You-Q XP Service Manual
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You-Q XP Service Manual

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Service Manual

XP
V2.0 from Jan. 1st 2015

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  • Page 1: Service Manual

    Service Manual V2.0 from Jan. 1st 2015...
  • Page 2 Copyright (C) 2015 Handicare BV All rights reserved. The information provided may not be reproduced and/or published in any form, or by any other means whatsoever( electronically or mechanically) without the prior written authorization of Handicare BV. The information provided is based on general data about the constructions known at the time of the publication of this manual.

  • Page 3: Table Of Contents

    2. Warranty and Liability 2.1. Warranty 2.2. Liability 3. Safety 3.1. Maximum user weight reduction when EQLASS is installed on an XP 3.2. Personnel qualifications 3.3. Cautions and warning statements 3.4. Pictograms on the wheelchair 4. Maintenance schedule & tooling 4.1.
  • Page 4 Table of contents 6. Maintenance on the control system 6.1. Replace the remote control (Shark, VR2 and R-Net) 6.2. Replace the remote control (DX2) 6.3. Replace the power module (Shark, VR2 and R-Net) 6.4. Replace the power module (DX2) 7. Troubleshooting 7.1.

  • Page 5: Introduction

    Always make sure that you work safely, particularly when you need to lift up the wheelchair. During maintenance and repair work you are at all times fully responsible to obey the local applicable guidelines and standards with regard to safety and environment. We advise you Service manual - XP...

  • Page 6: Product Identification

    1.5. Product identification TYPE/TYPE/TYP: You-Q Luca Qlass YEAR/JAAR/JAHR: 2015 LUQ1400520 USAGE: INDOOR/OUTDOOR GEBRUIKSGEBIED: BINNEN/BUITEN GEBRAUCHSGEBIET: INNERHALB/AUSSERHALB MAX.LOAD/MAXBELASTB./ZUL.GESAMTGEW.: 160 KG A. Model D. Usage area B. Year of manufacture E. Maximum load in kg C. Identification number Service manual - XP...

  • Page 7: Warranty And Liability

    Product: the electric wheelchair manufactured Handicare BV. • User: the person who actually uses the product. • Customer: the person who obtains the product from Handicare BV. • Dealer: the person/company who supplies the product from Handicare BV to the customer. Service manual - XP...

  • Page 8: Warranty

    Any repair to or reconditioning of the Product not authorised or performed by and/or on the instructions of Handicare BV shall not be covered by the scope of this warranty. If a Service manual - XP...

  • Page 9: Liability

    The Customers shall likewise save Handicare BV harmless from any against any liability resulting due to representations made by the Customer with regard to the Product which are incompatible with the quality or the normal use of the Product. Service manual - XP...

  • Page 10: Safety

    Safety Safety 3.1. Maximum user weight reduction when EQLASS is installed on an XP When an EQLASS seating system is installed on an XP, the maximum user weight is reduced to 136 kg. 3.2. Personnel qualifications Only service technicians that are trained and authorised by Handicare BV are allowed to do maintenance and repairs to the wheelchair.

  • Page 11: Pictograms On The Wheelchair

    Be careful when swinging the controller 'Push' mode on a slope. aside to avoid getting anything Trap danger crushed. Danger of getting fingers jammed. Battery charging connection Identification plate Attachment point of the tie down system for transportation on a vehicle. Service manual - XP...

  • Page 12: Maintenance Schedule & Tooling

    Inspection Twice a year / every 6 months Mechanical parts Inspection Yearly Bearings Inspection Yearly Tyres Check condition and profile Yearly Fasteners and bolts Check condition and Yearly tighten if necessary Wheelchair Check overall functionality Yearly Service manual - XP...

  • Page 13: Mechanical Tools

    Torque wrench, up to 60 Nm with sockets sizes: 10, 13, 17, 19 Allen keys sizes: 3, 4, 5, 6, 7, 8 Loctite 270 for bolt securing Loctite 648 Tie wraps color: black n/a: not applicable Service manual - XP...

  • Page 14: Electronical Tools

    Torque table Use the general torques as indicated in the table below, unless specified otherwise Thread Size Pitch (mm) Max. torque (Nm) 1.25 1.75 The minimum torque values are 7 - 9 % below the maximum values. Service manual - XP...

  • Page 15: Maintenance Tasks & Adjustments

    Set both freewheel switches in 'Drive' mode. Tilt the interface mounting frame forward for easy access as follows: a. Remove the screws A. b. Tilt the frame (B) until it locks in the tilted position. Remove the battery cover. Service manual - XP...
  • Page 16 Maintenance tasks & adjustments Remove the power module cover. Disconnect the batteries by removing the main fuses (A). Disconnect the motor cable (A) from the interconnection of the power module. Service manual - XP...

  • Page 17: Carrier

    Remove the drive wheel (E) from the motor axle. • Make sure that you do not loose the key (F). Replace the drive motor, depending on the drive type: • FWD: see step 6. • RWD: see step 7. Service manual - XP...
  • Page 18 Put some grease on the axle to prevent fretting. b. Mount the drive wheel on the axle. c. Make sure to lock the nut by folding the washer. Make sure that the drive wheel does not interfere with the motor. Completion See section 5.9. Service manual - XP...

