Invacare Storm Torque SP Service manual

Service Manual

STORM SERIES

WHEELCHAIRS

(RWD/MWD/FWD)

®

Arrow

®

Torque

SP

Ranger X

DEALER: KEEP THIS MANUAL. THE PROCEDURES

IN THIS MANUAL MUST BE PERFORMED BY AN

AUTHORIZED DEALER ONLY

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WARNING

THE PROCEDURES IN THIS MANUAL SHOULD ONLY BE PERFORMED BY

QUALIFIED TECHNICIAN.

DO NOT SERVICE OR OPERATE THIS EQUIPMENT WITHOUT FIRST

READING AND UNDERSTANDING THIS MANUAL AND THE OWNERS

MANUAL SUPPLIED WITH THE WHEELCHAIR. IF YOU ARE UNABLE TO

UNDERSTAND THE WARNINGS, CAUTIONS, AND INSTRUCTIONS,

CONTACT INVACARE TECHNICAL SUPPORT BEFORE ATTEMPTING TO

SERVICE OR OPERATE THIS EQUIPMENT - OTHERWISE INJURY OR

DAMAGE MAY RESULT.

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SPECIAL NOTES

WARNING/CAUTION notices as used in this manual apply to hazards or unsafe practices which could result in personal injury or property damage.

NOTICE

THE INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT

NOTICE.

WHEELCHAIR USER

As a manufacturer of wheelchairs, Invacare endeavors to supply a wide variety of

Action wheelchairs to meet many needs of the end user. However, final selection of the type of wheelchair to be used by an individual rests solely with the user and his/her healthcare professional capable of making such a selection.

WHEELCHAIR TIE-DOWN RESTRAINTS AND SEAT POSITIONING STRAPS

Invacare recommends that wheelchair users NOT be transported in vehicles of any kind while in wheelchairs. As of this date, the Department of Transportation has not approved any tie-down systems for transportation of a user while in a wheelchair, in a moving vehicle of any type.

It is Invacare’s position that users of wheelchairs should be transferred into appropriate seating in vehicles for transportation and use be made of the restraints made available by the auto industry. Invacare cannot and does not recommend any wheelchair transportation systems.

AS REGARDS RESTRAINTS - SEAT POSITIONING STRAPS - IT IS THE OBLIGATION OF THE DME

DEALER, THERAPISTS AND OTHER HEALTHCARE PROFESSIONALS TO DETERMINE IF A SEAT-

ING POSITIONING STRAP IS REQUIRED TO ENSURE THE SAFE OPERATION OF THIS EQUIP-

MENT BY THE USER. SERIOUS INJURY CAN OCCUR IN THE EVENT OF A FALL FROM A WHEEL-

CHAIR.

SAVE THESE INSTRUCTIONS

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TABLE OF CONTENTS


NOTE: The information in this owner's manual applies to the STORM ARROW, ** STORM TORQUE, STORM

X, JUNIOR MODELS and the RECLINER Wheelchairs except where specified.

NOTE: Procedures 1- 14 apply to rear wheel drive, mid wheel drive and front wheel drive wheelchairs EXCEPT where specified.

SPECIAL NOTES ...................................................................................................................................................... 2

SPECIFICATIONS ..................................................................................................................................................... 6

PROCEDURE 1 - GENERAL GUIDELINES .................................................................................................................... 8

REPAIR OR SERVICE INFORMATION .................................................................................................................. 8

OPERATING INFORMATION ................................................................................................................................ 8

WARNING/CAUTION LABEL LOCATION ............................................................................................................. 9

PROCEDURE 2 - TROUBLESHOOTING ..................................................................................................................... 11

FIELD LOAD TEST ........................................................................................................................................... 11

USING HYDROMETER TO CHECK BATTERY CELLS (LEAD ACID) ....................................................................... 11

MOTOR TESTING ............................................................................................................................................ 12

MOTOR BRUSH INSPECTION ........................................................................................................................... 13

ELECTRO-MECHANICAL PARKING BRAKE TESTING ......................................................................................... 13

PROCEDURE 3 - HARDWARE TORQUE SPECIFICATIONS ......................................................................................... 14

STANDARD SEAT FRAME ................................................................................................................................ 14

CAPTAINS VAN SEAT ...................................................................................................................................... 15

ADJUSTABLE SEAT FRAME ............................................................................................................................. 15

REAR WHEEL DRIVE BASE FRAME HARDWARE TORQUE SPECIFICATIONS ..................................................... 16

MID-WHEEL DRIVE BASE FRAME HARDWARE TORQUE SPECIFICATIONS ........................................................ 17

FRONT WHEEL DRIVE BASE FRAME HARDWARE TORQUE SPECIFICATIONS ............................................... 18

PROCEDURE 4 - ARMS ........................................................................................................................................... 19

REPLACING ARMREST PADS - CAPTAINS VAN SEAT ........................................................................................ 19

REPLACING CAPTAINS VAN SEAT ARMREST PLATE ......................................................................................... 19

PROCEDURE 5 - UPHOLSTERY/POSITIONING STRAP .............................................................................................. 20

REPLACING SEAT POSITIONING STRAP - CAPTAINS VAN SEATS ....................................................................... 20

REPLACING BACK UPHOLSTERY .................................................................................................................... 20

PROCEDURE 6 - SEAT FRAME ................................................................................................................................ 22

PREPARATIONS FOR REMOVING/INSTALLING SEAT FRAME (STANDARD FRAME, ADJUSTABLE FRAME AND

CAPTAINS VAN SEAT ...................................................................................................................................... 22

REPLACING EXACT SAME SIZE STANDARD SEAT FRAME ................................................................................ 23

REMOVING/INSTALLING STANDARD SEAT FRAME SUB-ASSEMBLY .................................................................. 23

CHANGING SEAT DEPTH ................................................................................................................................. 24

CHANGING SEAT WIDTH (STANDARD AND ADJUSTABLE SEAT FRAME) ............................................................. 26

INSTALLING/REMOVING ADJUSTABLE SEAT FRAME SUBASSEMBLY AND/OR COMPONENT REPLACEMENT ..... 27

INSTALLING/REMOVING CAPTAINS VAN SEAT ASSEMBLY ............................................................................. 29

REPLACING CAPTAINS VAN SEAT AND/OR CAPTAINS VAN SEAT FRAME ...................................................... 29

CONVERTING FROM STANDARD SEAT FRAME TO ADJUSTABLE SEAT FRAME OR VICE VERSA ................... 30

CONVERTING FROM ADJUSTABLE SEAT FRAME TO CAPTAINS VAN SEAT OR VICE VERSA .......................... 30

CONVERTING FROM STANDARD SEAT FRAME TO CAPTAINS VAN SEAT OR VICE VERSA ............................. 31

REMOVING/INSTALLING SEAT PAN................................................................................................................. 31

MOUNTING PLATE - SEAT ANGLE ADJUSTMENT AND INSTALLATION ORIENTATION ........................................ 32

PROCEDURE 7 - BASE FRAME ................................................................................................................................ 33

REPLACING SEAT MOUNTING PLATES ............................................................................................................. 33

REPLACING SEAT SUPPORT BRACKETS ......................................................................................................... 33

REPLACING SEAT SUPPORT BRACKET T-NUTS ............................................................................................... 34

REPLACING BATTERY CHARGER BRACKET AND T-NUT .................................................................................... 35

REMOVING/INSTALLING SEAT STOP SCREWS ................................................................................................. 36

PROCEDURE 8 - BACK FRAME ................................................................................................................................ 37

REPLACING CJ BACK BRACKETS .................................................................................................................... 37

CHANGING BACK HEIGHT ............................................................................................................................... 38

BACK ANGLE ADJUSTMENT ............................................................................................................................ 40

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** The Storm Torque model wheelchair is available in rear wheel drive ONLY.

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TABLE OF CONTENTS (Continued)

PROCEDURE 9 - BATTERIES ................................................................................................................................. 41

INSTALLING/REMOVING BATTERIES INTO/FROM BATTERY BOX(ES) ............................................................... 41

CONNECTING BATTERY CABLES ................................................................................................................... 42

WHEN TO CHARGE BATTERIES ..................................................................................................................... 46

CHARGING BATTERIES .................................................................................................................................. 46

REPLACING BATTERIES ................................................................................................................................. 48

INSTALLING/REMOVING GROUP 24 BATTERY BOXES .................................................................................... 48

INSTALLING/REMOVING GROUP 22 BATTERY BOX ......................................................................................... 49

PROCEDURE 10 - WIRING HARNESS ...................................................................................................................... 50

REMOVING/INSTALLING THE WIRING HARNESS .............................................................................................. 50

ADJUSTING LIMIT SWITCH .............................................................................................................................. 52

PROCEDURE 11 - RETENTION STRAP/RETAINER ................................................................................................. 53

REPLACING BATTERY BOX RETAINER/RETAINER CLIP - GROUP 24 BATTERY BASE FRAMES ........................... 53

PROCEDURE 12 - WHEELS/MOTORS ................................................................................................................... 54

REPLACING PNEUMATIC TIRES/TUBES - DRIVE WHEELS/CASTERS ................................................................. 55

REMOVING/INSTALLING DRIVE WHEELS ........................................................................................................... 55

REMOVING/INSTALLING DRIVE WHEEL HUB ..................................................................................................... 56

INSTALLING WHEEL LOCK BRACKET ONTO WHEEL CHAIR ............................................................................... 56

REMOVING/INSTALLING CASTERS .................................................................................................................... 57

REPLACING FORKS .......................................................................................................................................... 57

REMOVING/INSTALLING THE MOTOR (CONVENTIONAL MOTOR WITH GEARBOX) .............................................. 57

REMOVING/INSTALLING THE MOTOR (GEARLESS BRUSHLESS MOTOR) .......................................................... 59

PROCEDURE 13 - ELECTRONICS ......................................................................................................................... 61

REPOSITIONING MKIV JOYSTICK - VAN SEAT MODELS ..................................................................................... 61

REMOVING/INSTALLING MKIV CONTROLLER ..................................................................................................... 61

PROCEDURE 14 - RECLINER ................................................................................................................................ 63

POSITIONING LIMIT SWITCH............................................................................................................................... 63

ADJUSTING LIMIT SWITCH ................................................................................................................................. 63

REPLACING RECLINER CABLE ASSEMBLIES .................................................................................................... 64

REPLACING/ADJUSTING GAS CYLINDERS......................................................................................................... 65

CHANGING BACK HEIGHT ................................................................................................................................. 66

CHANGING SEAT DEPTH ................................................................................................................................... 67

CHANGING SEAT WIDTH ................................................................................................................................... 67

EQUIPMENT OPTION INSTALLING/REPLACING ADJUSTABLE 16 TO 19-INCH DEEP RECLINER SEAT FRAME ONTO

ARROW OR X BASE FRAME .......................................................................................................................... 68

PROCEDURE 15 - MWD WHEELCHAIRS ............................................................................................................... 69

REMOVING/INSTALLING GROUP 24 BATTERY BOX SUB-FRAME ........................................................................ 69

REMOVING/INSTALLING GROUP 22 BATTERY BOX TRAY ................................................................................... 69

EQUIPMENT OPTION CONVERTING GROUP 22 BATTERY BOX TRAY TO GROUP 24 BATTERY BOX SUB FRAME ..... 70

SHOCK REPLACEMENT .................................................................................................................................... 71

SHOCK SPRING REPLACEMENT ....................................................................................................................... 73

REPLACING STABILIZER FORK ASSEMBLY ....................................................................................................... 74

REPLACING STABILIZER WHEELS ..................................................................................................................... 74

REPLACING STABILIZER CYLINDER SPRING ...................................................................................................... 75

ADJUSTING WEIGHT DISTRIBUTION ................................................................................................................... 75

ADJUSTING STABILIZERS .................................................................................................................................. 76

REMOVING/INSTALLING GEARBOX .................................................................................................................... 77

REPLACING SUSPENSION ARM ........................................................................................................................ 77

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TABLE OF CONTENTS (Continued)

PROCEDURE 16 - RWD WHEELCHAIRS ............................................................................................................... 79

REMOVING/INSTALLING GROUP 24 BATTERY BOX SUB-FRAME ........................................................................ 79

REMOVING/INSTALLING GROUP 22 BATTERY BOX TRAY ................................................................................... 79

EQUIPMENT OPTION CONVERTING GROUP 22 BATTERY BOX TRAY TO GROUP 24 BATTERY BOX SUB FRAME .... 80

SHOCK REPLACEMENT .................................................................................................................................... 81

SHOCK SPRING REPLACEMENT ....................................................................................................................... 83

RUBBER ELEMENT REPLACEMENT - TORQUE AND X BASE FRAMES .............................................................. 84

EQUIPMENT OPTION CONVERTING TORQUE AND X RUBBER ELEMENTS TO SHOCKS .................................... 84

REMOVING/INSTALLING GEARBOX .................................................................................................................... 85

ADJUSTING WEIGHT DISTRIBUTION ................................................................................................................... 85

REPOSITIONING MOTOR/GEARBOX .................................................................................................................. 86

REPOSITIONING THE GEARLESS/BRUSHLESS MOTOR .................................................................................... 87

REPLACING SUSPENSION ARM FOR WHEELCHAIRS WITH MOTOR/GEARBOX ASSEMBLY .............................. 88

REPLACING THE SUSPENSION ARM FOR WHEELCHAIRS WITH GEARLESS/BRUSHLESS MOTOR ................... 89

ANTI-TIPPER WHEEL REPLACEMENT................................................................................................................ 89

REMOVING INSTALLING THE ANTI-TIP ASSEMBLY ............................................................................................. 90

PROCEDURE 17 - FWD WHEELCHAIRS ...................................................................................................................... 91

REMOVING/INSTALLING REAR SHROUD .................................................................................................................. 91

REMOVING/INSTALLING FRONT SHROUD ................................................................................................................ 91

REMOVING/INSTALLING SIDE SHROUD ASSEMBLY ................................................................................................ 91

REMOVING/INSTALLING COUNTERWEIGHT ............................................................................................................. 92

REPLACING GROUP 24 BATTERY BOX SUB-FRAME ............................................................................................... 93

REMOVING/INSTALLING SHOCKS............................................................................................................................. 94

SHOCK SPRING REPLACEMENT .............................................................................................................................. 95

TIE ROD REPLACEMENT .......................................................................................................................................... 95

REMOVING/INSTALLING GEARBOX .......................................................................................................................... 96

SENSOR CABLE ASSEMBLY REPLACEMENT ......................................................................................................... 97

REPLACING SUSPENSION ARM ............................................................................................................................... 98

REMOVING/INSTALLING WIRING HARNESS ............................................................................................................. 99

ADJUSTING WEIGHT DISTRIBUTION ....................................................................................................................... 101

INSTALLING 90 O FOOTBOARD ................................................................................................................................. 101

FOOTBOARD ADJUSTMENTS - DEPTH/HEIGHT/ANGLE ......................................................................................... 102

FOOTREST ANGLE ADJUSTMENTS ........................................................................................................................ 103

LIMITED WARRANTY ................................................................................................................................................. 107

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SPECIFICATIONS

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PHYSICAL

DIMENSIONS vARROW

SPECIFICATIONS

Seat Width Range:

250 lbs Rating

300 lbs. Rating

400 lbs. Rating

MWD/RWD

*16 to 22-in.

