backrest, etc.) and associated cable connection points before disassembly to facilitate reassembly. All connectors are equipped with mechanical safety devices that prevent disconnection during operation. To disconnect connectors, you must press the safety devices. During reassembly, ensure these safety devices are correctly engaged.

Hygiene

3.1 Handling of Returned Products

When reconditioning or repairing returned scooters:

Before Transport (in accordance with the biological agents directive)

Treat the product according to the following steps:

Procedure Step Component Application Conditioning Technique Workstation
Manual Cleaning Appliance surface used Before repair or reconditioning Apply cleaning detergent using a saturated wipe and remove residue. Cleaning and disinfection
Disinfection Appliance surface used Before repair or reconditioning Clean* the appliance surface using disinfectant-saturated wipes. Cleaning and disinfection

*The detergent "Nüscosept Spezial" has been tested on product surfaces.

Disinfection Tools

Additional Information

[Info] For more information, contact Invacare maintenance service.

Maintenance

4.1 General Safety Information for Installation Procedures

[NOTE] Collisions may occur if the spacer rings are removed from the drive wheels during installation. Spacer rings are often placed between the drive shaft and the wheel hub to compensate for tolerances. If the spacer rings are not replaced after removal, collisions may occur. -- Install the spacer rings in the exact same positions as before disassembly.

4.2 Torque Values

[CAUTION] If screws, nuts, or plastic fittings are not tightened correctly, you risk damaging the scooter. -- Always tighten screws, nuts, etc., to the specified torque. -- Only manually tighten screws or nuts not listed here.

The torque values specified in the following list are based on the thread diameter for nuts and bolts for which no specific value has been determined. All values assume dry, degreased threads.

Thread Torque in Nm ±10%
M4 3 Nm
M5 6 Nm
M6 10 Nm
M8 25 Nm
M10 49 Nm
M12 80 Nm
M14 120 Nm
M16 180 Nm

4.3 List of Accessories/Options

You can obtain installation instructions for additional accessories/options from your Invacare dealer or directly from Invacare.

4.4 Troubleshooting

4.4.1 Malfunctions

Proceed as follows in case of problems:

  1. First, identify the possible cause of the problem by referring to the following table.
  2. Check the status display on the control console. Evaluate the blinking code.
  3. Perform the necessary checks and repairs recommended in the following table.

4.4.2 Troubleshooting Driving Anomalies

Problem Other Symptoms Possible Cause Solution Documentation
Scooter does not start Control console status display does not light up Defective batteries Replace batteries Refer to the user manual
Completely discharged battery Pre-charge batteries
Power supply issue to the control console Check the main fuse Refer to the user manual for information on the main fuse location.
Defective control console Ensure cables connecting modules are not loose or damaged. Replace control console. Refer to section 6.5 Cable Check, page 18. Refer to section 8.2 Control Console Replacement, page 21.
Control console status display blinks Multiple possible causes Evaluate error code Refer to section 4.4.3 Error Codes and Diagnostic Codes, page 10.
Scooter jerks while driving None Defective drive motor(s) Replace motor(s) Refer to section 11.1 Drive Motor Replacement, page 31.
Defective potentiometer of the control lever Replace potentiometer Refer to section 8.3 Potentiometer Replacement, page 22.
Batteries not charging None Defective batteries Replace batteries Refer to section 6.3 Battery Replacement, page 17.
Flashing lights on charger Defective charger Replace charger Refer to the user manual
Scooter moves too slowly None Defective control console Replace control console Refer to section 8.2 Control Console Replacement, page 21.
Defective batteries Replace batteries Refer to section 6.3 Battery Replacement, page 17.

