Mirage Electric Wheelchair
Mirage Electric Wheelchair
en Power Wheelchair
Service Manual
For pre-sale and user information, see the user manual. WARNING
Indicates a hazardous situation that could result
For more information about the product, for example product in serious injury or death if it is not avoided.
safety notices and product recalls, contact your Invacare
representative. See addresses at the end of this document. CAUTION
Indicates a hazardous situation that could result
in minor or slight injury if it is not avoided.
1.2 General information
IMPORTANT
• Service and maintenance work must be carried out Indicates a hazardous situation that could result
taking this service manual into account. in damage to property if it is not avoided.
• It is imperative that you observe safety information. Gives useful tips, recommendations and
• Information about operation or about general information for efficient, trouble-free use.
maintenance and care work on the mobility device
should be taken from Service manual. This product complies with Directive 93/42/EEC
• You can find information about ordering spare parts in concerning medical devices. The launch date
the spare parts catalogue. of this product is stated in the CE declaration
• Spare parts MUST match original Invacare parts. Only of conformity.
use spare parts which have been approved by Invacare.
This symbol identifies a list of various tools,
• We reserve the right to make any alterations on the
components and items which you will need in
grounds of technical improvements.
order to carry out certain work.
• For more information about the product, for example
product safety notices and product recalls, contact your
local Invacare representative. For address and website 1.5 Images in this manual
see back page of this manual.
• The mobility device may only be maintained and The detailed images in this manual are given marks to
overhauled by qualified personnel. identify various components. Component marks in text and
• The minimum requirement for service technicians is operational instructions always relate to the image directly
suitable training, such as in the cycle or orthopedic above.
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.
4 1441763-E
Safety
2 Safety CAUTION!
Injury hazard if the vehicle starts moving
unintentionally during repair work
2.1 Safety and fitting instructions – Switch the power supply off (ON/OFF key).
– Engage the drive.
These safety instructions are intended to prevent accidents – Before lifting up, secure the vehicle by using
at work, and it is imperative that they are observed. chocks to block the wheels.
Before any inspection or repair work
CAUTION!
• Read and observe this repair manual and the associated
Fire and burn hazard due to electrical short-circuit
user manual.
– The mobility device must be completely
• Observe the minimum requirements for carrying out the
switched off before removal of voltage-carrying
work (see 1.2 General information, page 4 ).
components! To do this, remove the batteries.
Personal safety equipment – Avoid short-circuiting the contacts when
carrying out measurements on voltage-carrying
Safety shoes components.
The mobility device, and some of its components, are very
heavy. These parts can result in injuries to the feet if they CAUTION!
are allowed to drop. Risk of burns from hot surfaces on the motor
– Allow the motors to cool down before
• Wear standardized safety shoes during all work.
commencing work on them.
Eye protection
It is possible that battery acid can be discharged when CAUTION!
working on defective batteries or when handling batteries Injury hazard and risk of damage to vehicle due
improperly. to improper or incomplete maintenance work
– Use only undamaged tools in good condition.
• Always wear eye protection when working on any – Some moving parts are mounted in sockets
defective or possibly defective batteries. with PTFE coating (Teflon™). Never grease
these sockets!
Safety gloves
– Never use "normal" nuts instead of self-locking
It is possible that battery acid can be discharged when nuts.
working on defective batteries or when handling batteries – Always use correctly-dimensioned washers and
improperly. spacers.
– When reassembling, always replace any cable
• Always wear acid-proof safety gloves when working on ties which were cut during dismantling.
any defective or possibly defective batteries. – After completing your work / before renewed
General safety information and information about fitting start-up of the mobility device, check all
/ removal connections for tight fitting.
– After completing your work / before renewed
DANGER! start-up of the mobility device, check all parts
Risk of Death, Serious Injury, or Damage for correct locking.
Lighted cigarettes dropped onto an upholstered – Only operate the vehicle with the approved tire
seating system can cause a fire resulting in pressures (see technical data).
death, serious injury, or damage. Mobility device – Check all electrical components for correct
occupants are at particular risk of death or function. Note that incorrect polarity can result
serious injury from these fires and resulting fumes in damage to the electronics.
because they may not have the ability to move – Always carry out a trial run at the end of your
away from the mobility device. work.