  • Page 19: Replace A Drive Wheel

    Use a lifting platform. Remove screw, washer and nut A. Take out the old castor wheel (B) from the castor fork. Install the new castor wheel. • Use a new lock nut. Completion See section 5.9. Service manual - XP...

  • Page 20: Replace A Castor Fork

    Complete the maintenance. See section 5.9. 5.2.6. Replace the batteries Preparation See section 5.1. Procedure NOTICE! The illustration in this procedure shows the 31Ah battery pack. The 40Ah battery pack is larger and has two straps. Service manual - XP...

  • Page 21: Replace Main Fuse

    Make sure that the battery straps are tight. Completion See section 5.9. 5.2.7. Replace main fuse Preparation See section 5.1. Procedure Remove the old fuses (A). Put the new fuses in the fuse holders. Completion See section 5.9. Service manual - XP...

  • Page 22: Interface (All Types)

    Make sure that the interface is firmly locked by the mounting blocks and fasten the screws (A). Check if the wheelchair is stable in all available positions for seat lift and tilt. Service manual - XP...

  • Page 23: Adjust The Base Height Of The Interface

    Put the new actuator into the tilt mechanism. Connect the actuator cable. Make sure that the actuator cable can follow the movement of the mechanism but that the cable does not get jammed by the mechanism. Check the functionality of the actuator. Service manual - XP...

  • Page 24: Tilt + Lift Interface

    Put the new actuator into the tilt mechanism. Connect the actuator cable. Make sure that the actuator cable can follow the movement of the mechanism but that the cable does not get jammed by the mechanism. Check the functionality of the actuator. Service manual - XP...

  • Page 25: Legrests

    Remove the lever block (D) from the gasspring (A). The lever block is re-used with the new gasspring. Put the level block on the new gasspring. Put the new actuator in the legrest. Check the functionality of the actuator. Service manual - XP...

  • Page 26: Replace The Actuator Of The Central Legrest

    Put the new motor in the legrest. Fasten the locking screw. Connect the motor cable. Make sure that the motor cable is properly arranged. Use tie wraps. Put the seat cushion in the wheelchair. 10. Check the functionality of the actuator. Service manual - XP...

  • Page 27: Seating System Qlass

    11. Connect the actuator cable. 12. Make sure that the actuator cable is properly arranged on the seating system. 13. Check the functionality of the actuator. 14. Put the seat cushion on the wheelchair. Service manual - XP...

  • Page 28: Repiace The Tilt Actuator 25 Degrees

    Remove screw, washers and nut (D). Remove the mounting fork (E) from the actuator. The mounting fork is re-used with the new actuator. Put the mounting fork on the new actuator. Put the new actuator into the seating mechanism. Service manual - XP...

  • Page 29: Repiace The Tilt Actuator

    Put the new actuator into the tilt mechanism. Connect the actuator cable. Make sure that the actuator cable can follow the movement of the mechanism but that the cable does not get jammed by the mechanism. Check the functionality of the actuator. Service manual - XP...

  • Page 30: General Completion Of Maintenance

    Close the power module cover, make sure that it is well positioned. Install the battery cover and fasten the screws. Make sure that the power module cover is properly placed underneath the battery cover. Put the interface mounting frame down again. Service manual - XP...
  • Page 31 WARNING! After repairing, reprogramming or replacing parts, always check the functionality of the entire wheelchair. Pay special attention to safety features such as slowdown driving or drive inhibits when seat lift and tilt are both used. Service manual - XP...

  • Page 32: Maintenance On The Control System

    Replace the power module (DX2) The DX2 system has the main driving program stored in the remote and a backup of the program in the power module. Replacing the power module can be done without programming. For REM420: Service manual - XP...
  • Page 33 The display shows a selection sequence for the backup program. Replace the remote control. Select the module that has NOT been replaced. The backup program from this module will be used to automatically re-program the new module. Service manual - XP...

  • Page 34: Troubleshooting

    NOTICE! If the problem is not solved with the help of the solutions in the tables, contact your dealer/distributor or the Service Department of Handicare BV. Service manual - XP...

  • Page 35: General Diagnostics And Faultfinding

    Measure resistance from the speed limit cable in different seating positions. Bad cable connections or a broken resistor influences the drive inhibit signal. Incorrect programming Check for correct program. Re-program if needed. Service manual - XP...
  • Page 36 Check pressure and inflate power to drive properly wheels or castors is too low if needed. See User manual for correct value. Programming of speed and Check programming and Torque Settings is not make corrections if needed. correct Service manual - XP...
  • Page 37 Castor wheels "wobble" at Tyre pressure too high. Check tyre pressure and higher speed decrease if needed. See user manual for correct value. Too little load on the castor Modify seating setup if wheels. possible or decrease tyre pressure. Service manual - XP...
  • Page 38 (or actuator speed make corrections if needed. is too low) Contact manufacturer for correct settings. Actuator is internally not Check actuator functioning properly temperature after operation and/or check for excessive noise when operated. Replace actuator. Service manual - XP...
  • Page 39 Too much load on front Modify seating setup to castors (RWD). have better weight distribution. Wheelchair moves very Load compensation is too Modify load compensation rapidly and jerky high. in driving program. Check with manufacturer for correct settings. Service manual - XP...