MWD/RWD FWD

*19 to 24-in.

Seat Depth Range: *16 to 22-in.

*16 to 24-in.

** TORQUE **TORQUE SP

16 and 18-in.

16 and 18-in.

✪ 16 to 20-in.

● 16 to 20-in

*16 to 18-in.

X

*16 to 22-in.

*16 to 22-in.

JUNIOR

*12 to 16-in.

Back Height Range: *16 to 24-in.

Seat-to-Floor

(approximate)

Standard:

Optional:

MWD/RWD

17-1/2-in.

19-3/4-in.

21-in.

Overall Width of Base:

(w/o joystick)

Overall Length

(without front riggings)

Standard:

Long Frame:

24-5/8-in.

Overall Height

Standard:

Minimum:

Maximum:

MWD/RWD

34-1/4-in.

34-1/4-in.

44-1/4-in.

Recliner - (Std.)

Low Seat Frame: 51-1/2-in.

Med. Seat Frame: 53-3/4-in.

High Seat Frame: 55-1/2 in.

MWD/RWD

32-1/4-in.

35-1/4-in.

25-1/4-in.

FWD

35-1/2-in

35-1/2-in

45-1/2-in

52-3/4-in.

55-in.

24-5/8-in.

34-1/4-in.

N/A

N/A

N/A

N/A

58-1/2-in.

N/A

FWD

35-1/4-in 32-1/4-in.

N/A N/A

Weight

Standard Motor

W/O Batteries:

W/Batteries:

MWD/RWD

146 lbs.

Standard

Optional

248 lbs.

N/A

Shipping (approx.): 176 lbs.

Gearless/Brushless

Motor

W/O Batteries:

W/ Batteries:

Standard

Optional

166 lbs.

243 lbs.

268 lbs.

Shipping (approx.): 196 lbs.

Drive Axle:

FWD

199 lbs.

310 lbs.

N/A

229 lbs.

N/A

N/A

N/A

N/A

*◆Adjustable (MWD/RWD only)

149 lbs.

224 lbs.

249 lbs.

176 lbs.

169 lbs.

243 lbs.

268 lbs.

196 lbs.

Drive Wheels/Tires:

(Foam Filled or

Pneumatic)

Standard:

Optional:

14 X 3-in.

14 X 4-in.

FWD

18-1/4-in.

17-1/2-in.

20-1/2-in.

19-3/4-in.

21-3/4-in.

N/A

14 X 3-in.

14 X 4-in.

16, 18, 20,22-in. *16 to 22-in.

14 X 3-in.

14 X 4-in.

17-1/2-in.

19-3/4-in.

N/A

24-5/8-in.

34-1/4-in.

N/A

N/A

N/A

N/A

N/A

32-1/4-in.

N/A

149 lbs.

224 lbs.

N/A

176 lbs.

N/A

N/A

N/A

N/A

*◆Adjustable

14 X 3-in.

14 X 4-in.

*16 to 24-in.

17-1/2-in.

19-3/4-in.

21-in.

24-5/8-in.

34-1/4-in.

34-1/4-in.

44-1/4-in.

51-1/2-in.

53-1/4-in.

55-1/2-in.

32-1/4-in.

35-1/4-in.

149 lbs.

224 lbs.

249 lbs.

176 lbs.

169 lbs.

*12 to 15-in. w/CJ Back

Expandable to - *16 to 17-in.

*12 to 18-in.

Storm Base

17-1/2-in.

19-3/4-in.

Storm Base

34-1/4-in.

32-1/4-in.

40-1/2-in.

N/A

N/A

N/A

32-1/4-in.

35-1/4-in.

Storm Base

146 lbs.

246 lbs.

N/A

176 lbs.

166 lbs.

X Base

17-1/2-in.

19-3/4-in.

X Base

34-1/4-in.

32-1/4-in.

40-1/2-in.

X Base

149 lbs.

224 lbs.

249 lbs.

176 lbs.

169 lbs.

243 lbs.

268 lbs.

196 lbs.

266 lbs.

N/A

196 lbs.

243 lbs.

268 lbs.

196 lbs.

*◆Adjustable *◆Adjustable *Adjustable

14 X 3-in.

14 X 4-in.

14 X 3-in.

14 X 4-in.

* in 1-inch increments

* * Storm Torque/Torque SP model wheelchairs are available in rear wheel drive ONLY. Gearless Brushless Motor Option is

✪

available on Storm Torque ONLY.

With MKIV RII Controller.

● With MKIV Rx or A Controller.

u Non-Recliners ONLY. v Arrow specifications refer to RWD, MWD and FWD wheelchairs except where specified.

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SPECIFICATIONS

PHYSICAL DIMENSIONS

Casters w/Precision Sealed Bearings

Semi-Pneumatic

Standard:

Option:

Pneumatic or Foam Filled

Standard:

Option:

Pneumatic or Foam Filled

Standard:

Option:

SPECIFICATIONS (Continued)

vARROW s 300 lbs. Rating

8 X 1-3/4-in.

6 X 2-in.

8 X 2-in.

9 X 2-3/4-in.

400 lbs. Rating

(RWD,MWD only)

9 X 2-3/4-in.

8 X 2-in.

** TORQUE **TORQUE SP

8 X 1-3/4-in.

6 X 2-in.

8 X 2-in.

X

8 X 2-in.

8 X 2-in.

9 X 2-3/4-in.

9 X 2-3/4-in.

JUNIOR

8 X 1-3/4-in.

8 X 1-3/4-in. 8 X 1-3/4-in.

6 X 2-in.

6 X 2-in.

6 X 2-in.

8 X 2-in.

Anti-Tippers (3-inch wheels):

Caster Forks:

Footrest:

Armrests:

Seat Angle Adjustment:

Back Angle Adjustment:

Seat Cushion:

Chair Upholstery Options:

Battery/Size (Not Supplied):

Two (2) Required

(uGel Batteries) vARROW, ** TORQUE, **TORQUE SP, X and JUNIOR

Standard (N/A on FWD)

Standard, Shock Fork (Optional)

Telescoping Front Rigging Supports, Swing-Away (Standard),

Heavy Duty (Optional), 4-inch Longer Pivot Slide Tube (Optional)

Flip Back, Fixed or Adjustable Height (Desk and Full Length)

Adjustable (0 o to 10 o )

Adjustable (80 o to 100 o in 5 o increments)

Cushion (Optional)

Naugahyde and Nylon

BASE FRAMES

Arrow w/ Standard motor

- w/ **Gearless/Brushless motor

Torque w/ Standard Motor

- w/ Gearless/Brushless motor

**Torque SP w/ Standard Motor

Ranger X w/Standard Motor

- w/ Gearless/Brushless motor uSTD BATTERIES uOPT BATTERIES

Group 24

Group 22

Group 22

Group 22

Group 22

Group 22

Group 22

N/A

Group 24

Group 24

Group 24

N/A

Group 24

Group 24

PERFORMANCE ARROW

Speed

(M.P.H.):

0 to 5-3/4 (300 lbs. rating) RWD,MWD

0 to 4-1/4 (400 lbs. rating) RWD,MWD

*0 to 7-1/4 (300 lbs. rating)RWD,MWD

0 to 4 (400 lbs. rating) FWD

***Range(miles): up to 19 - RWD,MWD

(uGel Batteries) *up to 29 (Std) - RWD,MWD

*up to 29 (Opt) - RWD,MWD up to 16 - FWD

Weight

Limitation:

300 lbs. (Standard Unit); 400 lbs. (FWD)

*300 lbs. (Standard Unit)RWD,MWD

400 lbs. (Heavy Duty Unit) RWD,MWD

**TORQUE **TORQUESP

0 to 6-1/2 0 to 4-1/4

*0 to 7-1/4

X JUNIOR

0 to 6-1/2 Arrow Base X Base

0 to 6-1/2

*0 to 7-1/4 *0 to 7-1/4

0 to 6-1/2

*0 to 7-1/4 up to 16 (Std) up to 19 (Opt)

Up to 16 up to 16 (Std) up to 19 up to 23 (Std) up to 19 (Opt) *up to 29 (Std) up to 19 (Opt)

*up to 29 (Std)

*up to 35 (Std)

300 lbs.

✪ 250 lbs.

*300 lbs.

● 300 lbs.

*up to 29 (Std) *up to 35 (Opt) *up to 29 (Std)

*up to 35 (Opt)

300 lbs.

*300 lbs.

250 lbs.

up to 35 (Opt)

250lbs.

NOTE: Information below is unique to the Recliner. Refer to Arrow, X , Torque, and Torque SP for complete specifications.

RECLINER Widths Depths Back Heights Weight Limits (LBS.) Back Angle Range

14 to 24-in. 16 to 22-in. 18-1/2 to 26-in.

Arrow Base -300 Std./400 Optional

✪ Torque SP Base - 250

* With gearless/brushless motor option.

** Storm Torque/Torque SP wheelchairs are available in rear wheel drive ONLY. Gearless Brushless Motor Option is available on Storm Torque ONLY.

X, Torque,● Torque SP Base - 300

Arrow, X, Torque Base W/ Gearless/

Brushless Motor - 300 lbs.

***Range will vary with battery conditions,

surface, terrain and operators weight.

✪ With MKIV RII Controller.

s Arrow FWD has a 400 lb. rating.

90 o to 170 o

● With MKIV Rx or A Controller.

v Arrow specifications refer to RWD, MWD and FWD wheel- chairs except where specified.

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PROCEDURE 1

This Procedure Includes the Following:

Repair or Service Information

Operating Information

GENERAL GUIDELINES

REPAIR OR SERVICE INFORMATION

Set-up of the Electronic Control Unit is to be performed ONLY by individuals certified by

Invacare. The final tuning adjustments of the controller may affect other activities of the wheelchair. Damage to the equipment could occur under these circumstances. If non-certified individuals perform any work on these units, the warranty is void.

OPERATING INFORMATION

GENERAL WARNINGS

Performance adjustments should only be made by professionals of the healthcare field or persons fully conversant with this process and the driver's capabilities. Incorrect settings could cause injury to the driver, bystanders, damage to the chair and to surrounding property.

After the wheelchair has been set-up, check to make sure that the wheelchair performs to the specifications entered during the set-up procedure. If the wheelchair does NOT perform to specifications, turn the wheelchair OFF immediately and reenter set-up specifications. Repeat this procedure until the wheelchair performs to specifications.

DO NOT use parts, accessories, or adapters other than those authorized by Invacare.

TIRE PRESSURE

DO NOT use your wheelchair unless it has the proper tire pressure (P.S.I.). DO NOT overinflate the tires. Failure to follow these suggestions may cause the tire to explode and cause bodily harm. The recommended tire pressure is listed on the side wall of the tire.

ELECTRICAL

Grounding Instructions:

DO NOT, under any circumstances, cut or remove the round grounding prong from any plug used with or for Invacare products. Some devices are equipped with three-prong

(grounding) plugs for protection against possible shock hazards. Where a two-prong wall receptacle is encountered, it is the personal responsibility and obligation of the customer to contact a qualified electrician and have the two-prong receptacle replaced with a properly grounded three-prong wall receptacle in accordance with the National Electrical Code. If you must use an extension cord, use ONLY a three-wire extension cord having the same or higher electrical rating as the device being connected. In addition,

Invacare has placed RED/ORANGE WARNING TAGS on some equipment. DO NOT remove these tags. Carefully read battery/battery charger information prior to installing, servicing or operating your wheelchair.

BATTERIES

The warranty and performance specifications contained in this manual are based on the use of deep cycle gel cell or sealed lead acid batteries. Invacare strongly recommends their use as the power source for this unit.

Battery connecting cables are NOT interchangeable. Battery connecting cables with single fuse setup MUST only be used on wheelchairs with conventional motor/gearbox assembly. Otherwise, damage may result. Refer to INSTALLING/REMOVING BATTERIES

INTO/FROM BATTERY BOX(ES) in PROCEDURE 9 of this manual.

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GENERAL GUIDELINES PROCEDURE 1

WARNING/CAUTION LABEL LOCATION - RWD MODELS

NOTE: These caution labels are only found on battery boxes used with the gearless/brushless motor

GROUP 24 BATTERIES GROUP 22 BATTERIES

SUSPENSION ARM

U S E D

WITH CONVENTIONAL

MOTOR/GEARBOX

ASSEMBLY

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ONE (1) CONNECTOR BATTERY

BOX WIRING HARNESS

NOTE: This wiring harness is found on wheelchair models built BEFORE 11/15/99.

SUSPENSION ARM USED

WITH GEARLESS/BRUSHLESS

MOTOR

NOTE: This caution label is only found on wiring harnesses used with the conventional motor/gearbox application.

NOTE: This wiring harness is found on wheelchair models built AFTER 11/15/99.

NOTE: For models with the gearless/brushless motor, read the manufacturers CAUTION LABEL located on side of the motor.

(Drive wheel must be removed to view caution label.)

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NOTE: WARNING LABEL also found on side frame near the rear of the chair.

MUST

1070497

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WARNING/CAUTION LABEL LOCATION

MWD MODELS

NOTE: Stablilizer springs are found on models built

BEFORE 7/11/99 ONLY.

NOTE: CAUTION LABEL also found on side frame near the front of the chair.

Suspension Arm

(located on inside of drive wheel)

FWD MODELS

BATTERY BOX WIRING HARNESS

10

TROUBLESHOOTING PROCEDURE 2


Field Load Test

Using Hydrometer To Check Battery Cells (Lead

Acid)

Motor Testing

Motor Brush Inspection

Electro-Mechanical Parking Brake Testing

FIELD LOAD TEST (FIGURE 1)

NOTE: The following test can also be performed through the controller of the wheelchair along with a remote programmer. Refer to the individual CONTROLLER

MANUAL supplied with each wheelchair.

Old batteries lose their ability to store and release power, due to increased internal resistance. This means that as you try to take power from the battery, some of that power is used up in the process of passing through the battery, resulting in less voltage at the posts. The more power drawn, the lower the voltage available. When this lost voltage drops the output 1.0

volts under load (2.0 for a pair), replace the batteries.

Testing under load is the only way to spot this problem.

While special battery load testing equipment is available, it is costly and difficult to transport.

Use a digital voltmeter to check battery charge level at the charger connector. It is located on the base of the wheelchair frame.

NOTE: READ the instructions CAREFULLY before using the digital voltmeter.