4.4.3 Error Codes and Diagnostic Codes

Blinking Code Fault Consequence for Scooter Comments
1 Batteries need charging Continues to drive
  • Batteries are discharged. Recharge batteries as soon as possible.
  • Batteries are empty. Recharge batteries.
2 Battery voltage too low Stops driving
  • If you turn off the scooter for a few minutes, the batteries will recharge slightly, allowing a brief movement. This movement is only recommended in emergencies, as it causes excessive battery discharge.
3 Battery voltage too high Stops driving
  • Battery voltage is too high. If the battery charger is connected, disconnect it from the scooter.
  • The electronic system charges the batteries when going uphill and during braking. This malfunction is caused by an excessive increase in battery voltage during this operation. Turn off the scooter, then turn it back on.
4 Exceeding power supply time Stops driving
  • The scooter has used too much current for too long, possibly because the motor was overloaded or it was working against an insurmountable resistance. Turn off the scooter, wait a few minutes, then turn it back on.
5 Brake failure Stops driving
  • The electronic system has detected a motor short circuit. Check the electrical harness and the motor to locate the short circuit.
  • Contact your Invacare supplier.
6 No neutral position when starting the scooter Stops driving
  • Check that the freewheel lever is in the engaged position.
  • The brake coil or wiring is faulty. Check for an open circuit or short circuit in the magnetic brake and cables. Contact your Invacare supplier.
7 Potentiometer malfunction Stops driving
  • The control lever is not in the neutral position when the ignition is on. Place the lever in neutral, turn off the ignition, then turn it back on.
  • The control lever may need to be replaced. Contact your Invacare supplier.
  • The control lever control device may be defective or incorrectly connected. Check for an open circuit or short circuit in the cables.
  • The potentiometer is incorrectly adjusted and needs to be replaced. Contact your Invacare supplier.
8 Motor voltage error Stops driving
  • The motor or its wiring is defective. Check for an open circuit or short circuit in the cables.
  • Contact your Invacare supplier.
9 Various internal malfunctions Stops driving
  • Contact your Invacare supplier.
10 Push mode / Freewheel mode error Stops driving
  • The scooter has exceeded the maximum authorized speed for push or freewheel operation. Turn off the electronic system, then turn it back on.

4.4.4 Maintenance Schedule

Component Check Solution Remarks
Seat Check welds, fastenings, and upholstery Tighten screws, replace parts if damaged
Check seat suspension Generously grease the spring, replace parts if damaged Refer to section 5.3 Replacement of Seat Spring/Suspension, page 14.
Frame assembly (chassis)/battery mounting Check fastenings, welds, and battery mounting Tighten screws, replace parts if damaged
Check battery fastening straps
Check drive wheel tightening Tighten hub nuts, replace if necessary
Wheels and wheel suspension Check tightening, play, and lateral float of front wheels Adjust/replace Installation and removal of wheels, refer to section 9 Wheels, page 24
Check tires Repair or replace if damaged Refer to the user manual
Check alignment and steering column Tighten screws. Check alignment and steering.
Motor units, coupling mechanism Check functions in drive and push modes Replace motor if necessary. Refer to the user manual
Check coupling mechanism. Tighten/adjust/replace screws/nuts
Ensure batteries are not damaged Replace batteries Refer to the user manual
Batteries Check battery voltage Recharge batteries Refer to the user manual
Check contacts and terminals Clean contacts and terminals
Check status display (blinking) Evaluate blinking code Refer to section 4.4.3 Error Codes and Diagnostic Codes, page 10.
Check fastening Tighten or replace fastening
Control units Check cable, connector plug Replace cable, connector plug
Check lever function Replace control lever
Check power supply Replace cable, connector plug, or console
Check software version. New version available? Perform software update
Screws Check that screws are tight Tighten screws if necessary

Seating Systems

5.1 Seat Removal/Installation

[WARNING] Risk of scooter falling. Before each use, ensure the seat is locked in position. The seat lever must be pulled fully to lock the seat. Otherwise, the scooter may fall, potentially injuring the user and/or damaging the scooter.

Disassembly

  1. Pull the seat locking lever A upwards to unlock the seat.
  2. Turn the seat assembly B to the side.
  3. Firmly hold the seat by the backrest and the front edge.
  4. Lift the seat away from the support tube C.

Installation

  1. Lower the seat B onto the support tube C.
  2. Turn the seat until it faces forward and locks into position.
  3. Lift the seat to ensure it is securely fastened.