  • Page 40: Diagnostics And Troubleshooting For Shark Controls

    Remove both fuses from the batteries before you change any cables, fuses and/or modules. This way the power way is disconnected from the wheelchair. NOTICE! For more detailed information about Shark Controllers, specific manuals can be downloaded from the website: www.dynamiccontrols.com. Service manual - XP...
  • Page 41 The ON-OFF light flashes 9 Communication fault in the Check all connections and times Shark system correct them if needed. If the fault signal is still present after this, replace the controller. Service manual - XP...
  • Page 42 Service Department of Handicare BV. The ON-OFF light flashes System does not 'fit'. Check if the controller type 11 times System modules are not corresponds with the power compatible. module. Replace one of the two if needed. Service manual - XP...

  • Page 43: Diagnostics And Troubleshooting For Dx2 Controls

    Remove both fuses from the batteries before you change any cables, fuses and/or modules. This way the power is disconnected from the wheelchair. NOTICE! For more detailed information about DX2 Controllers, specific manuals can be downloaded from the website: www.dynamiccontrols.com. Service manual - XP...
  • Page 44 Only replace the power module if the error occurs immediately when you switch on the power module. If the error occurs when you start to drive, the entire motor circuit causes this error. In this case, replace the motor. Service manual - XP...
  • Page 45 The ON-OFF light flashes 8 The battery voltage is high: This usually occurs during times above 32 V (trickle) charging. Frequent occurrences will result in a defective power module. Correct the charger settings. Service manual - XP...
  • Page 46 Program the entire drive 11 times System modules are not system for the relevant compatible. wheelchair with the aid of the DX-Wizard program on the PC. Always confirm the programming by switching the wheelchair on and off. Service manual - XP...

  • Page 47: Cable And Module Schemes

    1x 70A 9002473 Batteries 6000043 6000573 6000573 Motor Motor Cable lenghts are not drawn to scale! Shark 1 6000038 6000039 Lighting 6000215 6000038 6000039 1002945 (1.5 m) 6000759 Cable lenghts are not drawn to scale! Shark 2 Service manual - XP...
  • Page 48 Cable lenghts are not drawn to scale! Shark 3 Shark Qlass Tilt45 & Recline (Lights optional) 6000038 6000039 Lighting 6000215 6000038 6000039 6000792 (2.5 m) 6000759 6000778 6000778 Tilt 45° Recline 9002615 Cable lenghts are not drawn to scale! Shark 4 Service manual - XP...
  • Page 49 Cable and module schemes Shark EQlass Tilt30° & Recline (Lights optional) 6000038 6000039 Lighting 6000215 6000038 6000039 1002945 (1.5 m) 6000759 6000778 6000778 Tilt 30° Recline 9002615 Cable lenghts are not drawn to scale! Shark 5 Service manual - XP...

  • Page 50: Dx2 Controls

    (3000417) 6000038 00355.0018 (1.75 m) 6000039 01502.1110 Legrest Left Lighting 6000216 6000333 9002616 9001233 6000038 (3000417) Legrest Right 6000333 9002616 9001233 6000039 (3000417) 01502.1110 Gyro Qontroll (optional) Cable lenghts are not drawn to scale! DX2 2 Service manual - XP...
  • Page 51 9002615 00355.0074 (2.7 m, RWD) 00355.0018 (1.75 m, FWD) (3000417) 6000039 Legrest Angle Lighting 6000216 6000333 6000038 (3000417) Foot Plate Elevation 6000039 6000333 (3000417) Gyro Qontroll (optional) Cable lenghts are not drawn to scale! DX2 4 Service manual - XP...
  • Page 52 00355.0018 (1.75 m) Recline 6000333 9002615 (3000417) 6000038 00355.0074 (2.7 m, RWD) 00355.0018 (1.75 m, FWD) 6000039 Lighting 6000216 6000038 6000688 Lift (3000418) 6000039 Gyro Qontroll (optional) Cable lenghts are not drawn to scale! DX2 6 Service manual - XP...
  • Page 53 (3000418) 6000038 00355.0074 (2.7 m, RWD) 00355.0018 (1.75 m, FWD) 6000039 Legrest Angle Lighting 6000216 6000038 6000333 (3000417) Foot Plate Elevation 6000039 6000333 (3000417) Gyro Qontroll (optional) Cable lenghts are not drawn to scale! DX2 8 Service manual - XP...

  • Page 54: Version History

    Version history Version history Version Release date Changes V1.0 Jan. 8th 2014 First released version. V2.0 Jan. 1st 2015 New company name. Service manual - XP...

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