NOTE: Invacare recommends that ONLY qualified service personnel perform this test.

1. Ensure that power is OFF.

2. Make sure battery is fully charged. An extremely discharged battery will exhibit the same symptoms as a bad one.

3. Remove the footrests from the wheelchair and perform one (1) of the following:

A. RWD MODELS - place the CASTERS of the wheelchair against a wall, workbench or other stationary object.

B. MWD MODELS - place the STABILIZER wheels of the wheelchair against a wall, workbench or other stationary object.

C. FWD MODELS -place the DRIVE wheels of the wheelchair against a wall, workbench or other stationary object.

4. Place the voltmeter leads into the charger plug on the wheelchair. Most digital voltmeters are not affected by polarity, however, analog meters (meters with swinging needles) can be and should be used carefully. A good meter reading should be 25.5 to 26 VDC.

5. Have two (2) individuals (one [1] on each arm) apply as much downward pressure as possible on the arms of the wheelchair.

6. Turn the wheelchair ON and push the joystick forward, trying to drive the wheelchair through the stationary object. This puts a heavy load on the batteries as they try to push through the stationary object. Read the meter while the motors are straining to determine the voltage under load.

NOTE: If the voltage drops to less than 23.5 volts from a pair of fully charged batteries while under load, they should be replaced regardless of the unloaded voltages.

Battery Charger

Connector

(-)

(+)

Digital Voltmeter

FIGURE 1 - FIELD LOAD TEST

USING HYDROMETER TO CHECK

BATTERY CELLS (LEAD ACID)

(FIGURE 2)

NOTE: Perform this procedure when a digital voltmeter is not available.

WARNING

NEVER smoke or strike a match near the batteries. If the caps of the battery cells are removed, NEVER look directly into them when charging the battery.

The use of rubber gloves and chemical goggles or face shields is recommended when working with batteries.

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PROCEDURE 2 TROUBLESHOOTING

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WARNING

When reading a hydrometer, DO NOT allow any liquid to come in contact with your eyes or skin. It is a form of acid and can cause serious burns, and in some cases, blindness. If you do get battery acid on you, flush the exposed areas with cool water IMMEDIATELY. If the acid comes into contact with eyes or causes serious burns, get medical help IMMEDIATELY.

The battery acid can damage your wheelchair, clothing, and household items.

Therefore, take readings cautiously and only in designated areas.

ONLY use distilled water when topping off the battery cells.

Most batteries are not sold with instructions.

However, warnings are frequently noted on the cell caps. Read them carefully.

1. Remove the battery box(es). Refer to INSTALLING/

REMOVING BATTERY BOXES - GROUP 24 BAT-

TERY BASE FRAMES or INSTALLING/REMOVING

BATTERY BOX - GROUP 22 BATTERY BASE

FRAMES in PROCEDURE 9 of this manual.

2. Remove the battery caps from the battery.

3. Squeeze the air from the hydrometer.

4. Place the hydrometer into a battery cell.

NOTE: DO NOT fill hydrometer more than 3/4 full.

5. Draw up sufficient acid to cover float balls.

6. Tap lightly to remove air bubbles.

7. Number of floating balls indicates charge.

Number of Floating Balls

2

3

0

1

4

* 5

* Check charging system.

Discharged

25% Charged

50% Charged

75% Charged

100% Charged

Overcharged

8. Flush the liquid back into the same cell after reading the float. Repeat this step until all cells have been properly read. A shorted or dead cell can be detected when it is the only cell that does not charge.

Number of Floating

TROUBLESHOOTING

FIGURE 2 - USING HYDROMETER TO CHECK

BATTERY CELLS (LEAD ACID)

9. Flush hydrometer in cold running water by allowing the water to rise into hydrometer as far as possible.

Do this several times to guard against burn damage.

10. Replace the battery caps.

11. Reinstall battery boxes. Refer to INSTALLING/RE-

MOVING BATTERY BOXES - GROUP 24 BATTERY

BASE FRAMES or INSTALLING/REMOVING BAT-

TERY BOX - GROUP 22 BATTERY BASE FRAMES in PROCEDURE 9 of this manual.

MOTOR TESTING (FIGURE 3)

NOTE: This procedure should only be performed on wheelchairs with the conventional motor/gearbox assembly. For gearless/brushless motors, there are no serviceable parts. Return motor to manufacturer for testing.

1. On the 4-pin motor connector, locate the two (2) contacts in the red and black housings.

2. Set the digital multimeter to measure ohms ( Ω ).

3. Measure the resistance between the two (2) motor contacts.

NOTE: A normal reading is between 1 and 5 ohms

( Ω ). A reading of 0 ohms ( Ω ) or in excess of 15 ohms

( Ω ) indicates a problem. High readings are generally caused by bad connections and/or damaged brushes.

Contact authorized dealer or Invacare.

12

TROUBLESHOOTING PROCEDURE 2

Cap

Motor

4 Pin Motor Connector

FIGURE 4 - MOTOR BRUSH INSPECTION

FIGURE 3 - MOTOR TESTING

MOTOR BRUSH INSPECTION

(FIGURE 4)

NOTE: This procedure should only be performed on wheelchairs with conventional motor/gearbox assembly.

There are two (2) contact brushes on ACTION STORM motors located under the brush caps on the motor housing. If these caps are hard to remove they are either overtightened or the motor has become very hot. Let motors cool. If caps still cannot be removed, it is recommended that the motor be sent to Invacare Technical Services for inspection/repair.

NOTE: It is very important to note which way the brush comes out of the motor. The brush MUST be placed into the motor exactly the same way to ensure good contact with the commutator.

1. Once the motor brush caps have been removed, pull the brushes out of the motor. The end of the brushes should be smooth and shiny and the spring should not be damaged or discolored. If one or both of the brushes are damaged, only the damaged or worn brushes need be replaced. It is very important that any time a brush is replaced, it must be burned in.

This is accomplished by running the motor for one hour in each direction with a half hour break in-between. This should also be done with little or no load on the motor, i.e., put the wheelchair up on blocks so the drive (large) wheels do not contact the ground and run the wheelchair. A motor with only one brush replaced will only carry a small percentage of its rated load capacity until the NEW brush is burned in.

ELECTRO-MECHANICAL PARKING

BRAKE TESTING (FIGURE 5)

NOTE: This procedure should only be performed on wheelchairs with conventional motor/gearbox assembly.

1. On the four-pin motor connector, locate the side by side connectors in the black housings.

2. Set the digital multimeter to read ohms ( Ω ).

3. Measure the resistance between the two (2) brake contacts. A normal reading is 100 ohms ( Ω ). A reading of 0 ohms ( Ω ) or a very high reading; i.e., MEG ohms or O.L.

(out of limit) indicates a shorted brake or an open connection respectively. If either condition exists, send the motor to Invacare Technical Service for inspection/repair.

CAUTION

A shorted electro-mechanical brake will damage the brake output section in the controller. DO NOT connect a shorted electromechanical brake to a good controller module. A shorted brake MUST be replaced.

NOTE: A bad motor can damage the controller module but a bad controller will NOT damage a motor.

Cap Motor

4 Pin Motor Connector

Ohmmeter

FIGURE 5 - ELECTRO-MECHANICAL

PARKING BRAKE TESTING

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PROCEDURE 3 HARDWARE TORQUE SPECIFICATIONS

HARDWARE TORQUE SPECIFICATIONS

STANDARD SEAT FRAME

*Torque to

60 in/lbs

*Loctite ® and

Torque to

75 in/lbs

*Loctite and

Torque to

75 in/lbs

Torque to

156 in/lbs

**Torque to

156 in/lbs

**Torque to

156 in/lbs

**Torque to

156 in/lbs

**Torque to

156 in/lbs

NOTE:

* These torque specifications also apply to the adjustable seat frame assembly.

** These torque specifications also apply to the captains van seat and adjustable seat frame assemblies.

14

HARDWARE TORQUE SPECIFICATIONS PROCEDURE 3

HARDWARE TORQUE SPECIFICATIONS

*CAPTAINS VAN SEAT *ADJUSTABLE SEAT FRAME

Torque to

156-in/lbs Torque to

156-in/lbs

Torque to

75-in/lbs

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Torque to

156 in/lbs

Loctite and Torque to

75 in/lbs

Torque to

156 in/lbs

Torque to

156-in/lbs

Torque to

156-in/lbs

* NOTE: For additional torque specifications, refer to the torque specifications drawing for the standard seat frame assembly.

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REAR WHEEL DRIVE BASE FRAME HARDWARE

TORQUE SPECIFICATIONS

Loctite and torque to

160 in/lbs

Torque to

160 in/lbs

Torque to

1020 in/lbs

REAR OF

WHEELCHAIR

Loctite and

Torque to

75 in/lbs

Torque to

160 in/lbs

Tighten until snug

Torque to

160 in/lbs

Torque to

160 in/lbs


75 in/lbs

Wheel Halves -

Torque to 75 in/lbs

8 - inch Wheels -




CONVENTIONAL MOTOR/GEARBOX

FRONT OF

WHEELCHAIR

Pneumatic with Flat-Free

Wheel Halves - Torque to

160 in/lbs

Pneumatic Wheel Halves -

8 - inch - Torque to 18 in/lbs


GEARLESS/BRUSHLESS MOTOR

NOTE: All torque specifications called out for the conventional motor/gearbox assembly are applicable to the gearless/brushless motor except for the following:

Torque to 13 ft/lbs.

Torque to 75 in/lbs.


Torque to 25 in/lbs.


16

HARDWARE TORQUE SPECIFICATIONS PROCEDURE 3

MID-WHEEL DRIVE BASE FRAME HARDWARE


FRONT OF

WHEELCHAIR


160 in/lbs Torque to

160 in/lbs

Tighten

until snug

Torque to

40 in/lbs

Torque to

1020 in/lbs

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75 in/lbs

Torque to

160 in/lbs

Torque to

160 in/lbs

REAR OF

WHEELCHAIR

Torque to

160 in/lbs

Loctite and

Torque to

75 in/lbs








Wheel Halves - Torque to 160 in/lbs


8 - inch - Torque to 18 in/lbs 9 -

inch - Torque to 160 in/lbs

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FRONT-WHEEL DRIVE BASE FRAME HARDWARE


REAR OF

WHEELCHAIR

Torque to

156 in/lbs

Torque to

1020 in/lbs

Torque to

156 in/lbs Torque to

160 in/lbs

Torque to

15 in/lbs

Torque to

360 in/lbs






Wheel Halves - Torque to 160 in/lbs




Torque to

156 in/lbs

Torque to

160 in/lbs

Torque to

156 in/lbs

Torque to

360 in/lbs



Loctite and

Torque to

75 in/lbs

Torque to

156 in/lbs

FRONT OF

WHEELCHAIR

18

ARMS PROCEDURE 4


Replacing Armrest Pads - Captains Van Seats

Replacing Captains Van Seat Armrest Plate

WARNING

After ANY adjustments, repair or service and BEFORE use, make sure that all attaching hardware is tightened securely - otherwise injury or damage may result.

REPLACING ARMREST PADS -

CAPTAINS VAN SEATS (FIGURE 1)

1. Remove the mounting screws that secures the front of the armrest pad to the armrest plate.

2. Remove the mounting screw that secures the rear of the armrest pad and armrest insert to the armrest plate.

3. Remove the existing armrest pad and position the

NEW armrest pad on the armrest plate.

4. Line up the mounting holes in the armrest insert, armrest plate and NEW armrest pad.

5. Reinstall the rear mounting screw through the armrest insert, armrest plate and armrest pad and tighten securely.

6. Reinstall the front mounting screw into the armrest plate and NEW armrest pad and tighten securely.

REPLACING CAPTAINS VAN SEAT

ARMREST PLATE (FIGURE 2)

1. If necessary, remove the three (3) mounting screws, spacers and locknuts that secure the joystick mounting bracket to the armrest plate.

2. Remove armrest pad. Refer to REPLACING ARM-

REST PADS - CAPTAINS VAN SEATS in this procedure of the manual.

3. Remove the mounting screw, washers and locknut that secure the existing armrest plate to the arm weldment.

4. Position the NEW armrest plate on the armrest weldment and secure with the mounting screw, washers, and locknut. Refer to FIGURE 2 for correct hardware orientation.

5. Reinstall van style armrest pad. Refer to REPLAC-

ING ARMREST PADS - CAPTAINS VAN SEATS in this procedure of the manual.

6. If necessary, reinstall the three (3) mounting screws, spacers and locknuts that secure the joystick mounting bracket to the armrest plate.

7. Repeat STEPS 1-6 for the opposite armrest plate, if necessary.

Washer

Locknut

REAR FRONT

Mounting

Screw

Armrest

Insert

Armrest

Pad

Armrest

Plate

Arm Weldment

Washer

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Mounting

Screw

Mounting

Screw

Armrest Plate

FIGURE 1 - REPLACING ARMREST PADS -

CAPTAINS VAN SEATS

FIGURE 2 - REPLACING CAPTAINS VAN SEAT

ARMREST PLATE

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PROCEDURE 5 UPHOLSTERY/POSITIONING STRAP

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Replacing Seat Positioning Strap - Captains Van

Seats

Replacing Back Upholstery

WARNING

After ANY adjustments, repair or service and BE-

FORE use, make sure that all attaching hardware is tightened securely - otherwise injury or damage may result.

REPLACING SEAT POSITIONING

STRAP - CAPTAINS VAN SEATS

(FIGURE 1)

1. Remove the van style seat from the van seat frame.

Refer to INSTALLING/REMOVING CAPTAINS VAN

SEAT ASSEMBLY in PROCEDURE 6 of this manual.

2. Remove the two (2) rear mounting screws, washers, and locknuts that secure the seat positioning straps to the van seat frame.

NOTE: The washer is positioned between the seat positioning strap and the mounting screw.

3. Secure the NEW seat positioning strap halves with the mounting screws, washers and locknuts to the van seat frame and torque to 75-inch pounds.

4. Reinstall the van style seat to the van seat frame.

Refer to INSTALLING/REMOVING CAPTAINS VAN

SEAT ASSEMBLY in PROCEDURE 6 of this manual.

Van Seat Frame

Seat Positioning

Strap

REAR OF SEAT

FRAME

Mounting

Screw

Locknuts

Washer FRONT OF SEAT

FRAME

FIGURE 1 - REPLACING SEAT POSITIONING STRAP -

CAPTAINS VAN SEATS

REPLACING BACK UPHOLSTERY

(FIGURE 2)

1. Remove one (1) armrest from the wheelchair. Refer to

INSTALLING/REMOVING FLIP BACK ARMRESTS in

PROCEDURE 4 of the owners manual, 1081227.

2. If applicable, remove the two (2) mounting screws and locknuts that secure the spreader bar to the back canes.

3. Remove the two (2) mounting screws and washers that secure the existing back upholstery to the back canes.

4. Cut the tie-wraps that secure the bottom of the existing back upholstery to the back canes.

NOTE: Note the back angle before disassembly for proper reinstallation.