5.2 Replacement of Seat Support Tube

[Tools] 17 mm wrench (2)

[CAUTION] Risk of tipping. If a seat suspension/seat support tube is installed incorrectly, the 3-wheel model may tip when going uphill. -- Always install the seat support tube with only two holes. -- Always install the medium or short seat support tube when retrofitting.

  1. Remove the seat; refer to section 5.1 Seat Removal/Installation, page 13.
  2. Remove the battery pack; refer to section 6.2 Battery Pack Removal/Installation, page 16.
  3. Remove the fastening bolt, nut, and washers from the seat support tube.
  4. Replace the seat support tube.
  5. Adjust the seat height.
  6. Reinsert the fastening bolt, nut, and washers, and tighten.

5.3 Replacement of Seat Spring/Suspension

[CAUTION] Accident risk. Accidental rolling can cause accidents. -- Chock the scooter to prevent it from rolling.

When disassembling, note the position of small parts like screws and washers. Place them correctly for reassembly in the correct order.

Seat support tubes are available in the following lengths for seat suspensions:

[Tools] 13 mm wrench, 17 mm wrench (2), Grease

  1. Chock the scooter to prevent it from rolling.
  2. Remove the seat; refer to section 5.1 Seat Removal/Installation, page 13.
  3. Loosen the bolted connection (1) on the mounting sleeve (4) and counter-hold.
  4. Loosen the bolted connection (2) on the rear closure (3) and counter-hold.
  5. Remove bolts (3 and 9), the nut, and washers.
  6. Remove the seat support tube (4) from the receptacle tube (1).
  7. Remove the connection hook (2).
  8. Remove the bellows (5), including the spring (7) and plastic end caps (6 and 8).
  9. Install the plastic end caps (6 and 8) onto the new spring.
  10. Generously grease the spring. It must be completely covered.
  11. Install the bellows (5), including the spring (7) and plastic end caps (6 and 8).
  12. Install the connection hook (2).
  13. Insert the seat support tube (4) into the receptacle tube (1) and push gently.
  14. Replace bolts (3 and 9), the nut, and washers.
  15. Firmly tighten the bolts of the seat support tube.
  16. Replace the seat.

Batteries

[CAUTION] Risk of injury and material damage from incorrect battery handling. Pay attention to the warnings on the batteries. Use exclusively the battery type specified in the technical characteristics.

[CAUTION] Risk of fire and burns from battery terminal short circuits. Take all necessary precautions to ensure that the battery terminals are never short-circuited by tools or mechanical components of the scooter. Ensure that the protective caps are reinstalled on the battery terminals when not working on them.

[CAUTION] Risk of pinching. Batteries can be extremely heavy. You could injure your hands. Handle them with care. Be careful not to drop batteries on the floor when removing them from the chassis. Be careful with your hands. Use appropriate lifting techniques.

When disassembling, be careful not to misplace small parts like screws and washers. Place them correctly for reassembly in the correct order.

6.1 General Battery Handling Guidelines

6.2 Battery Pack Removal/Installation

[CAUTION] Risk of injury from handling heavy parts. -- Use appropriate lifting techniques.

[CAUTION] Risk of injury from falling scooter parts. Removing the battery pack releases the LITE-LOCK™ mechanism, allowing the front frame to separate from the rear frame. -- Do not lift or move the scooter without the battery pack, unless you intend to disassemble it; see 6.2.1 Motor Unit Removal/Installation, page 16, or Scooter Disassembly for Transport in the user manual.

Battery Pack Removal

  1. Remove the seat; refer to section 5.1 Seat Removal/Installation, page 13.
  2. Grasp the battery pack handle A, pull the battery pack latch B with your thumb, and remove the battery pack.

Battery Pack Installation

  1. Remove the seat; refer to section 5.1 Seat Removal/Installation, page 13.
  2. While holding the battery pack handle A, gently lower the pack into the scooter's battery compartment.
  3. Press the battery pack to engage the pack connector with the connector at the base of the scooter.
  4. Ensure the battery pack latch B engages in the support tube mounting hole.
  5. Reinstall the seat; refer to 5.1 Seat Removal/Installation, page 13.