– DO NOT smoke while using this mobility device.
CAUTION!
WARNING! Risk of injury and damage to property, if the
Risk of Serious Injury or Damage maximum speed reduction on a wheelchair with
Storing or using the mobility device near open a lifter does not function correctly
flame or combustible products can result in The wheelchair’s control unit must reduce the
serious injury or damage. maximum possible speed as soon as the lifter is
– Avoid storing or using the mobility device near raised.
open flame or combustible products. – Test the maximum speed reduction for correct
function after any maintenance work or
CAUTION! modifications to the wheelchair.
Risk of crushing
Various components such as the drive unit,
batteries, seat etc are very heavy. This results in
injury hazards to your hands.
– Note the high weight of some components.
This applies especially to the removal of drive
units, batteries and the seat.
1441763-E 5
Invacare® Mirage
6 1441763-E
Hygiene
3 Hygiene
Disinfection tools
• One way wipes (fleece)
• Brushes to clean difficult to access areas
Further information
1441763-E 7
Invacare® Mirage
CAUTION!
Risk of damage to power module due to shorts
in motor brake
– NEVER connect a motor brake with a short to
an intact power module.
– Always replace shorted brakes immediately.
8 1441763-E
Testing
1441763-E 9
Invacare® Mirage
10 1441763-E
Service
1441763-E 11
Invacare® Mirage
5.5 Troubleshooting 1. First assess the possible cause of the problem using the
following table.
5.5.1 Operational faults 2. Check the remote status display. Evaluate the flash error
code.
Proceed as follows if you have any problems: 3. Carry out the necessary checks and repairs as
recommended in the following table.
The various power modules can be fitted in connection with
diferent remotes in the mobility device. Rectification of
operational faults depends on the power module fitted. The
12 1441763-E
Service
power modules used are described in the corresponding The tables for rectification of operational faults listed
controls manual. in the following chapters are only an excerpt from
the original manufacturer's manuals. You can obtain
the original manuals from Invacare®.
1441763-E 13
Invacare® Mirage
Fault Sub
Description Notes
Code Code
3 Left motor error (M2) 00 Motor short circuit
01 Motor open circuit
02 Motor connection fault (short to B-)
03 Motor terminal connected to B+
04 Motor voltage consistency fault (probably fault with power module
electronics).
05 Motor bridge fault (probably fault with power module electronics).
06 Too many hardware current limit events
07 Current measurement offset out of range
08 Hardware current limit fault
4 Right motor fault (M1) 00 Motor short circuit
01 Motor open circuit
02 Motor connection fault (short to B-)
03 Motor terminal connected to B+
04 Motor voltage consistency fault (probably fault with power module
electronics).
05 Motor bridge fault (probably fault with power module electronics).
06 Too many hardware current limit events
07 Current measurement offset out of range
08 Hardware current limit fault
5 Left park brake error 00 Left park brake-drive time test failed
01 left park brake output enabled when chair idle
02 left park brake output did not enable when entering drive
03 left park brake fault during power up test
04 left park brake feedback low during drive (park brake short circuit)
6 Right park brake error (M1) 00 Right park brake-drive time test failed
01 Right park brake output enabled when chair idle
02 Right park brake output did not enable when entering drive
03 Right park brake fault during power up test
04 Right park brake feedback low during drive (park brake short circuit)
7 Remote error 00 Local remote fault (electronics, power button fault etc)
01 Joystick fault at remote
02 Speed pot fault at remote
14 1441763-E
Service
Fault Sub
Description Notes
Code Code
8 Power module error 00 Power Module Fault
01 RAM fault
02 ROM fault
03 CPU fault
04 EEPROM fault
05 Watchdog fault
06 Stack fault
07 Software fault
08 Power up testing fault
09 Relay fault or Pre-charge fault
0A Bridge fault or Disable all fault
0B Electronics fault
0C Calibration settings fault
9 Remote Communications 00 Loss of communications between remote and power module
Fault
01 Limp mode due to unreliable communications
10 Unknown error 00 Catch all fault output
11 Incompatible remote 00 Wrong remote type is connected. Ensure that the power module type
code matches the remote type code.