5. On the side of the wheelchair that the armrest was removed, remove one (1) of the mounting screws, washer, spacer, and locknut that secures the back cane to the seat frame.

NOTE: To avoid losing the insert in each back cane, thread the mounting screw just removed through the cane from the inside of the wheelchair to hold the insert in place.

6. Remove the other mounting screw, washer, spacer, and locknut that secures the back cane to the seat frame.

7. Slide the back cane out of the spreader bar (If applicable) and the existing back upholstery.

8. Remove other armrest from the chair. Refer to IN-

STALLING/REMOVING FLIP BACK ARMRESTS in


9. Repeat STEPS 5-7 for the opposite side of the wheelchair.

10. Slide the other back cane out of the spreader bar (if applicable) and the existing back upholstery.

11. Slide one(1) back cane into NEW back upholstery and through spreader bar (if applicable).

12. Secure back cane to the seat frame from the outside of the wheelchair with the existing two (2) mounting screws, washers, spacers, and locknuts. Use Loctite

242 and torque to 75-in/lbs.

13. Repeat STEPS 11-12 for opposite back cane.

14. Secure the top of the NEW back upholstery to the back canes with the two (2) existing mounting screws.

20

UPHOLSTERY/POSITIONING STRAP PROCEDURE 5

NOTE: When replacing the back upholstery, back assembly or changing back height, follow these guidelines for spreader bar height:

STANDARD MODELS

BACK HEIGHT

16-inches*

17-inches*

18-19-inches*

20-24-inches u SPREADER BAR

HEIGHT

5-inches

5-inches

7-inches

7-inches

NOTE: Spreader Bar required on ALL back heights between 20-24-inches. *Spreader bar required on back heights 16,17,18, or 19 ONLY if the width or depth of the chair exceeds 19-inches.

uHeight of Spreader Bar from Bottom of Back

Canes to Top of Spreader Bar Clamp.

Back Cane

(STEPS 3, 12)

Locknuts

(STEPS 5, 6)

HEAVY DUTY MODELS

NOTE: Spreader bar required on all back heights.

BACK HEIGHT

16-17-inches


HEIGHT

5-inches

7-inches uHeight of Spreader Bar from Bottom of Back


15. If applicable, reposition the spreader bar at the correct height for the corresponding back height and torque the mounting hardware to 60-in/lbs.

16. Reinstall the armrest onto the wheelchair. Refer to IN-



Mounting

Screw

(STEPS 3, 14)

Washer

(STEPS 3, 14)

Back

Upholstery

(STEPS 3, 7)

Spacers

(STEPS 5, 6)

Locknut

(STEP 2)

Locknut

(STEP 2)

Spreader Bar

(STEPS 2, 7, 16)

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Mounting

Screw

(STEP 2)

Insert

Washers

(STEPS 5, 6)

Mounting Screws


(STEPS 5, 6)

Mounting Screw


(STEP 2)

Mounting

Screws

(STEPS 5, 6)

Washers

(STEPS 5, 6)

Seat Frame

FIGURE 2 - REPLACING BACK UPHOLSTERY

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PROCEDURE 6 SEAT FRAME

This Procedure includes the following:

Preparation for Removing/Installing Seat Frame

(Standard Frame, Adjustable Frame, and Captains Van Seat) ............................Page 21

Replacing Exact Same Size Standard

Seat Frame ..............................................Page 22

Removing/Installing Standard Seat Frame

Sub-Assembly .........................................Page 22

Changing Seat Depth ...............................Page 23

Changing Seat Width (Standard and Adjustable

Seat Frame) .............................................Page 25

Installing/Removing Adjustable Seat Frame

Sub-Assembly and/or Component

Replacement ...........................................Page 26

Installing/Removing Captains Van Seat

Assembly ................................................Page 28

Replacing Captains Van Seat and/or Captains

Van Seat Frame .......................................Page 28

Converting From Standard Seat Frame to

Adjustable Seat Frame or Vice Versa .......Page 29

Converting From Adjustable Seat Frame to

Captains Van Seat or Vice Versa...............Page 29

Converting From Standard Seat Frame to

Captains Van Seat or Vice Versa...............Page 30

Removing/Installing Seat Pan ..................Page 30

Mounting Plate - Seat Angle Adjustment and

Installation Orientation .............................Page 31

1. Remove footrest assemblies. Refer to PROCEDURE

4 in of the owners manual, 1081227.

2. Remove battery box(es). Refer to INSTALLING/RE-

MOVING GROUP 24 BATTERY BOXES or INSTALL-

ING/REMOVING GROUP 22 BATTERY BOX in PRO-

CEDURE 9 of this manual.

Adjustment Lock

Lever for Joystick

(STEP 4)

Battery

Box(es)

(STEP 2)

Back Upholstery

(STEP 10)

Flip Back

Armrests

(STEP 6A)

Footrest

Location

(STEP 1)

Joystick

(STEPS

3,5)

WARNING

After ANY adjustments, repair or service and BEFORE use, make sure that all attaching hardware is tightened securely otherwise injury or damage may result.

Seat Positioning

Strap (STEP 7)

Seat Pan

(STEP 7)

Controller, Left/Right Motor

Connectors (STEPS 8,9)

NOTE: The procedures in this section of the manual refer to NON-RECLINER seat frames only, EXCEPT Seat

Angle Adjustment. For recliner seat frames, refer to PRO-

CEDURE 14 of this manual.

STEP 6B

Height

Adjustment

Holes

PREPARATIONS FOR REMOVING/

INSTALLING SEAT FRAME

(STANDARD FRAME, ADJUSTABLE

FRAME, AND CAPTAINS VAN SEAT)

(FIGURE 1)

Captains

Van Seat

Base

Socket

Screw

NOTE: When installing/replacing components of the wheelchair, refer to the individual procedure for correct use of

LOCTITE 242 and torque specifications or PROCEDURE

3 of this manual.

NOTE: To reinstall these components, reverse the following steps.

22

NOTE: Illustration depicts tubular seat frame only. Preparation steps for the captains van seat apply in the same manner.

FIGURE 1 - PREPARATIONS FOR REMOVING/

INSTALLING SEAT FRAME (STANDARD FRAME,

ADJUSTABLE FRAME, AND CAPTAINS VAN SEAT)

SEAT FRAME PROCEDURE 6

3. Cut tie wraps and disconnect joystick from controller.

4. Turn the lever on the adjustment lock to release the adjustment lock from the joystick mounting tube.

5. Remove the joystick from the wheelchair.

6. Perform one (1) of the following:

A. STANDARD OR ADJUSTABLE SEAT

FRAMES - Remove the flip-back armrests from the wheelchair. Refer to INSTALLING/REMOVING

FLIP BACK ARMRESTS in PROCEDURE 4 of the owners manual, 1081227.

B. CAPTAINS VAN SEAT - Remove the mounting screw that secures the armrest to the van seat frame. Repeat for opposite side.

7. For standard and adjustable seat frames, remove the seat pan (including seat positioning straps). Refer to

REMOVING/INSTALLING SEAT PAN in this procedure of the manual.

8. Disconnect battery and left/right motor connectors from the controller. Refer to REPLACING WIRING HAR-

NESS in PROCEDURE 10 of this manual.

9. Remove tie-wraps that secures the wiring harness to the seat frame and the charger cable from its mounting bracket. Refer to REPLACING WIRING HARNESS in PROCEDURE 10 of this manual.

10. For standard and adjustable seat frames, remove the back upholstery (including back canes and spreader bar, if applicable). Refer to REPLACING BACK UP-

HOLSTERY in PROCEDURE 5 of the manual.

11. Refer back to the starting procedure to complete the desired change.

4. Reinstall the components previously removed in STEP

1. Perform the instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND CAP-

TAINS VAN SEAT) in this procedure of the manual.

REMOVING/INSTALLING


SUBASSEMBLY (FIGURE 2)

NOTE: Perform steps required from starting procedure.

Removing

1. Remove the four (4) mounting screws, locknuts and spacers, if applicable, that secure the standard seat frame subassembly to the seat mounting plates.

2. Remove the existing standard seat frame.

Mounting Screws

(Torque to 156inch pounds)

Mounting Screws


Standard

Seat

Assembly

Spacer

(16-inch

Wide Only)

REPLACING EXACT SAME SIZE


Spacer

(16-inch Wide

Only)

Seat

Mounting

Plate





2. Remove the existing standard seat frame subassembly and install the NEW standard frame. Refer to RE-

MOVING/INSTALLING STANDARD SEAT FRAME

SUBASSEMBLY in this procedure of the manual.

3. FOR 12-15-INCH SEAT DEPTHS ONLY: Remove the CJ back brackets from the existing standard seat frame and install onto the NEW standard seat frame.

Refer to REMOVING/INSTALLING CJ BACK BRACK-

ETS FROM SEAT FRAME in this procedure of the manual.

23

Locknuts

Base Frame

NOTE: For 16-inch wide seat frames, there will be spacers positioned between the seat frame and the seat mounting plates.

FIGURE 2 - REMOVING/INSTALLING STANDARD

SEAT FRAME SUB-ASSEMBLY

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Installing

1. Position NEW standard seat frame subassembly on seat mount plates.

2. Secure NEW standard seat frame subassembly onto seat mounting plates with the existing four (4) mounting screws, locknuts and spacers, if applicable. Torque to 156-inch pounds.


B. If the desired change only requires a NEW seat pan, refer to REMOVING/INSTALLING SEAT PAN in this procedure of the manual.

C. For all other seat depth changes, perform the following: l PREPARATIONS FOR REMOVING/IN-

STALLING SEAT FRAME (STANDARD

FRAME, ADJUSTABLE FRAME, AND CAP-


Perform one (1), two (2), or all three (3) of the procedures listed below depending on the components required for the desired seat depth determined from STEPS 1-5:

CHANGING SEAT DEPTH

Standard Seat Frame

NOTE: Review the chart below. This will determine the components needed to obtain the desired seat depth.

COMPONENT IDENTIFICATION TABLE

FOR STANDARD SEAT FRAME

12-inches to

15-inches

16-inches

17-inches

18-inches

19-inches

20-inches

21-inches

22-inches

SEAT FRAME COMPONENTS

CJ BACK

SEAT BRACKETS

DEPTH REQUIRED

YES

NO

NO

NO

NO

NO

NO

NO

SEAT

PAN

17-inch

16-inch

17-inch

18-inch

19-inch

20-inch

21-inch

22-inch

SEAT

FRAME

DEPTH

16-inch deep

16-inch deep

16-inch deep

18-inch deep

18-inch deep

20-inch deep

20-inch deep

22-inch deep

1. Find current seat depth in left hand column in the chart.

l REMOVING/INSTALLING CJ BACK BRACK-

ETS in this procedure of the manual.

l REMOVING/INSTALLING STANDARD SEAT


l REMOVING/INSTALLING SEAT PAN in this procedure of the manual.

After completing the procedure(s) listed above, perform the steps outlined in PREPARATIONS FOR

REMOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND

CAPTAINS VAN SEAT) to complete the desired seat depth change.

Adjustable Seat Frame (FIGURE 3)

NOTE: Review the chart below. This will determine the components needed to obtain your desired seat depth.

COMPONENT IDENTIFICATION TABLE

FOR STANDARD SEAT FRAME

SEAT FRAME COMPONENTS

CJ BACK

SEAT BRACKETS SEAT SIDE CENTER

DEPTH REQUIRED PAN FRAME FRAME

2. Follow that row to right under seat frame components.

3. Verify and note the components of the current seat depth.

4. Repeat STEPS 1-3 for your desired seat depth.

5. Compare existing components of the current seat depth and the required components for the desired seat depth.


A. If the current seat depth and the desired seat depth is within the 12-15-inch seat depth range, this change can be accomplished by repositioning the back canes on the CJ back brackets. Refer to CHANG-

ING SEAT DEPTH BETWEEN 12-15-INCHES in this procedure of the manual.

24

12-inches to

15-inches

16-inches

17-inches

18-inches

19-inches

20-inches

21-inches

22-inches

YES

NO

NO

NO

NO

NO

NO

NO

17-inch

16-inch

17-inch

20-inch

21-inch

Short

Short

Short

Long

Long

22-inch X-Long

Short

Short

Short

18-inch Medium Short

19-inch Medium Short

Long

Long

Long

NOTE: Note the four (4) different lengths of side frames short, medium, long, and X-long, as well as the two different center frames, short and long. These components are interchanged to obtain the various different seat depths.


1. Find current seat depth in left hand column in the chart.

2. Follow that row to right under seat frame components.

3. Verify and note the components of the current seat depth.

4. Repeat STEPS 1-3 for the desired seat depth.

5. Compare existing components of the current seat depth and the required components for the desired seat depth.

To adjust the depth of the seat on the wheelchair, use the following guidelines:

If the current seat depth is and the desired seat depth are within the 12-15-inch seat depth range, this change can be accomplished by repositioning the back canes on the CJ back brackets. Refer to CHANGING SEAT DEPTH BE-

TWEEN 12-15-INCHES in this procedure of the manual.

If the desired change only requires a NEW seat pan, refer to

REMOVING/INSTALLING SEAT PAN in this procedure of the manual.

If the desired change requires the removal/installation of CJ back brackets, refer to REMOVING/INSTALLING CJ BACK

BRACKETS in PROCEDURE 8 of this manual.

If the desired change requires a new side frame, and/or new center frame, perform the following steps:

A. Perform the instructions outlined in SEAT FRAME

REMOVING/INSTALLING PREPARATIONS FOR

STANDARD FRAME, ADJUSTABLE FRAME, AND

CAPTAINS VAN SEAT in this procedure of the manual.

NOTE: Note the mounting hole position of the side frame for proper installation of the NEW side frame.

B. Remove the two (2) mounting screws, coved washers, spacers, and locknuts that secure the side frame to the center frame.

C. Remove the side frame from the center frame.

D. Repeat STEPS A and B for opposite side frame.

If the desired seat depth requires a new center frame, determined in STEPS 1-5 perform STEPS

E - G, otherwise proceed to STEP H.

E. Remove the four (4) mounting screws that secure the EXISTING center frame to support brackets.

F. Remove existing center frame from seat mount plates.

G. Secure NEW center frame to support brackets with the existing four (4) mounting screws and locknuts.

Torque to 156-inch pounds.

H. Secure NEW side frame to the center frame at the position noted previously. Torque to 75-inch pounds.

25

NOTE: If seat width adjustment is also desired, refer to CHANGING SEAT WIDTH in this procedure of the manual for mounting hole locations and allowable seat width/seat depth combinations.