6.2.1 Motor Unit Removal/Installation

[CAUTION] Risk of injury from handling heavy parts. -- Use appropriate lifting techniques.

Motor Unit Removal
  1. Pull the seat support tube to lift the chassis.
  2. The motor unit will then detach from the chassis.
Motor Unit Installation
  1. Pull the seat support tube to lift the chassis and hook it to the motor unit.
  2. Replace the battery pack; refer to 6.2 Battery Pack Removal/Installation, page 16.
  3. Ensure the battery pack latch is locked.
  4. Replace the seat; refer to 5.1 Seat Removal/Installation, page 13.

6.3 Battery Replacement

[Tools] Phillips screwdriver, 8 mm wrench (18 Ah battery only)

Diagram: Batteries 12 Ah, clips and cover. Batteries 18 Ah, clips and cover.

  1. Remove the seat; refer to section 5.1 Seat Removal/Installation, page 13.
  2. Remove the battery pack; refer to section 6.2 Battery Pack Removal/Installation, page 16.
  3. Turn the battery pack over.
  4. Remove screws A on both sides of the battery pack.
  5. Carefully turn the battery pack upright and remove the battery cover.

Depending on the battery type, disconnect the connectors as follows:

  1. Remove all connection plugs from the battery terminals. Disconnect the battery cable harness in the following order: a. BLACK cable B from the negative terminal of the battery on the right battery. b. RED cable C from the positive terminal of the battery on the left battery. c. WHITE cable D from the positive terminal of the battery on the right battery. d. WHITE cable E from the negative terminal of the battery on the left battery.
  2. Remove screws F and clips G.
  3. Replace the batteries.
  4. Install the new batteries and secure them with the clips.
  5. Install all connection plugs onto the battery terminals. Connect the cable harness to the batteries in the following order: a. BLACK cable B to the negative terminal of the battery on the right battery. b. RED cable C to the positive terminal of the battery on the left battery. c. WHITE cable D to the positive terminal of the battery on the right battery. d. WHITE cable E to the negative terminal of the battery on the left battery.
  6. Install the remaining parts by reversing the procedure.
  7. Test all functions.

Diagram: Clips for 18 Ah batteries shown as an example.

6.4 How to Correctly Handle Damaged Batteries

[WARNING] Risk of burns. -- Never touch or remove overheating batteries. Only disconnect the charger. -- Never touch leaking batteries.

[WARNING] Risk of burns. Risk of injury from acid discharge. -- Always wear protective acid-resistant gloves when handling batteries. -- Always wear protective goggles when handling batteries.

First aid in case of acid discharge

In case of eye contact

Place damaged batteries in an acid-resistant container immediately after removal.

Always transport damaged batteries in a suitable acid-resistant container.

Wash all objects that may have come into contact with acid thoroughly with water.

Disposal of Used or Damaged Batteries

[WARNING] Environmental risk. -- DO NOT dispose of batteries with household waste. -- DO NOT dispose of batteries in fire. -- Batteries MUST be deposited at an approved site. Disposal is legally required and free of charge. -- Only discharged batteries can be disposed of. -- Cover battery terminals before disposal.

[CAUTION] Risk of fire and burns from improper battery storage. -- Take all necessary precautions to ensure that battery terminals are never short-circuited by metal parts or liquids. -- Ensure that the battery terminals have been installed before storage.

Batteries follow specific disposal rules. Your supplier has all the information available for safely exchanging and disposing of defective batteries.

6.5 Cable Check

  1. Turn off the control.
  2. Open the control console; see 8.2 Control Console Replacement, page 21.
  3. Check for visible damage, crushing marks, or abrasion marks on all cables.
  4. Replace damaged cables.
  5. Gently pull on each connector. The connector should not come out of its socket if pulled lightly.
  6. If a connector is loose, press it gently to insert it into the socket. It should click into place.
  7. Ensure the connector is fully inserted into its socket.
  8. Remove the batteries; refer to section 6.3 Battery Replacement, page 17.
  9. Check for visible damage, crushing marks, or abrasion marks on the battery cables.
  10. Replace damaged cables.
  11. Reassemble all components by reversing the procedure.
  12. Test all scooter functions.