5.6 Chassis 1. Remove parts that are in the way, such as batteries,
armrests, legrests, and anti-tippers. Removing wheels
5.6.1 Removing Chassis Components and motors is optional.
• 4 mm Allen key Batteries See corresponding user manual.
• 5 mm Allen key
Backrest See 5.11.1 Replacing Backrest
• 8 mm wrench (2x)
Unit, page 25.
• 10 mm wrench (2x)
• 13 mm wrench (2x) Legrest See 5.14 Footrests / Legrests,
• 17 mm wrench (2x) page 27.
• Flat screwdriver
armrest See 5.13 Armrests, page 26.
• Mallet
Anti-Tipper See 5.8.8 Replacing Anti-Tipper,
page 22.
Propulsion unit See 5.7.1 Replacing Motor, page
18.
Curb climber See 5.6.6 Replacing Curb Climber,
page 17.
Castor wheels See 5.8.2 Replacing Castor Wheels,
page 19.
Drive wheels See 5.8.4 Replacing drive wheel,
page 20.
2. If seat clamp (7) is locked, unlock both right and left
hand side and fold wheelchair frame.
3. Remove legrest holder. See 5.14.1 Replacing Legrest
Fig. 5-1 Holder, page 27.
4. Remove plastic frame fittings (12) carefully.
5. Remove X-Brace and seat stays. See 5.6.3 Replaxing
X-Brace, page 16.
6. Remove battery rails. See 5.6.5 Replacing Battery Rails,
page 16.
7. Remove rear seat saddles (6). See 5.6.2 Replacing Seat
Saddles, page 16.
1441763-E 15
Invacare® Mirage
Fig. 5-3
Fig. 5-4
• 4 mm Allen key
• 5 mm Allen key
• 10 mm wrench (2x)
• 13 mm wrench (2x)
• 17 mm wrench (2x)
16 1441763-E
Service
3.
Fig. 5-6
Loosen and remove nut A and washer B.
4. Secure gas spring C! Pull bolt F and washer E out
of holder D.
5.
Fig. 5-5
• 4 mm Allen key
• 10 mm Allen key
• 10 mm wrench
• 13 mm wrench (2x)
• 19 mm wrench
Removing Curb Climber Hold in place bolt E. Loosen and remove nut A
including washer B.
1. Secure mobility device against rolling away. 9. Replace gas spring C.
2. If necessary, remove parts that are in the way like
legrests.
1441763-E 17
Invacare® Mirage
Fig. 5-10
• Flat screwdriver
Fig. 5-11
18 1441763-E
Service
5.8 Wheels 1. Remove castor plastic cap with flat screwdriver. Counter
lower nut E and remove upper nut J.
5.8.1 General Warning Information on Wheel Replacement 2. Pull out castor fork assembly. out of steering head tube.
Make sure not to damage threads of steering head shaft
WARNING! H.
Risk of injury 3. Counter steering head shaft H. Remove nut E and
If a tire with one or more damaged rim threads is washer F.
inflated, rim could burst and cause serious injury. 4. If necessary, replace ball bearings I, see 5.8.3 Installing
– Do not inflate tire if one or more rim threads Ball Bearings, page 19. Make sure not to damage
are damaged. steering head tube.
– Immediately replace rim with damaged threads. 5. Remove end caps C.
6. Counter axle bolt B. Remove axle nut A.
CAUTION! 7. Remove axle bolt B and wheel D.
Risk of injury from wheels coming loose 8. If necessary, repair flat tire. See 5.8.7 Repairing tire
If wheels are insufficiently secured during puncture (drive wheel), page 21.
mounting, they can come loose when driving. Installing Castor Wheels
– When mounting wheels tighten bolts with
prescribed torque. CAUTION!
– Secure all bolts using a suitable blocker. Incorrect reassembly can damage the bearings
– Never use normal nuts instead of self-locking and cause the casters to fall out
nuts. The single-row angular ball bearing rings are not
– Always use new nuts and bolts with an identical on both sides. There is only one correct
undamaged coating. way to insert them.
– The bearings must always be assembled so that
CAUTION! the narrow borders of the ball bearings are
Risk of injury due to uncontrolled movement of facing each other (inside).
mobility device – The steering head bolts and nuts must always
– Turn power off. be pressing against the wide (outside) border of
– Engage motors. the ball bearings! Otherwise, the bearings will
– Secure mobility device against rolling away by be pressed apart and damaged by the bolts.
placing wedges under wheels.