Mounting

Screws


Coved

Washers

Side Frame

Support Brackets

FIGURE 3- CHANGING SEAT DEPTH - ADJUSTABLE

SEAT FRAME

Mounting Screws


Side

Frame

Spacers

Locknuts

Center

Frame

Changing Seat Depth Between 12 and 15-

Inches (FIGURE 4)

NOTE: There are two (2) sizes of CJ back brackets. Refer to the following chart to determine if the seat depth required is obtainable by repositioning the back canes only, or if the

CJ back brackets must be replaced.

CJ BACK BRACKET (SEAT DEPTH) RANGES

12 and 13-inches OR 14 and 15-inches

If seat depth required is within seat depth range of the original CJ back brackets, only the back canes need to be repositioned. Refer to the following procedure.

If the seat depth required is NOT within the seat depth range of the original CJ back brackets, the CJ back brackets must be replaced before repositioning the back canes. Refer to REMOVING/INSTALLING CJ

BACK BRACKETS in PROCEDURE 8 of this manual.

F

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E

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T

S

E

F

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A

M

E

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T

S

E


1. Remove the armrests from the wheelchair. Refer to IN-



2. Cut the tie wraps that secure the back upholstery to the

CJ back brackets.

3. Pull the bottom of the back upholstery away from the rear of the seat pan.

4. Remove mounting screw, washer and coved washer from the top mounting hole of the CJ back bracket and back cane.

NOTE: Before removing the back canes from the CJ back brackets, note the BACK ANGLE for reinstallation.

NOTE: To avoid losing the insert in each back cane, line up the holes in the insert with the holes in the back cane and start one of the screws through the cane from the inside of the wheelchair to hold the insert in place.

5. Remove the mounting screw, washer and coved washer from the bottom mounting hole of the CJ back bracket and the back cane.

6. Reposition the back cane to the desired seat depth and angle. If changing the back angle as well, refer to

BACK ANGLE ADJUSTMENT in PROCEDURE 8 of this manual.

7. Secure bottom of the back upholstery to the seat pan.

8. Secure the bottom of the back upholstery to the CJ back brackets with new tie wraps.

9. Use Loctite 242 and torque the mounting screws to

75-inch pounds.

10. Repeat the STEPS 1-9 for the opposite back cane.

11. Reinstall the armrests onto the wheelchair. Refer to IN-



CHANGING SEAT WIDTH

(STANDARD AND ADJUSTABLE

SEAT FRAME)

Standard Seat Frame

NOTE: If changing seat width below 16-inches wide, you must convert to an adjustable seat frame. Refer to CONVERT-

ING FROM STANDARD TO ADJUSTABLE SEAT

FRAME OR VICE VERSA in this procedure of the manual.

For all changes above 16-inches wide, perform the outlined steps.





2. Remove the existing standard seat frame subassembly and install the NEW standard frame. Refer to RE-

MOVING/INSTALLING STANDARD SEAT FRAME


3. FOR 12-15-INCH SEAT DEPTHS ONLY: Remove the CJ back brackets from the existing standard seat frame and install onto the NEW standard seat frame.

Refer to REMOVING/INSTALLING CJ BACK BRACK-

ETS in PROCEDURE 8 of this manual.

4. Reinstall the components previously removed in STEP





Back Cane

CJ Back

Bracket

Coved

Washers

Threaded

Insert

Seat

Frame

Washers

Mounting Screws (Torque to 75-inch pounds)

FIGURE 4 - ADJUSTING SEAT DEPTH - CHANGING

SEAT DEPTH BETWEEN 12 AND 15-INCHES

Adjustable Seat Frame (FIGURE 5)

NOTE: If changing seat width above 16-inches wide, you must convert to a standard seat frame. Refer to CONVERT-

ING FROM STANDARD TO ADJUSTABLE SEAT

FRAME OR VICE VERSA in this procedure of the manual.

For all changes below 16-inches wide, perform the outlined steps.





2. Review the following chart for the allowable seat width and seat depth combinations for the adjustable seat frame.

26


ALLOWABLE SEAT WIDTH AND DEPTH

S

E

A

T

D

E

P

T

H

16

17

18

19

12

13

14

15

20

21

22

COMBINATIONS FOR ADJUSTABLE SEAT FRAME

12

✓

✓

✓

SEAT WIDTH

13

✓

✓

✓

✓ ✓

✓ ✓

N/A N/A

N/A N/A

N/A N/A

N/A N/A

N/A N/A

N/A N/A

14

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

15

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

16

✓

✓

✓

✓

✓

NOTE: The seat widths and seat depths enclosed in the outlined box will require the use of CJ back brackets and a

17-inch deep seat pan.

3. Remove the two (2) mounting screws, coved washers, spacers, and locknuts that secure the side frame to the center frame.

4. Adjust side frame to desired width determined from

STEP 2. See DETAIL A for proper mounting hole position.

5. Secure side frame to center frame with existing mounting screws, coved washers, spacers, and locknuts.

Torque mounting screws to 75-inch pounds.

B. For all other changes regarding seat frame changes, refer back to the starting procedure to complete the desired change.

DETAIL “A”

12-inches

13-inches

14-inches

15-inches

16-inches

Mounting

Screws

STEPS 3-6

Coved

Washers

Side Frame

Side

Frame

Center

Frame

Spacers

Locknut

FIGURE 5 -CHANGING SEAT WIDTH - ADJUSTABLE

SEAT FRAME

WARNING

Both side frames MUST be adjusted to the same mounting hole position to maintain proper weight balance of user and seat

INSTALLING/REMOVING

ADJUSTABLE SEAT FRAME

SUBASSEMBLY AND/OR

COMPONENT REPLACEMENT

(FIGURE 6)

frame. If weight is not balanced, injury to the assistant and/or user and damage to the wheelchair may result.

6. Repeat STEPS 3-5 for opposite side frame.

Converting from Adjustable Seat Frame to

Standard Seat Frame or Captains Van Seat


A. For adjusting the seat width only, perform the instructions outlined in PREPARATIONS FOR RE-

MOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND

CAPTAINS VAN SEAT) in this procedure of the manual.

NOTE: When performing the steps outlined in

PREPARATIONS FOR REMOVING/INSTALL-

ING SEAT FRAME (STANDARD FRAME, AD-

JUSTABLE FRAME, AND CAPTAINS VAN

SEAT) the seat pan, seat cushion, back upholstery and spreader bar (if applicable), will need to be replaced. Spreader bars are only required on seat depths greater than 19-inches.

NOTE: This section must be performed in conjunction with a starting procedure.

1. Remove the four (4) mounting screws that secure the two (2) support brackets of the adjustable seat frame subassembly to the seat mounting plates.

2. To complete conversion, refer back to the starting procedure to complete the desired change.

27

Converting from Standard Seat Frame or

Captains Van Seat To Adjustable Seat Frame

NOTE: This section must be performed in conjunction with a starting procedure.

NOTE: When converting the seat frame, you will need a seat pan, seat cushion, back upholstery and spreader bar (if applicable). Spreader bars are only required on seat depths of greater than 19-inches.

F

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E

A

T

S

E

F

R

A

M

E

A

T

S

E


1. Secure both support brackets to the seat mounting plates with four (4) mounting screws and locknuts as shown in

FIGURE 6. Torque mounting screws to 156-inch pounds.

2. Secure the center frame to the support brackets with four (4) mounting screws, locknuts, and spacers. Torque to 156-inch pounds.

3. Insert the side frame into the center frame and secure with mounting screw, coved spacer, spacer, and locknut. Torque to 75-inch pounds. Repeat for opposite side frame.

4. To complete conversion, refer back to the starting procedure to complete the desired change.

Mounting Screws

(Torque to 156-inch pounds)

Mounting Screws


Component Replacement





NOTE: Note the mounting hole position of the current side frame(s) for proper installation of the NEW side frame(s).

2. Remove the two (2) mounting screws, coved spacers, spacers, and locknuts that secure the side frame to the center frame.

Mounting Screws


Side Frame

Coved Washer

Center Frame

Spacer

Side Frame

Support

Bracket

Locknuts

Mounting Screws


Support

Bracket

Mounting Screws


Locknuts

Mounting

Plate

Base

Frame

Locknuts

FIGURE 6 - INSTALLING/REMOVING ADJUSTABLE SEAT FRAME SUBASSEMBLY AND/OR COMPONENT

REPLACEMENT

28



A. If center frame needs replaced, repeat STEP 2 for opposite side frame and proceed to STEP 4.

B. If opposite side frame needs replaced, repeat STEP

2, then proceed to STEP 6. Otherwise proceed to

STEP 6.

4. Remove the four (4) mounting screws and locknuts that secure the center frame to the support brackets.

5. Secure NEW center frame to support brackets with existing four (4) mounting screws and locknuts. Torque to

156-inch pounds.

WARNING

Both side frames MUST be adjusted to the same mounting hole position to maintain proper weight balance of user and seat frame. If weight is not balanced, injury to the assistant and/or user and damage to the wheelchair may result.

6. Install new/existing side frame(s) into new/existing center frame at the mounting position previously noted. Torque to 75-inch pounds.





Mounting

Screws


Seat

Mounting

Plate

Locknuts

Captains Van

Seat

Seat Mounting

Plate

Base Frame

INSTALLING/REMOVING CAPTAINS

VAN SEAT ASSEMBLY (FIGURE 7)

NOTE: This procedure is to be performed in conjunction with a starting procedure. Proceed to the section that reflects the desired change.

FIGURE 7 - REMOVING/INSTALLING CAPTAINS VAN

SEAT ASSEMBLY

REPLACING CAPTAINS VAN SEAT

AND/OR CAPTAINS VAN SEAT

FRAME (FIGURE 8)





2. Remove the captains van seat assembly from the wheelchair. Refer to INSTALLING /REMOVING CAPTAINS

VAN SEAT ASSEMBLY in this procedure of the manual.

Installing Captains Van Seat

1. Position the captains van seat on the seat mounting plates at the position shown in FIGURE 7.

2. Line up mounting holes in the captains van seat frame and the mounting holes in the seat mounting plates.

3. Secure the captains van seat to the seat mounting plates with four (4) mounting screws, and locknuts. Torque to

156-inch pounds.


Captains

Van Seat

Captains

Van Seat

Frame

Removing Captains Van Seat

1. Remove the four (4) mounting screws and locknuts that secure the captains van seat to the seat mounting plates.

2. Remove captains van seat from seat mounting plates.


Washer

Mounting Screw


Spacer

29

FIGURE 8 - REPLACING CAPTAINS VAN SEAT AND/

OR CAPTAINS VAN SEAT FRAME

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T

S

E

F

R

A

M

E

A

T

S

E


3. Remove the four (4) mounting screws, two (2) washers, and two (2) spacers that secure the captains van seat to the seat frame.

4. Replace the captains van seat or the seat frame.

5. Secure new/existing captains van seat to the new/existing captains van seat frame with existing four (4) mounting screws and spacers. Torque to 75- inch pounds.

6. Install new captains van seat assembly onto the wheelchair. Refer to INSTALLING/REMOVING CAPTAINS VAN

SEAT ASSEMBLY in this procedure of the manual.





CONVERTING FROM STANDARD

SEAT FRAME TO ADJUSTABLE

SEAT FRAME OR VICE VERSA






A. Remove the existing standard seat frame subassembly. Refer to REMOVING/INSTALLING STAN-

DARD SEAT FRAME SUBASSEMBLY in this procedure of the manual.

B. Remove the adjustable seat frame subassembly.

Refer to REMOVING/INSTALLING ADJUSTABLE

SEAT FRAME SUBASSEMBLY AND/OR COM-

PONENT REPLACEMENT in this procedure of the manual.


A. Install the standard frame subassembly. Refer to

INSTALLING/REMOVING STANDARD SEAT

FRAME SUBASSEMBLY in this procedure of the manual.

B. Install the adjustable seat frame subassembly. Refer to INSTALLING/REMOVING ADJUSTABLE



4. ADJUSTABLE FRAMES ONLY: Adjust side frame to desired seat width. Refer to CHANGING SEAT WIDTH in this procedure of the manual for mounting hole locations and allowable seat width/seat depth combinations.

5. STANDARD AND ADJUSTABLE FRAME WITH 12-

15-INCH SEAT DEPTHS ONLY: Remove the CJ back brackets from the existing standard seat frame and install onto the NEW standard seat frame. Refer to RE-

MOVING/INSTALLING CJ BACK BRACKETS in PRO-


30





CONVERTING FROM ADJUSTABLE

SEAT FRAME TO CAPTAINS VAN

SEAT OR VICE VERSA






A. Remove the adjustable seat frame subassembly.

Refer to REMOVING/INSTALLING STANDARD

SEAT FRAME SUBASSEMBLY in this procedure of the manual.

B. Remove the captains van seat Assembly. Refer to

INSTALLING/REMOVING CAPTAINS VAN SEAT

ASSEMBLY in this procedure of the manual.

3. Perform one (1) of the following sections:

Adjustable Frames

A. Install the adjustable seat frame subassembly. Refer to INSTALLING/REMOVING ADJUSTABLE



B. Adjust side frames to desired seat width. Refer to

CHANGING SEAT WIDTH in this procedure of the manual for mounting hole locations and allowable seat width/seat depth combinations.

C. 12-15-INCH SEAT DEPTHS ONLY: Install the CJ back brackets, seat positioning strap, and quick release pin from the onto the adjustable seat frame.

Refer to REMOVING/INSTALLING CJ BACK

BRACKETS in PROCEDURE 8 of this manual.

D. Perform the instructions outlined in PREPARA-

TIONS FOR REMOVING/INSTALLING SEAT

FRAME (STANDARD FRAME, ADJUSTABLE

FRAME, AND CAPTAINS VAN SEAT) in this procedure of the manual.

Captains Van Seat

A. Install the captains van seat. Refer to INSTALLING/

REMOVING CAPTAINS VAN SEAT ASSEMBLY in this procedure of the manual.

B. Adjust the captains van seat to the desired position.

Refer to ADJUSTING CAPTAINS VAN SEAT in this procedure of the manual.


C. Perform the instructions outlined in PREPARA-

TIONS FOR REMOVING/INSTALLING SEAT

FRAME (STANDARD FRAME, ADJUSTABLE

FRAME, AND CAPTAINS VAN SEAT) in this procedure of the manual.

3. Remove the six (6) mounting screws, locknuts, and spacers that secure the seat pan, seat positioning strap, and quick release pin to the seat frame.

NOTE: When removing seat pan, note tab position of quick release pin to the seat positioning strap.

CONVERTING FROM STANDARD

SEAT FRAME TO CAPTAINS VAN

SEAT OR VICE VERSA






A. Remove the standard seat frame subassembly.

Refer to REMOVING/INSTALLING STANDARD

SEAT FRAME SUBASSEMBLY in this procedure of the manual.

B. Remove the captains van seat Assembly. Refer to

INSTALLING/REMOVING CAPTAINS VAN SEAT



A. Install the captains van seat. Refer to INSTALLING/

REMOVING CAPTAINS VAN SEAT ASSEMBLY in this procedure of the manual.