Covers

7.1 Replace Rear Covers

[Tools] Phillips screwdriver

  1. Remove screws A and B to detach the rear cover C from the chassis D.
  2. Remove screws E to detach the motor protection cover F from the chassis D.
  3. Install parts by reversing the procedure.

Diagram: Rear cover assembly with labels A-F.

7.2 Front Cover Replacement

[Tools] 10 mm socket wrench, Phillips screwdriver

  1. Remove covers A.
  2. Remove screws B.
  3. Remove screws C.
  4. Remove the front cover D from the chassis E.
  5. Install parts by reversing the procedure.

The front cover assembly is identical for the 3-wheel and 4-wheel versions.

Diagram: Front cover assembly with labels A-E.

Control Systems

8.1 Power Module Replacement

[CAUTION] Accident risk. When the scooter is stationary on its wheels, it is no longer slowed by the motor brake. The scooter may roll away uncontrollably. -- Place the rear chassis of the scooter on a wooden support block before removing the wheels. -- Chock the scooter to prevent it from rolling.

[CAUTION] Risk of burns from power cord short circuit. Completely disconnect the scooter's power before disassembling internal power components. Do not forget to remove the batteries. -- Avoid short-circuiting contacts when taking measurements on live electrical components.

[CAUTION] Any modification to the driving program may alter the scooter's driving characteristics and stability. -- Only specialized Invacare suppliers are authorized to make modifications to the driving program. -- Invacare guarantees the safe operation of the scooter, particularly regarding stability, only for standard, unmodified driving programs.

The electronic system is supplied with a standard driving program. If you have made customer-specific modifications to the driving program, you will need to reapply them after installing the new power module.

When disassembling, note the position of small parts like screws and washers. Place them correctly for reassembly in the correct order.

[Tools] Phillips screwdriver

[For adapting the driving program] Programming software or manual programming device and installation manual for the control system, available from Invacare.

  1. Remove the seat; refer to section 5.1 Seat Removal/Installation, page 13.
  2. Remove the battery pack; refer to section 6.2 Battery Pack Removal/Installation, page 16.
  3. Remove the motor unit; refer to section 6.2.1 Motor Unit Removal/Installation, page 16.
  4. Place the chassis vertically on its seat adapter.
  5. Secure the chassis to prevent it from tipping over.
  6. Remove the four screws A from the power module cover B.
  7. Open the power module cover.
  8. Disconnect all plugs from the power module.
  9. Remove screws C on both sides of the power module.
  10. Replace the power module.
  11. Install parts by reversing the procedure.
  12. Modify the driving program.
  13. Complete scooter installation.
  14. Test all functions.

8.2 Control Console Replacement

[CAUTION] Risk of burns from power cable short circuit. Completely disconnect the scooter's power before disassembling internal power components. Do not forget to remove the batteries. -- Avoid short-circuiting contacts when taking measurements on live electrical components.

[CAUTION] Risk of damage to the control console from high current/voltage. -- Disconnect the battery cable before removing/installing the control console. -- Ensure all pins are correctly connected.

[NOTE] Risk of damage to the printed circuit board from electrostatic discharge. -- Handle printed circuit boards only in electrostatically protected areas (EPA).

When disassembling, note the position of small parts like screws and washers. Place them correctly for reassembly in the correct order.

[Tools] Phillips screwdriver

  1. Remove the seat; refer to section 5.1 Seat Removal/Installation, page 13.
  2. Remove the battery pack; refer to section 6.2 Battery Pack Removal/Installation, page 16.
  3. Pull the colored cover A upwards to remove it from its mounting.
  4. Secure the lower cover B. Remove screws C.
  5. Remove the lower cover.
  6. Remove all plugs from the upper control console D.
  7. Replace the control console.
  8. Install parts by reversing the procedure.
  9. Test all functions.

8.3 Potentiometer Replacement

[CAUTION] Risk of burns from power cable short circuit. Completely disconnect the scooter's power before disassembling internal power components. Do not forget to remove the batteries. -- Avoid short-circuiting contacts when taking measurements on live electrical components.