After installation, castor wheels should rotate freely
Risk of damage to rim threads but bearings should have no play.
Incorrectly tightened screws can cause damage
to rim threads. 1. Install parts in reverse order.
– Tighten rim screws with recommended 2. Test all functions.
tightening torque. 3. First tighten nuts to 20 Nm ± 2 Nm.
4. Then loosen them slightly.
5. Then retighten to 15 Nm ± 1.5 Nm.
5.8.2 Replacing Castor Wheels
5.8.3 Installing Ball Bearings
CAUTION!
Incorrect installation can damage bearings and
cause 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.
– The bearings must always be assembled so that
narrow borders of the ball bearings are facing
each other (inside).
– The steering head bolts and nuts must always
be pressing against wide (outside) border of
ball bearings! Otherwise, the bearings will be
pressed apart and damaged by the bolts.
• 13 mm wrench (2x)
• 19 mm wrench (2x)
• Torque wrench
• Flat screwdriver (large)
• Wooden block (approx. 12 cm x 12 cm x 30 cm
for propping up mobility device)
1441763-E 19
Invacare® Mirage
After installation wheels should rotate freely but bearings 3. Loosen and remove countersunk center screw and
should have no play. washer.
4. Pull hub off motor shaft
5.8.4 Replacing drive wheel
Degreasing Mounting Holes and Motor Shaft
CAUTION! The following describes the degreasing of the threaded
Risk of crushing to hands and feet by weight of mounting holes and surface of the motor shaft.
mobility device
– Pay attention to hand and feet. To ensure a secure connection between the shaft and the
– Use proper lifting techniques. hub and guarantee the function of the retaining compound
and thread locking adhesive according to DIN 267-28, the
• Torx wrench with threaded mounting holes and surface of the motor shaft
– TX40 Bit must be cleaned of all grease. This process refers to all
• Mounting kit wheelchairs, on which the axial direction of movement
• Wooden block (approx. 12 x 12 x 30 cm) for of the rear wheels is secured by the "wheel hub cover"
propping up mobility device (Z122014-0002 and Z122014-9005) using a hub screw with
a thread locking adhesive. To do this, a spritz of Loctite®
Take care of small parts and observe sequence in 7063 (or a cleaner with identical features) is sprayed into
which component parts are installed. Set them out the shaft’s threaded mounting hole () and on its surface.
in an orderly fashion so that they can be installed The cleaner must be allowed to evaporate completely before
again easily in correct sequence. connecting the parts to one another.
This cleaning instruction is also valid for other screw joints
1. Prop up mobility device using wooden block. where screws with a retaining compound or thread locking
2. coating are used. It is also important to ensure that the
threaded surfaces are free of grease when securing a
screwed joint with screw adhesive, e.g. Loctite®.
20 1441763-E
Service
Fig. 5-14
• 4 mm Allen key
• 5 mm Allen key
1441763-E 21
Invacare® Mirage
22 1441763-E
Service
Fig. 5-18
1441763-E 23
Invacare® Mirage
Fig. 5-19
24 1441763-E
Service
Fig. 5-20
1. Loosen screw C.
2. Pull holder D out off remote bracket B.
3. If necessary, loosen hand screw A and remove remote
bracket B.
Installing Headlight Holder
1. Install parts in reverse order.
2. Test correct installation.
5.11 Seating
This manual refers to configurations with standard seat
system.
For other seat systems (for example Modulite), refer to the
corresponding manual. Fig. 5-22
Fig. 5-21
Replacing Backbrace
1. Remove both hand screws A on backrest unit.
2. Remove back brace B.
3. Install parts in reverse order. Fig. 5-23 Schematic representation of a padded fabric seat
1441763-E 25
Invacare® Mirage
Installing headrest
• Phillips screwdriver, size 2
1. Install parts in reverse order.
2. Tighten hand screw B hand-tight.
1. Remove any parts that are in the way, such as armrests
3. Test all functions.
and seat cushion.