B. Install the standard seat frame. Refer to REMOV-

ING/INSTALLING STANDARD SEAT FRAME SUB-


4. STANDARD FRAMES ONLY ON 12-15-INCH SEAT

DEPTHS ONLY: Install the CJ back brackets from the onto the adjustable seat frame. Refer to REMOVING/

INSTALLING CJ BACK BRACKETS in PROCEDURE

8 of this manual.





6. Adjust the captains van seat to the desired position. Refer to ADJUSTING CAPTAINS VAN SEAT in this procedure of the manual.

Installing

1. Position the NEW seat pan on the seat frame, aligning the mounting holes of the seat pan and the mounting holes of the seat frame.

2. Position the seat positioning strap and quick release pin tab onto the seat frame and secure with mounting screw and locknut. See FIGURE 9 for proper orientation. Repeat for other seat positioning strap.

NOTE: Check seat positioning strap for proper length. The width range for the four (4) seat positioning straps are: 12-16inches wide (Junior), 16-19-inches wide, 20-22-inches wide, and 23-24-inches wide.

3. Reinstall the remaining mounting screws, locknuts, and spacers. Torque all mounting screws to 75-inch pounds.

4. Remove the protective strips from new seat pan and reinstall the seat cushion onto the seat pan.


A. When changing the seat width or depth, refer back to that procedure to complete the desired change.

Mounting

Screws

Seat

Positioning

Strap

Seat

Pan

REMOVING/INSTALLING SEAT PAN

(FIGURE 9)

Removing

1. Remove the seat cushion from the seat pan.

2. Remove the flip-back armrests from the wheelchair. Refer to INSTALLING/REMOVING FLIP BACK ARMRESTS in PROCEDURE 4 of the owners manual, 1081227.

Tab

Spacer

Seat Frame

Locknut

Quick Release Pin Locknut

NOTE: Illustration shows standard frame only for clarity.

The seat pan removes/installs onto the adjustable seat frame the way.

FIGURE 9 - REMOVING/INSTALLING SEAT PAN

F

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E

A

T

S

E

31

F

R

A

M

E

A

T

S

E


B. Reinstall the flip-back armrests from the wheelchair.

Refer to INSTALLING/REMOVING FLIP BACK ARM-

RESTS in PROCEDURE 4 of the owners manual,

1081227.

MOUNTING PLATE - SEAT ANGLE

ADJUSTMENT AND INSTALLATION

ORIENTATION (FIGURE 10)

Seat Angle Adjustment

NOTE: The angle of the seat is factory set providing the user with a 5 o seat dump. This angle can changed by adjusting either the front or back of the seat mount plate to obtain any angle between 0 o or 10 o seat dump.

NOTE: There are three (3) heights of seat mounting plates; low, medium, and high. See chart below for proper settings.

1. To obtain a 0 o seat dump (DETAIL A):

A. Loosen the two (2) mounting screws that secure the rear of the seat frame to the seat mount plate.

B. Position the mounting screws at the bottom of the rear slot.

LOW

Thicker End

MEDIUM AND HIGH

Angled End of Seat

Mounting Plate

C. Securely tighten both mounting screws. Torque to

15-in/lbs.

2. To obtain a 10 o seat dump (DETAIL A):

A. Loosen the two (2) mounting screws that secure the front of the seat frame to the seat mount plate.

B. Position the mounting screws at the bottom of the front slot.

C. Securely tighten both mounting screws. Torque to

15-in/lbs.

Installation Orientation

1. Medium and High Seat Mounting Plates: Install with the angled end toward the front of the wheelchair.

2. Low Seat Mounting Plates: Install with the thicker end toward the front of the wheelchair.

Rear of Seat Frame

Mounting

Screw DETAIL A

Front of Seat

Frame Medium Height

Seat Mount Plate

Mounting Screw

SEAT

MOUNT

PLATE

LOW

HEIGHT

REAR OF

CHAIR

0 o

FRONT OF

CHAIR

SEAT DUMP

5 o

REAR OF

CHAIR

FRONT OF

CHAIR

REAR OF

CHAIR

10 o

FRONT OF

CHAIR

REAR OF

CHAIR

FRONT OF

CHAIR

REAR OF

CHAIR

FRONT OF

CHAIR

REAR OF

CHAIR

FRONT OF

CHAIR

MEDIUM

HEIGHT

REAR OF

CHAIR

FRONT

OF CHAIR

REAR OF

CHAIR

FRONT OF

CHAIR

REAR OF

CHAIR

FRONT OF

CHAIR

HIGH

HEIGHT

FIGURE 10 - MOUNTING PLATE - SEAT ANGLE ADJUSTMENT AND INSTALLATION ORIENTATION

32

BASE FRAME PROCEDURE 7


Replacing Seat Mounting Plates

Replacing Seat Support Brackets

Replacing Seat Support Bracket T-Nuts

Replacing Battery Charger Bracket and T-Nut

Removing/Installing Seat Stop Screws

6. Adjust seat mounting plates to desired angle. Refer to

MOUNTING PLATE - SEAT ANGLE ADJUSTMENT

AND INSTALLATION ORIENTATION in PROCEDURE

6 of this manual.

7. Reverse STEP 2A, 2B or 2C.




TAINS VAN SEAT) in PROCEDURE 6 of this manual.

WARNING



REPLACING SEAT MOUNTING

PLATES (FIGURE 1)

NOTE: When replacing components of the wheelchair, refer to the individual procedure for correct use of LOCTITE 242 and torque specifications or PROCEDURE 3 of this Manual.






A. Remove standard seat frame subassembly. Refer to REMOVING/INSTALLING STANDARD SEAT

FRAME SUBASSEMBLY in PROCEDURE 6 of this manual.

B. Remove adjustable seat frame subassembly. Refer to INSTALLING/REMOVING ADJUSTABLE

SEAT FRAME ASSEMBLY AND OR COMPO-

NENT REPLACEMENT in PROCEDURE 6 of this manual.

C. Remove captains van seat. Refer to INSTALLING/

REMOVING CAPTAINS VAN SEAT ASSEMBLY in

PROCEDURE 6 of this manual.

NOTE: Before removing seat mounting plates, note the position of the washers.

3. Remove the two (2) mounting screws, washers and bolt strap bracket that secure the seat mounting plate to the seat support bracket.

4. Secure NEW seat mounting plate with existing two (2) mounting screws, washers, and bolt straps to seat support bracket using Loctite 242 and torque to 156-inch pounds.

5. Repeat STEPS 1-2 for opposite side, if necessary.

NOTE: For illustrations of the three (3) different seat mounting plates, refer to MOUNTING PLATE - SEAT ANGLE

ADJUSTMENT AND INSTALLATION ORIENTATION in

PROCEDURE 6 of this manual.

Washer

Bolt Strap

Seat

Mounting

Plate

Mounting

Screws

Seat

Support

Bracket

Washer

Mounting

Screws

FIGURE 1 - REPLACING SEAT MOUNTING PLATES

REPLACING SEAT SUPPORT

BRACKETS (FIGURE 2)

1. Perform the instructions outlined in PREPARATIONS FOR

REMOVING/INSTALLING SEAT FRAME (STANDARD

FRAME, ADJUSTABLE FRAME, AND CAPTAINS VAN

SEAT) in PROCEDURE 6 of this manual.










3. Remove seat mount plates. Refer to REPLACING SEAT

MOUNTING PLATES in this procedure of the manual.

NOTE: Note the position of the seat support brackets before removing to ensure proper reinstallation.

33

F

R

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E

B

A

F

R

A

M

E

S

E

B

A

PROCEDURE 7 BASE FRAME

WARNING

Do not adjust the position of the seat support bracket in this procedure. If an adjustment is desired, refer to ADJUSTING

WEIGHT DISTRIBUTION in PROCEDURE 15 -

MWD WHEELCHAIRS, PROCEDURE 16 - RWD

WHEELCHAIRS, or PROCEDURE 17 - FWD

WHEELCHAIRS of this manual.

4. Remove the two (2) mounting screws and washers that secure the seat support bracket to the base frame.

WARNING

When installing seat support bracket, ensure the mounting screws are threaded into the T-Nuts located inside the channel of the base frame.

5. Secure the NEW seat support bracket to base frame with the existing two (2) mounting screws and washers.


6. Reinstall seat mount plates. Refer to REPLACING SEAT


7. Adjust seat mount plates to desired angle. Refer to



6 of this manual.






Washer

Mounting Screws

Seat Support

Bracket

Base

Frame

T-Nut







3. Remove the seat mount plates. Refer to REPLACING SEAT


NOTE: Before removing seat mounting plates, note the position of the washers.

4. Remove the seat support brackets. Refer to REPLAC-

ING SEAT SUPPORT BRACKETS in this procedure of the manual.

5. Remove the seat stop screw that is closest to the end cap. Refer to REMOVING/INSTALLING SEAT STOP

SCREWS in this procedure of the manual.

6. Remove the end cap and channel cover.

7. Slide existing T-Nut(s) out of channel.

8. Insert NEW T-Nut(s) into channel in correct orientation.

9. Replace channel cover and end cap.

WARNING

The seat stop screws must be in place before operation of your power wheelchair.

Ensure the T-Nut(s) are positioned between both seat stop screws.

10. Use Loctite 242 frame.

and reinstall seat stop screw into base

11. Reinstall the seat seat support brackets. Refer to RE-

PLACING SEAT SUPPORT BRACKETS in this procedure of the manual.

Channel Cover

Mounting Screw

Washer

Channel

Seat Support

Bracket

FIGURE 2 - REPLACING SEAT SUPPORT BRACKETS

REPLACING SEAT SUPPORT

BRACKET T-NUTS (FIGURE 3)

Stop

Screw








34

Base

Frame

End Cap

T-Nut

FIGURE 3 - REPLACING SEAT SUPPORT BRACKET

T-NUTS

BASE FRAME PROCEDURE 7

12. Reinstall the seat mount plates. Refer to REPLACING

SEAT MOUNTING PLATES in this procedure of the manual.

13. Adjust seat mounting plates to desired angle. Refer to



6 of this manual.






8. Secure the battery charger connector to the mount bracket with the EXISTING two (2) mounting screws.

Tighten securely.






Battery

Charger

Mount

Bracket

Mounting Screw

Battery

Charger

Connector

REPLACING BATTERY CHARGER

BRACKET AND T-NUT

NOTE: There is no T-nut on the FWD models.

RWD and MWD Models (FIGURE 4)


FOR REMOVING/INSTALLING THE SEAT FRAME

(STANDARD FRAME, ADJUSTABLE FRAME, AND

CAPTAINS VAN SEAT) in PROCEDURE 6 of this manual.










3. Remove the seat support brackets. Refer to RE-

PLACING SEAT SUPPORT BRACKETS in this procedure of this manual.

4. Remove the two (2) mounting screws that secure the battery charger connector to the mount bracket.

5. Remove battery charger connector from mount bracket.

6. Remove the mounting screw which secures the battery charger mount bracket to the T-nut located in the channel of the base frame.

7. Replace battery charger mount bracket and secure to base frame with existing mounting screw.

NOTE: To replace the Battery Charger Bracket T-Nut, perform STEPS 3-13 in REPLACING SEAT SUPPORT

BRACKET T-NUTS in this procedure of the manual.

Base

Frame

T-nut

FIGURE 4 - RWD AND MWD MODELS

Arrow FWD Model (FIGURE 5)


A. For LOW MOUNT BRACKETS, perform

STEPS 1-11.

B. For MEDIUM/HIGH MOUNT BRACKETS perform STEPS 4-9 ONLY.


FOR REMOVING/INSTALLING THE SEAT FRAME


CAPTAINS VAN SEAT) in PROCEDURE 6 of this manual.










4. Remove the front shroud. Refer to REMOVING/IN-

STALLING FRONT SHROUD in PROCEDURE 17 of the manual.

F

R

A

M

E

S

E

B

A

35

F

R

A

M

E

S

E

B

A

PROCEDURE 7 BASE FRAME

5. Remove the two (2) mounting screws that secure the battery charger connector to the mount bracket.

6. Remove battery charger connector from mount bracket.

7. Remove the mounting screw which secures the battery charger mount bracket to the base frame.

8. Replace the battery charger mount bracket and secure it to the base frame with the EXISTING mounting screw. Securely tighten.

9. Secure the battery charger connector to the mount bracket with the EXISTING two (2) mounting screws.

Tighten securely.






Mounting Screw

Battery

Charger

Connector

Mounting

Screw

REMOVING/INSTALLING SEAT

STOP SCREWS (FIGURE 6)

NOTE: This procedure is for RWD and MWD wheelchairs ONLY.

NOTE: The front seat stop screw should only be removed if replacing a T-nut for either the seat support bracket or the battery charger mount bracket. The rear seat stop screw should never be removed.

1. Unthread seat stop screw from base frame.

WARNING

The seat stop screws must be in place before operation of your power wheelchair.

Ensure the seat support bracket is posi tioned between both seat stop screws.

2. When reinstalling the front seat stop screw, ensure the seat support bracket is located in-between both seat stop screws. Use loctite 242 and tighten securely.

Seat Support Bracket

Base

Frame Rear Seat

Stop Screw

Front Seat Stop Screw

FIGURE 6 - REMOVING/INSTALLING SEAT

STOP SCREWS

Battery

Charger

Mount

Bracket

Base Frame

FIGURE 5 - ARROW FWD MODEL

36

BACK FRAME PROCEDURE 8


Removing/Installing CJ Back Brackets

Changing Back Height

Back Angle Adjustment

WARNING


NOTE: The procedures in this section of the manual refer to NON-RECLINER seat frames only. For recliner seat frames, refer to PROCEDURE 14 of this manual.

REMOVING/INSTALLING CJ BACK

BRACKETS (FIGURE 1)

NOTE: The following procedure is for Jr. wheelchairs only.

NOTE: This procedure is to be performed in conjunction with a starting procedure except when replacement of CJ back brackets is desired.

Removing CJ Back Brackets

1. If necessary, perform the instructions outlined in PREPA-

RATIONS FOR REMOVING/INSTALLING SEAT

FRAME (STANDARD FRAME, ADJUSTABLE FRAME,

AND CAPTAINS VAN SEAT) in PROCEDURE 6 of this manual.

2. Remove the locknuts and washers that secure the CJ back bracket to the back angle plate.

3. Remove the mounting screw and locknut that secures the quick release pin and CJ back bracket and seat positioning strap to the seat frame.

4. Remove the existing CJ back bracket.

5. Repeat STEPS 2-4 for the opposite CJ back bracket.


A. For replacement of CJ back brackets, proceed to

REMOVING/INSTALLING CJ BACK BRACKETS in this procedure of the manual.