[CAUTION] Risk of damage to the control console from high current/voltage. -- Disconnect the battery cable before removing/installing the control console. -- Ensure all pins are correctly connected.

[CAUTION] Accident risk. Incorrect potentiometer adjustment can lead to dangerous driving situations. -- Connect the potentiometer to the control lever support.

[NOTE] Risk of damage to the printed circuit board from electrostatic discharge. -- Handle printed circuit boards only in electrostatically protected areas (EPA).

[Tools] Phillips screwdriver, Digital multimeter

  1. Remove the seat; refer to section 5.1 Seat Removal/Installation, page 13.
  2. Remove the battery pack; refer to section 6.2 Battery Pack Removal/Installation, page 16.
  3. Remove the control console; see 8.2 Control Console Replacement, page 21.
  4. Remove screws A on the potentiometer.
  5. Replace the potentiometer.
  6. Install parts by reversing the procedure.
  7. Test all functions (test run).

8.4 Driving Program Update

Scooter driving programs are continuously updated and improved by Invacare. Therefore, we advise you to check if the version number is up-to-date each time a wheelchair is brought in for repair, as well as during routine inspections.

If a newer version is available, the driving program must be updated. The procedure for updating the driving program is described in the Wizard software user manual.

The electronic system is supplied with a standard driving program. If the driving program has been customized, this customization must be reapplied after installing the new driving program.

[CAUTION] Any modification to the driving program may alter the scooter's behavior and stability! -- Only specialized Invacare suppliers are authorized to make modifications to the driving program. -- Invacare guarantees the safe operation of the wheelchair, particularly regarding stability, only if standard driving programs have not been modified.

Wheels

9.1 Wheel Replacement (4-wheel version/rear wheel of 3-wheel version)

[CAUTION] Risk of injury due to uncontrolled scooter movement. -- Turn off the power. -- Engage the motors. -- To prevent the scooter from rolling, place chocks under the wheels. -- Place the rear chassis of the scooter on a wooden support block before removing the wheels.

When disassembling, be careful not to misplace small parts like screws and washers. Place them correctly for reassembly in the correct order.

[Tools] 12 mm wrench, Rubber mallet, Flathead screwdriver, Lifting device

Wheel Removal

  1. Chock the scooter to prevent it from rolling.
  2. Place a lifting device under the chassis near the battery pack.
  3. Remove the plastic cover A.
  4. Remove the locking nut B and washer C.
  5. Remove the wheel D from the axle E. If necessary, loosen the wheel by lightly tapping it with a rubber mallet.

Wheel Installation

  1. Install parts by reversing the procedure. Ensure you use a new locking nut.
  2. Test all functions.

Diagram: Wheel assembly with labels A-E.

9.2 Axle/Front Wheel Replacement (3-wheel version)

[CAUTION] Accident risk. Placing the chassis vertically on its end can cause accidents. -- Secure the chassis to prevent it from tipping over.

[NOTE] The plastic fairing may be damaged if you try to lift the scooter by the fairing. -- The scooter should only be lifted by the chassis.

When disassembling, be careful not to misplace small parts like screws and washers. Place them correctly for reassembly in the correct order.

[Tools] 12 mm wrench, 13 mm wrench

  1. Remove the seat; refer to section 5.1 Seat Removal/Installation, page 13.
  2. Remove the battery pack; refer to section 6.2 Battery Pack Removal/Installation, page 16.
  3. Remove the motor unit; refer to section 6.2.1 Motor Unit Removal/Installation, page 16.
  4. Place the chassis vertically on its seat adapter.
  5. Secure the chassis to prevent it from tipping over.

Wheel Removal

  1. Loosen the self-locking nut F. Block the axle bolt A to prevent slippage.
  2. Slowly remove the axle.
  3. Remove the wheel C with spacer washers B and a washer E from the fork D.

Wheel Installation

  1. Install parts by reversing the procedure. Ensure the washers and spacer are correctly positioned.
  2. Install a new self-locking nut and tighten it.
  3. Test all functions.