2. Loosen and remove eight screws including rosette.
3. Replace seat. 5.12.2 Replacing Headrest Mounting Bracket
4. Install parts in reverse order.
• 4 mm Allen key
Replacing Seat Board
CAUTION!
Risk of injury and damage
An incorrectly installed safety clip can come off
and the seat board can unexpectedly fall down,
which can lead to injuries.
– Make sure that you install safety clip correctly
and it engages.
Fig. 5-26
Removing bracket
Fig. 5-24
Not all bolts and washers are shown in illustration.
1. Remove any parts that are in the way, such as armrests
and seat cushion. 1. Loosen and remove bolts E including washers F,
2. Remove four safety clips B. mounting plate D and bottom side of bracket C.
3. Lift off seat board A. 2. Remove top side of bracket B including nuts A.
Installing bracket
5.12 Headrest / Neckrest
1. Install parts in reverse order.
5.12.1 Replacing Headrest 2. Test all functions.
5.13 Armrests
5.13.1 Replacing Armrest
Replacing Armpad
Fig. 5-28
Fig. 5-27
26 1441763-E
Service
Fig. 5-29
Fig. 5-31
• 4 mm Allen key
• 5 mm Allen key
• 10 mm wrench
• 5 mm Allen key
1441763-E 27
Invacare® Mirage
Fig. 5-36
• 10 mm wrench (2x)
Fig. 5-35
1. Counter nut K.
2. Loosen and remove bolt F including nut K, washer(s)
(H and J) and locking part G.
Replacing Hanger Lock (since July 2015)
Fig. 5-37
• 4 mm Allen key
Removing Foot Plate / Heel Strap
1. Loosen and remove screw including saddle washer and 1. Loosen and remove screw C, saddle washers B and
locking part. nut G.
2. Pull legrest A out of foot plate D.
5.14.3 Replacing Angle- And Depth-Adjustable Foot Plate 3. Loosen and remove screw E including plastic bolt H.
4. Remove heel strap F.
• 5 mm Allen key Installing Foot Plate / Heel Strap
1. Install parts in reverse order.
Ensure that saddle washers B are in correct
position.
2. Test all functions.
28 1441763-E
Service
Fig. 5-38
1441763-E 29
Invacare® Mirage
6 Accessories
6.1 Accessories
• Swing-away tray, left-hand mounted
• Swing-away tray, right-hand mounted
• Taxi Clamp
• Tie-Down Clamp (Rear and Front)
• Battery transportation strap
• Mirror
• Caneholder
The installation instructions for accessories are available at your provider or directly from Invacare.
30 1441763-E
Notes
Invacare Sales Companies
Australia: Canada: Ireland: New Zealand:
Invacare Australia PTY. Ltd. Invacare Canada LP Invacare Ireland Ltd, Invacare New Zealand Ltd
1 Lenton Place, North Rocks NSW 570 Matheson Blvd E. Unit 8 Unit 5 Seatown Business Campus 4 Westfield Place, Mt Wellington 1060
2151 Mississauga Ontario Seatown Road, Swords, County Dublin New Zealand
Australia L4Z 4G4, Canada Tel : (353) 1 810 7084 Phone: 0800 468 222
Phone: 1800 460 460 Phone: (905) 890 8300 Fax: (353) 1 810 7085 Fax: 0800 807 788
Fax: 1800 814 367 Fax: (905) 501 4336 ireland@invacare.com sales@invacare.co.nz
orders@invacare.com.au www.invacare.ie www.invacare.co.nz
www.invacare.com.au
United Kingdom: Eastern Europe, Middle East & CIS:
Invacare Limited Invacare EU Export
Pencoed Technology Park, Pencoed Kleiststraße 49
Bridgend CF35 5AQ D-32457 Porta Westfalica / Germany
Tel: (44) (0) 1656 776 222 Tel: (49) (0)57 31 754 540
Fax: (44) (0) 1656 776 220 Fax: (49) (0)57 31 754 541
uk@invacare.com webinfo-eu-export@invacare.com
www.invacare.co.uk www.invacare-eu-export.com
Manufacturer:
Invacare Deutschland GmbH
Kleiststraße 49
D-32457 Porta Westfalica
Germany
1441763-E 2018-05-01
Making Life’s Experiences Possible®
*1441763E*