B. For all other seat frame changes, refer back to the starting procedure to complete the desired change.

NOTE: Ensure the CJ back bracket is mounted in the front holes of the back angle plates as shown in DETAIL A.

WARNING

Always wear your seat positioning strap.

3. Position the seat positioning strap and quick release pin under the CJ back bracket.

4. Secure the quick release pin, seat positioning strap, and

CJ back bracket to the seat frame. Torque to 75-inch pounds.

5. Install washers and locknuts onto the threaded studs of the CJ back bracket. Torque to 75-inch pounds.


A. For replacing CJ back brackets only, perform the instructions outlined in PREPARATIONS FOR RE-

MOVING/INSTALLING SEAT FRAME (STANDARD

FRAME, ADJUSTABLE FRAME, AND CAPTAINS

VAN SEAT) in PROCEDURE 6 of this manual.

B. For all other seat frame changes, refer back to the starting procedure to complete the desired change.

CJ Bracket mounts in

Front Holes on

Back Angle

Plates.

Toward Front of

Wheelchair

Back

Angle

Plate

Mounting

Screw

CJ Back

Threaded

Bracket

Studs

DETAIL “A”

Seat

Positioning

Strap

Washers

Quick

Release

Pin

Installing CJ Back Brackets

1. If necessary, perform the instructions outlined in PREPA-

RATIONS FOR REMOVING/INSTALLING SEAT

FRAME (STANDARD FRAME, ADJUSTABLE FRAME,

AND CAPTAINS VAN SEAT) in PROCEDURE 6 of this manual.

2. Install the threaded studs of the CJ back bracket through the back angle plates as shown in FIGURE 1.

37

Locknuts

Seat

Pan

Locknut

Seat Frame

FIGURE 1 - REMOVING/INSTALLING CJ BACK

BRACKETS

F

R

A

M

E

C

K

B

A

F

R

A

M

E

C

K

B

A

PROCEDURE 8 BACK FRAME

CHANGING BACK HEIGHT

(FIGURE 2)

NOTE: If changing the back height, new back upholstery may be needed as well. Refer to the following chart to determine if new back upholstery is needed:

BACK UPHOLSTERY HEIGHT RANGES

16-17-INCHES

18-19-INCHES

20-INCHES

21-22-INCHES

23-24-INCHES

If back height required is within the range of the original back height, only new back canes will be needed.

If the back height required is NOT within the range of the original back height, new back upholstery, as well as new back canes will be needed.

NOTE: Existing hardware and inserts will be reused.

1. Remove the armrests from the wheelchair. Refer to IN-



NOTE: Note the correct mounting screw mounting positions to ensure the proper back angle for reinstallation.

2. Remove the two (2) mounting screws and washers that secure the existing back upholstery to the back canes.

3. Remove the four (4) mounting screws, washers, spacers, and locknuts that secure the existing back canes to the seat frame.

4. Remove the inserts from the existing back canes.

5. Remove the back assembly from the wheelchair.

6. If applicable, loosen, but do not remove the mounting screws and locknuts that secure the spreader bar to the existing back canes.

7. Remove existing back canes from the back assembly.

8. Slide the inserts into the bottom of the NEW back canes.

9. Line up the mounting holes of the inserts with the mounting holes in the back canes.

NOTE: To keep the inserts lined up for reinstallation onto the wheelchair, start one (1) of the mounting screws through the back cane from inside of the wheelchair to hold the insert in place.

10. Slide the NEW back canes through the existing/NEW back upholstery and spreader bar.

11. If applicable, loosely tighten the mounting screws that secure the spreader bar to the NEW back canes.

12. Line up the mounting holes in the back canes with the mounting holes in the seat frame.

NOTE: If needing a reference for proper mounting holes for the back angle required, or if changing the original back angle, refer to BACK ANGLE ADJUSTMENT in this procedure of the manual.

WARNING

The back canes MUST be fastened securely to the seat frame BEFORE using the wheelchair. Torque to 75-inch pounds.

13. Secure the two (2) NEW back canes to the seat frame with the existing four (4) mounting screws, washers, spacers, and locknuts. Use Loctite 242 and torque to

75-inch pounds.

14. Secure the top of the existing/new back upholstery to the back canes with the two (2) existing mounting screws and washers.

15. Secure bottom of the existing/NEW back upholstery to rear of the seat pan.

16. Secure the bottom of the existing/NEW back upholstery to the back canes with new tie-wraps.

NOTE: Clean upholstery with warm DAMP cloth and mild detergent to remove superficial soil.

38

WARNING

Laundering or moisture will reduce flame retardancy of the upholstery.

NOTE: When replacing the back upholstery, back assembly or changing back height, follow these guidelines for spreader bar height (where applicable):

BACK HEIGHT

16-inches*

17-inches*

18-19-inches*

20-24inches u SPREADER BAR

HEIGHT

5-inches

5-inches

7-inches

7-inches

NOTE: Spreader Bar required on back heights 20-24inches. *Spreader bar ONLY required on these back heights if the width or depth of the chair exceeds 19-inches.

u Height of Spreader Bar from Bottom of Back Canes to Top of Spreader Bar Clamp.

HEAVY DUTY MODELS

NOTE: Spreader bar required on all Heavy Duty models.

BACK HEIGHT

16-17-inches


HEIGHT

5-inches

7-inches uHeight of Spreader Bar from Bottom of Back


BACK FRAME PROCEDURE 8

17. If necessary, reposition the spreader bar at the correct height for the corresponding back height and torque the mounting hardware to 60-inch pounds.

18. Reinstall the armrest onto the wheelchair. Refer to

INSTALLING/REMOVING FLIP BACK ARMRESTS in PROCEDURE 4 of the owners manual, 1081227.

Back Cane

(STEPS 3, 10)

Spacers

(STEPS 3, 13)

Locknuts

(STEPS 3, 13)

F

R

A

M

E

C

K

B

A

Mounting

Screw

(STEPS 2, 14)

Washer

(STEPS 2, 14)

Back

Upholstery

Locknut

(STEPS 6,11)

Mounting

Screw

(STEPS 6,11)

Insert

(STEPS 4,8)

Mounting Screws


(STEPS 3, 13)

Washers

(STEPS 3, 13)

Seat Frame

FIGURE 2 - CHANGING BACK HEIGHT

39

Locknut

(STEPS 6,11)

Spreader Bar

(STEPS 6,17)

Mounting Screw


(STEPS 6,11)

Mounting Screws

(STEPS 3, 13)

Washers

(STEPS 3, 13)

F

R

A

M

E

C

K

B

A

PROCEDURE 8 BACK FRAME

BACK ANGLE ADJUSTMENT

(FIGURE 3)

1. Remove armrests from the wheelchair. Refer to IN-



2. Remove the mounting screw and washer from the top mounting hole of back angle plate and back cane.

NOTE: To avoid losing the insert in each back cane, thread the mounting screw through the cane from the inside of wheelchair to hold the insert in place.

3. Remove the mounting screw and washer from the bottom mounting hole of the back angle plate and

back cane.

4. Reposition the back canes into the correct mounting holes of the back angle plate to obtain a back angle between 80 o and 100 o in 5 o increments.

5. Torque mounting screws to 75-inch pounds.

6. Reinstall the armrests onto the wheelchair. Refer to INSTALLING/REMOVING FLIP BACK ARM-

RESTS in PROCEDURE 4 of the owners manual,

1081227.

TO ACHIEVE A BACK ANGLE OF:

ANGLE BACK CANE MOUNTING HOLE

80 O Top

Bottom

BACK ANGLE PLATE HOLE

TOP Front

BOTTOM Rear

85 O Top

2nd from Bottom

TOP Front

BOTTOM Center

90 O

Top

Bottom

TOP Front

BOTTOM Front

95 O Top

2nd from Bottom

TOP Center

BOTTOM Front

100 O Top

Bottom

FIGURE 3 - BACK ANGLE ADJUSTMENT

40

TOP Rear

BOTTOM Front

BATTERIES PROCEDURE 9


Installing/Removing Batteries Into/From Battery

Box(es)

Connecting Battery Cables

When to Charge Batteries

Charging Batteries

Replacing Batteries

Installing/Removing Group 24 Battery Boxes

Installing/Removing Group 22NF Battery Boxes

WARNING

Make sure power to the wheelchair is OFF before performing this procedure.


Invacare strongly recommends that battery installation and battery replacement ALWAYS be done by a qualified technician.


FORE use, make sure all attaching hardware is tightened securely - otherwise injury or damage may result.

INSTALLING/REMOVING

BATTERIES INTO/FROM BATTERY

BOXES (FIGURE 1)

NOTE: To remove the battery(ies) from the battery box(es), reverse the following procedure.

NOTE: Have the following tools available:

TOOL

Battery Lifting Strap

1/2-inch (6 pt) Box Wrench

QTY

1

1

COMMENTS

Supplied

Not Supplied

WARNING

ALWAYS use a battery lifting strap when lifting a battery. It is the most convenient method and assures that the battery acid will not spill. It also helps to prolong the life of the battery.

DO NOT tip the batteries. Keep the batteries in an upright position.

Place the wheelchair in a well ventilated area where work can be performed without risking damage to carpeting or floor covering.

The warranty and performance specifications contained in this manual are based on the use of deep cycle gel cell or sealed lead acid batteries.

Invacare strongly recommends their use as the power source for this unit.

NOTE: If there is battery acid in the bottom or on the sides of the battery box(es) or battery(ies), apply baking soda to these areas to neutralize the battery acid. Before reinstalling the

NEW or existing battery(ies), clean the baking soda from the battery box(es) or battery(ies).

NOTE: When securing battery lifting strap to battery, observe polarity markings located on the ends of the battery lifting strap, (+) side to POSITIVE (+) battery post and (-) side to NEGATIVE (-) battery post.

1. If necessary, remove the battery boxes from the wheelchair. Refer to INSTALLING/REMOVING BATTERY

BOXES - GROUP 24 BATTERY BASE FRAMES in this procedure of the manual.

2. Secure battery lifting strap to battery terminal(s)/post(s)

(FIGURE 1).

CAUTION

Some battery manufacturers mold a carrying strap and/or hold down flanges directly into the battery case. Batteries which interfere with the battery box cannot be used for these applications.

Attempting to “wedge” a battery into a battery box may damage the box and/or the battery.

3. Place batteries into battery box bottom.

Battery

Lifting

Strap

Molded Carrying Straps (Must be removed before installation)

Group 24

Battery Box Bottom

Group 22NF

Battery Box

Bottom

FIGURE 1 - INSTALLING/REMOVING BATTERIES

INTO/FROM BATTERY BOXES

I

E

E

R

S

T

T

B

A

41

I

E

E

R

S

T

T

B

A

PROCEDURE 9

CONNECTING BATTERY CABLES

(FIGURE 2)

WARNING

NEVER allow any of your tools and/or battery cable(s) to contact BOTH battery post(s) at the same time. An electrical short may occur and serious personal injury or damage may occur.


When tightening the clamps, always use a box wrench. Pliers will “round off” the nuts.

NEVER wiggle the battery terminal(s)/post(s) when tightening. The battery may become damaged.

The POSITIVE (+) RED battery cable MUST connect to the POSITIVE (+) battery terminal(s)/ post(s), otherwise serious damage will occur to the electrical system.

Group 24 Batteries

NOTE: Perform this procedure on one (1) battery and battery box at a time. Repeat procedure for other battery box.

1. Position battery box top next to battery box bottom as shown in FIGURE 2.

2. Peel back battery clamp covers to expose battery clamp on each battery cable as follows:

A. RED battery clamp cover from RED battery cable.

B. BLACK battery clamp cover from BLACK battery cable.

BATTERIES

3. Connect NEGATIVE N battery cable clamp to NEGA-

TIVE(-) battery post and connect POSITIVE P battery cable clamp to POSITIVE (+) battery post (DETAIL A).

4. Secure the battery cable clamp(s) to the battery post(s) with provided hex screws and nuts. Securely tighten.

5. Verify battery cable clamps(s) are correctly installed and securely tightened.

6. Reposition battery clamp covers over battery post(s).

7. Install the battery box top(s).

9. Install the battery box(es) into the wheelchair. Refer to

INSTALLING/REMOVING BATTERY BOX(ES) in this procedure of this manual.

NOTE: New Battery(ies) MUST be fully charged BEFORE using, otherwise the life of the battery(ies) will be reduced.

10. If necessary, charge the battery(ies). Refer to CHARG-

ING BATTERIES in this procedure of the manual.

42


DETAIL “A”

NEGATIVE

(-)

Battery

Terminal/

Post

Battery Box Bottom Battery

POSITIVE

(+)

Battery

Terminal/

Post

TWO (2) CONNECTOR BATTERY BOX

RED POSITIVE (+)

Battery Cable

Two (2) Connector

Battery Box Top

Black

NEGATIVE (-)

Battery

Cable

Clamp

BLACK

NEGATIVE (-)

Battery

Cable

RED

Battery

Clamp

Cover

RED

POSITIVE (+)

Battery

Cable Clamp NEGATIVE (-)

Battery Terminal/Post

Battery Box

Bottom

POSITIVE (+)

Battery Terminal/Post

BLACK

Battery

Clamp

Cover

ONE (1) CONNECTOR BATTERY BOX

Black NEGA-

TIVE (-)

Battery Cable

One (1) Connector

Battery Box Top

Black NEGA-

TIVE (-)

Battery Cable

Clamp

RED POSI-

TIVE (+)

Battery

Cable

NEGATIVE (-)

Battery

Terminal/Post

Battery Box

Bottom

POSITIVE (+)

Battery

Terminal/Post

RED

Battery

Clamp

Cover

Red POSI-

TIVE (+)

Battery Cable

Clamp

FIGURE 2 - CONNECTING BATTERY CABLE(S) - GROUP 24 BATTERIES

I

E

E

R

S

T

T

B

A

43

I

E

E

R

S

T

T

B

A

PROCEDURE 9 BATTERIES

Group 22 Battery Base Frames (FIGURE 3)

NOTE: Refer to WARNINGSand CAUTIONS in the front of this procedure.

NOTE: Note polarity of white battery cable (jumper) battery terminal ends.

1. Remove battery terminal cap(s) from battery terminal(s) ends. Refer to DETAIL A in FIGURE

3.

2. Connect WHITE battery cable (jumper) NEGATIVE

N

terminal end to NEGATIVE (-) battery terminal/ post of front battery and connect POSITIVE

P

terminal end to POSITIVE (+) battery terminal/post of rear battery.

3. Place battery top upside down on top of rear battery.

4. Connect NEGATIVE (-) BLACK battery cable of the battery box top to NEGATIVE (-) battery terminal/post of rear battery.

5. Position battery box top right side up and rotate outward toward right to expose POSITIVE (+) battery terminal/post of front battery.