Diagram: Front fork assembly with labels A-F.

9.3 Front Axle Replacement (4-wheel version)

[CAUTION] Accident risk. Placing the chassis vertically on its end can cause accidents. -- Secure the chassis to prevent it from tipping over.

[NOTE] Risk of damage to the electric vehicle. The plastic fairing may be damaged if you try to lift the scooter by the fairing. -- The scooter should only be lifted by the chassis.

When disassembling, be careful not to misplace small parts like screws and washers. Place them correctly for reassembly in the correct order.

[Tools] 12 mm wrench, 17 mm wrench

  1. Remove the seat; refer to section 5.1 Seat Removal/Installation, page 13.
  2. Remove the battery pack; refer to section 6.2 Battery Pack Removal/Installation, page 16.
  3. Remove the motor unit; refer to section 6.2.1 Motor Unit Removal/Installation, page 16.
  4. Place the chassis vertically on its seat adapter.
  5. Secure the chassis to prevent it from tipping over.

Axle Disassembly

  1. Remove the front wheels; refer to section 9.1 Wheel Replacement (4-wheel version/rear wheel of 3-wheel version), page 24.
  2. Remove the coupling rods B from the steering tube (not shown in the diagram).
  3. Hold the end of the coupling rod with a wrench while removing nut A to prevent it from turning.
  4. Loosen and remove nuts A of the coupling rods B.
  5. Remove the coupling rods from the steering plates C.
  6. Loosen and remove screws E, washers F, and nuts G, including the washer.
  7. Remove the steering plates from the axle D.
  8. Remove screw H, washer I, and nut J.
  9. Remove the axle D from the chassis.

Axle Installation

  1. Install parts by reversing the procedure.
  2. Test all functions.

Diagram: Front axle assembly with labels A-J.

9.4 Anti-tip Wheel Replacement

[Tools] 10 mm wrench (2)

Wheel Removal

  1. Remove bolt A and nut B.
  2. Pull wheel C out of the rear chassis.
  3. Replace the wheel.

Wheel Installation

  1. Install parts by reversing the procedure. Tighten the self-locking nut just enough for the wheel to still turn freely without resistance.
  2. Test all functions.

Diagram: Anti-tip wheel assembly with labels A-C.

Handlebar

10.1 Tiller Removal / Installation

[Tools] 2 x 13 mm wrenches

Disassembly

  1. Remove the control console; see 8.2 Control Console Replacement, page 21.
  2. Press on the steering cover A.
  3. Remove nuts B and washers C to detach screw D.
  4. Remove the steering bar E from the steering pivot F.
  5. Remove screw G, washers H, and steering stop I.
  6. Remove the steering pivot F from the steering tube J.

The steering pivot removal is identical for the 3-wheel and 4-wheel versions.

Installation

  1. Install parts by reversing the procedure. Ensure the steering stop I engages in the steering bar E.
  2. Test all functions.

Diagram: Tiller assembly with labels A-J. Chassis not shown for better overview.

10.2 Fork Replacement (3-wheel version)

Note the position and orientation of the wheel and fastening hardware before removing them.

[Tools] 13 mm wrench, 32 mm wrench

  1. Remove the seat; refer to section 5.1 Seat Removal/Installation, page 13.
  2. Remove the battery pack; refer to section 6.2 Battery Pack Removal/Installation, page 16.
  3. Remove the motor unit; refer to section 6.2.1 Motor Unit Removal/Installation, page 16.
  4. Remove the front cover; refer to section 7.2 Front Cover Replacement, page 19.
  5. Remove the front wheels; refer to section 9.1 Wheel Replacement (4-wheel version/rear wheel of 3-wheel version), page 24.
  6. Remove the tiller; refer to section 10.1 Tiller Removal / Installation, page 28.
  7. Remove the steering bearing kit A.
  8. Remove the fork B from the steering column support C. This action requires significant force.
  9. Remove the ball bearing D.
  10. Install parts by reversing the procedure.
  11. Test all functions.

Diagram: Fork assembly with labels A-D.

10.3 Steering Column Replacement (4-wheel version)

[Tools] 13 mm wrench, 32 mm wrench

  1. Remove the seat; refer to section 5.1 Seat Removal/Installation, page 13.
  2. Remove the battery pack; refer to section 6.2 Battery Pack Removal/Installation, page 16.
  3. Remove the motor unit; refer to section 6.2.1 Motor Unit Removal/Installation, page 16.
  4. Remove the front cover; refer to section 7.2 Front Cover Replacement, page 19.
  5. Remove the front wheel; refer to section 9.2 Axle/Front Wheel Replacement (3-wheel version), page 25.
  6. Remove the tiller; refer to section 10.1 Tiller Removal / Installation, page 28.
  7. Remove nuts A.
  8. Remove steering bars B from the steering tube C.
  9. Remove the steering bearing kit D.
  10. Pull the steering tube to remove it from the steering column support E. This action requires significant force.
  11. Remove ball bearing F.
  12. Install parts by reversing the procedure.
  13. Test all functions.

Diagram: Steering column assembly with labels A-F.

Motor Components

11.1 Drive Motor Replacement

[CAUTION] Accident risk. When the scooter is stationary on its wheels, it is no longer slowed by the motor brake. The scooter may roll away uncontrollably. -- Place the rear chassis of the scooter on a wooden support block before removing the wheels.

[CAUTION] Accident risk. Accidental rolling can cause accidents. -- Chock the scooter to prevent it from rolling.

When disassembling, note the position of small parts like screws and washers. Place them correctly for reassembly in the correct order.

Power module plugs are unlikely to be connected incorrectly as they are all different sizes and can only be connected to one socket.

[Tools] 8 mm wrench, 13 mm wrench, Phillips screwdriver, Rubber mallet, Lifting device, Cable ties

  1. Remove the seat; refer to section 5.1 Seat Removal/Installation, page 13.
  2. Remove the battery pack; refer to section 6.2 Battery Pack Removal/Installation, page 16.
  3. Remove the motor unit; refer to section 6.2.1 Motor Unit Removal/Installation, page 16.
  4. Support the motor unit with a lifting device.
  5. Remove the rear cover; refer to section 7.1 Replace Rear Covers, page 19.
  6. Remove the wheels. Refer to section 9.1 Wheel Replacement (4-wheel version/rear wheel of 3-wheel version), page 24.
  7. Remove screws A and washers B.
  8. Remove supports C.
  9. Fold the drive backwards onto the chassis and anti-tip wheels.
  10. Remove the motor D from the bottom of the rear chassis.
  11. Replace the motor.
  12. Install parts by reversing the procedure.

Install the motor plug in a floating manner. That is, ensure the plug has some play after tightening the bolts. Tighten bolts to 1.5 Nm max.

  1. Secure the motor cable using a cable tie.
  2. Install parts by reversing the procedure.
  3. Test all functions.

Diagram: Motor assembly with labels A-D.

Contact Information

Belgium & Luxemburg: Invacare nv, Autobaan 22, B-8210 Loppem, Tel: (32) (0)50 83 10 10, Fax: (32) (0)50 83 10 11, marketingbelgium@invacare.com, www.invacare.be

Canada: Invacare Canada LP, c/o Motion Concepts Canada, 84 Citation Drive Unit 11, Concord, Ontario L4K 3C1

France: Invacare Poirier SAS, Route de St Roch, F-37230 Fondettes, Tel: (33) (0)2 47 62 64 66, contactfr@invacare.com, www.invacare.fr

Switzerland: Invacare AG, Neuhofweg 51, CH-4147 Aesch BL, Tel: (41) (0)61 487 70 80, Fax: (41) (0)61 488 19 10, switzerland@invacare.com, www.invacare.ch

Recycling Information (FR)

[Recycling] This appliance, its accessories, cords, and batteries are recyclable. Return upon delivery, at store drop-off, or at a recycling center. Collection points at www.quefairedemesdechets.fr. Prioritize repairing or donating your appliance!

Invacare, Making Life's Experiences Possible®, Yes, you can.

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DTEC011388 1577884~E madbuild

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