6. Connect POSITIVE (+) RED battery cable on battery box top to POSITIVE (+) battery terminal/post of front battery.

7. Replace battery terminal cap(s) onto battery cable terminal end(s).

8. Rotate top toward left into position. Secure in place.

9. Install the battery box into the wheelchair. Refer to

INSTALLING/REMOVING 22NF BATTERY BOX in the Owners Manual supplied with the chair.

NOTE: New Battery(ies) MUST be fully charged BE-

FORE using, otherwise the life of the battery(ies) will be reduced.

10. If necessary, charge the battery(ies). Refer to

CHARGING BATTERIES in the Owners Manual supplied with the wheelchair.

44

PROCEDURE 9

Front

Battery

Single

Battery

Box

Bottom

Rear

Battery

BATTERIES

STEP 2

FRONT

REAR

Front

Battery

Rear

Battery

WHITE Battery Cable

(Jumper)

POSITIVE (+)

RED Battery

Cable

STEPS 3 AND 4

FRONT

Battery

Box Bottom

NEGATIVE (-)

Battery

Terminal/Post

NEGATIVE (-)

BLACK Battery

Cable

Battery

Box Top

(Under Side shown)

I

E

E

R

S

T

T

B

A

Fuse

Block

DETAIL “A”

STEPS 5 AND 6

POSITIVE (+) RED Battery Cable

POSITIVE (+)

Battery

Terminal/Post

Terminal Cap

Front

Battery

Rear

Battery

Battery

Box Top

Battery Box Bottom

NOTE: Battery box top cut away for clarification purposes only.

Terminal End

FIGURE 3 - CONNECTING BATTERY CABLES - SINGLE 22NF BATTERY BOX

45


I

E

E

R

S

T

T

B

A

WHEN TO CHARGE BATTERIES

(FIGURE 6)

The Battery Discharge Indicator (BDI) is a bar graph display located on the MKIV joystick. It will keep you informed as to power availability. A visual warning is given before the power becomes too low to operate the wheelchair. At full charge the two (2) LEFT segments and the farthest RIGHT segment of the bar graph will be illuminated. As the battery becomes discharged, the farthest RIGHT segment will progressively move to the LEFT until only the last two (2) bars

(LEFT) are illuminated. At this level the last two (2) bars

(LEFT) will start to Flash ON and OFF to indicate that the end user should charge the batteries as soon as possible.

Battery Discharge

Indicator (BDI)

MKIV- A JOYSTICK

Battery Discharge

Indicator (BDI)

Battery Discharge

Indicator (BDI) (in LCD

Readout)

MKIV- A+ JOYSTICK

MKIV- X JOYSTICK

FIGURE 6 - WHEN TO CHARGE BATTERIES

CHARGING BATTERIES (FIGURE 7)

NOTE: New batteries MUST be fully charged prior to initial use of the wheelchair.

WARNING

Never attempt to recharge the batteries by attaching cables directly to the battery terminals or clamps. Always use the recharging plug located on the side of the wheelchair frame.

DO NOT attempt to recharge the batteries and operate the power wheelchair at the same time.

During use and charging, unsealed batteries will vent hydrogen gas which is explosive in the right concentration with air.

CAUTION

Always charge new batteries before initial use or battery life will be reduced.

NOTE: As a general rule, batteries should be recharged daily to assure the longest possible life and minimize the required charging time. Plan to recharge the batteries when it is anticipated the wheelchair will not be used for a long period of time.

The range per battery charge using recommended batteries should be approximately 5 to 9 hours of typical operation. Extensive use on inclines may substantially reduce per charge mileage.

Description and Use of Battery Chargers

The charger automatically reduces the charge from an initially high rate to a zero reading at a fully charged condition.

If left unattended, the charger should automatically shut-off when full charge is obtained.

There are some basic concepts which will help you understand this automatic process. They are:

The amount of electrical current drawn within a given time to charge a battery is called the charge rate. If, due to usage, the charge stored in the battery is low, the charge rate is high, as indicated by the green light on the charger.

Initially, the green light will stay illuminated for a short period of time followed by a longer period of off time. As a charge builds up, the charge rate is reduced, and the green light will stay illuminated for a longer period of time followed by a shorter off time.

WARNING

If the charger circuit breaker is tripping ON and OFF, unplug the charger and contact

Invacare Technical Services, 1-800-832-4707.

46


NOTE: If performing the charging procedures independently,

READ and CAREFULLY follow the individual instructions for each charger (supplied or purchased).

NOTE: If charging instructions are not supplied, consult a qualified service technician for proper procedures.

Required Items:

TOOL

Battery Charger uExtension Cord

QUANTITY COMMENTS

1

1

Supplied

Not Supplied u (3-prong plug, 15 ampere current rating; industrial type)

1. Attach the battery charger connector to the charger cable/ battery harness.

NOTE: The battery charger connector is factory installed on the RIGHT side of the wheelchair. It can be positioned on either side of the wheelchair for user convenience.

NOTE FOR RECLINERS ONLY: If the wheelchair is a recliner, the battery charger connector as well as the limit switch, are factory set on the RIGHT side of the wheelchair. However, they can be positioned on either side for user convenience. The limit switch MUST BE positioned on the same side as the battery charger connector.

2. Plug the chargers AC power cord, or extension, into the grounded 120 VAC wall outlet.

3. Wait until charging is complete.

Battery Charger Connector

From Battery Charger

Three (3)

Pronged Plug

Top View of Wheelchair

Battery Charger

From

Battery

Charger

REAR OF

RWD/MWD MODELS

ARROW FWD MODEL

WHEELCHAIR

Charger Cable

Battery Boxes

Battery Charger Mount Bracket

Base Frame

I

E

E

R

S

T

T

B

A

47

Battery Charger

Mount Bracket and Connector

NOTE: Shrouds and drive wheels not shown for clarification purposes only.

FIGURE 7 - CHARGING BATTERIES

NOTE: Allow eight (8) hours for normal charging. Larger batteries (greater than 55 ampere-hours) or severely discharged batteries may require up to sixteen (16) hours to be properly charged and equalized. If charger operates for sixteen (16) hours and is unable to fully charge the batteries, an internal timer turns the charger off and begins to fast blink the green light.

I

E

E

R

S

T

T

B

A


It is advantageous to recharge frequently rather than only when necessary. In fact, a batterys life is extended if the charge level is maintained well above a low condition.

REPLACING BATTERIES

NOTE: Invacare recommends that both batteries be replaced if one (1) battery is defective.

Recommended Battery Types

WARNING

The warranty and performance specifications contained in this manual are based on the use of deep cycle gel cell or sealed lead acid batteries. Invacare strongly recommends their use as the power source for this unit.

Failure to use the correct battery size and/ or voltage may cause damage to your wheelchair and give you unsatisfactory performance.

BATTERY SIZE

POWER CHAIR QTY VOLTS Standard Optional

Arrow w/ motor/gearbox 2

2

12

12

Group 24 Group 22

Group 22 Group 24 w/ G/B motor

Torque with motor/gearbox 2 with G/B motor 2

12

12



Torque SP with motor/gearbox 2 with G/B motor

Storm X

N/A with motor/gearbox 2 with G/B motor 2

12 Group 22 N/A

N/A

12

12

N/A N/A



NOTE: G/B denotes gearless/brushless.

NOTE: Both battery sizes are deep cycle batteries.

NOTE: Charge batteries daily. It is critical not to let them run low at any time.

1. Remove the battery box(es) from the wheelchair. Refer to INSTALLING/REMOVING GROUP 24 BATTERY

BOXES or INSTALLING/REMOVING GROUP 22 BAT-

TERY BOX in this procedure of the manual.

2. Remove the existing batteries from the battery box(es).

Refer to INSTALLING/REMOVING BATTERIES INTO/

FROM BATTERY BOX(ES) in this procedure of the manual.

3. Clean the new battery terminals. Refer to CLEANING

BATTERY TERMINALS in this procedure of the manual.

4. Install the new batteries into the battery box(es). Refer to INSTALLING/REMOVING BATTERIES INTO/FROM

BATTERY BOX(ES) in this procedure of the manual.

Cleaning Battery Terminals

WARNING

Most batteries are not sold with instructions.

However, warnings are frequently noted on the cell caps. Read them carefully.

DO NOT allow the liquid in the battery to come in contact with skin, clothes or other possessions. It is a form of acid and harmful or damaging burns may result. Should the liquid touch your skin, wash the area IM-

MEDIATELY and thoroughly with cool water. In serious cases or if eye contact is made, seek medical attention IMMEDIATELY.

1. Examine the battery clamps and terminals for corrosion.

2. Verify plastic caps are in place over the battery cell holes.

3. Clean the terminals and inside the battery clamps by using a battery cleaning tool, wire brush, or medium grade sand paper.

NOTE: Upon completion, these areas should be shiny, not dull.

4. Carefully dust off all metal particles.

INSTALLING/REMOVING GROUP

24 BATTERY BOXES (FIGURE 8)

NOTE: To remove the battery boxes from the wheelchair, reverse the following procedure.

Installing

NOTE: FWD wheelchairs only - Remove the counterweight before performing this procedure. Refer to REMOV-

ING/INSTALLING COUNTERWEIGHT in PROCE-

DURE 16 of this manual.

1. Verify that the ON/OFF switch on the joystick is in the

OFF position.

2. Place two (2) connector battery box onto the battery subframe assembly with guide pins facing the inside of the wheelchair.

3. Slide the two (2) connector battery box along the subframe until its guide pins are engaged in the sub-frame connector.

4. Secure the battery box carrying strap to the lid of the two

(2) connector battery box.

NOTE: Visually inspect to ensure the connection is properly made. Connectors MUST be fully engaged.

48


NOTE: Make certain that the carrying strap of the first battery box installed is positioned on top of the battery box and will not interfere with the second battery box guide pins during installation.

5. Place one (1) connector battery box onto battery subframe.

6. Slide one (1) connector battery box along the subframe until its guide pins are engaged in the connector of the two (2) connector battery box.

7. Secure the battery box carrying strap to the lid of the one

(1) connector battery box.

NOTE: Visually inspect to ensure the connection is properly made. Connectors MUST be fully engaged.

CAUTION

The battery box retainer MUST be locked

(clipped) securely to hold the battery boxes firmly in place or battery box connectors may be damaged causing erratic chair operation.

8. Pull the battery box retainer down over the end of front battery box until it is securely clipped (locked) into place.

*Base Frame

NOTE: Position carrying strap on top of battery box

Guide Pins

INSTALLING/REMOVING GROUP

22 BATTERY BOX (FIGURE 9)

NOTE: This procedure is for MWD/RWD chairs ONLY.

NOTE: To install the battery box onto the wheelchair, reverse the following procedure.

1. Place the wheelchair in a well ventilated area where work can be performed without risking damage to carpeting or floor covering.

2. Verify that the ON/OFF switch on the joystick is in the

OFF position.

3. Disconnect the battery cable from the outside of the battery box.

4. Disconnect the battery box retention strap.

5. Remove the battery box.

6. Slide the four (4) clips that secure the battery box cover to the battery box to the OPEN position.

NOTE: Arrows on the battery box cover point to the open position.

7. Remove battery box cover from the battery box.

Arrows

Battery Box

Retention Strap

Battery Box

Sub-Frame

Guide Pins

Two (2) Connector

Battery Box

One (1) Connector Battery Box

*Base Frame

FIGURE 9 - INSTALLING/REMOVING GROUP

22 BATTERY BOX

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B

A

Battery Box

Retainer Bar

*NOTE: Illustration depicts base frame for RWD and

MWD models. Batteries remove/Install for the Arrow

FWD in the same manner.

FIGURE 8 - INSTALLING/REMOVING GROUP

24 BATTERY BOXES

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PROCEDURE 10 WIRING HARNESS


Removing/Installing the Wiring Harness

Adjusting Limit Switch

4. Disconnect the battery harness/charger cable (BLUE) from the controller connector (BLUE).

5. Remove the two mounting screws that secure the charger cable to the mounting bracket.

6. Remove the wiring harness.

WARNING



REMOVING/INSTALLING THE

WIRING HARNESS (FIGURE 1)

NOTE: This procedure is for the FWD and MWD models ONLY. For the removing and installing the wiring harness on the Arrow FWD refer to REMOVING/

INSTALLING WIRING HARNESS in PROCEDURE

17 of this manual.

Removing

1. Remove the battery box(es). Refer to INSTALLING/RE-

MOVING GROUP 24 BATTERY BOXES or INSTALL-

ING/REMOVING GROUP 24 BATTERY BOX in PRO-



For Group 24 Batteries - remove the two mounting screws and locknuts that secure the wiring harness bracket to the base frame (DETAIL A).

For Group 22 Batteries - cut the tie wrap that secures the rear portion of the wiring harness and joystick cable to the rear of the seat frame (DETAIL B).


SECOND GENERATION WHEELCHAIRS

WITH MOTOR/GEARBOX ASSEMBLY

A. Cut tie-wraps A and B that secure the two (2) motor/controller connections and the controller/ wiring harness connection (BLUE connectors) together (DETAIL C).

B. Cut tie-wrap C that secures the battery charger cable, motor connector cable, controller connector cable, and wiring harness cable to the base frame (DETAIL C).


WITH GEARLESS/BRUSHLESS MOTOR

A. Cut tie-wrap A that secures the battery charger cable to the base frame (DETAIL B).

NOTE: For STEPS 4-6 refer to Detail C or D.

50

Installing

1. For Group 24 Batteries Only - Install NEW wiring harness w/bracket to the rear of the sub-frame and torque mounting screws to 160-inch pounds

(DETAIL A).

2. For Group 22 and Group 24 Batteries - Secure the charger cable to the mounting bracket with the two (2) mounting screws. Securely tighten (DE-

TAIL C OR D).

3. For Group 22 and Group 24 Batteries - Connect the battery harness/charger cable (BLUE) to the controller connector (BLUE) (DETAIL C or

D).



WITH MOTOR/GEARBOX ASSEMBLY

A. For Group 22 and Group 24 Batteries -

Group the two (2) motor/controller connections together along with the controller/wiring harness connection (BLUE) and secure with TIE-

WRAPS A and B (DETAIL C).

B. For Group 22 and Group 24 Batteries - Secure the Wiring Harness Cable, Battery Charger

Cable, Controller Connector Cable, and Motor

Connector Cable to the suspension arm with

TIE-WRAP C (DETAIL C).


WITH GEARLESS/BRUSHLESS MOTOR

OPTION:

A. For Group 22 and Group 24 Batteries - Secures the battery charger cable to the base frame with TIE-WRAP A (DETAIL D).

5. For Group 22 Batteries Only - Tie-wrap NEW wiring harness and joystick cable to the rear of the seat frame (DETAIL B).

6. Reinstall the battery box(es). Refer to INSTALLING/

REMOVING GROUP 24 BATTERY BOXES or IN-

STALLING/REMOVING GROUP 22 BATTERY BOX in PROCEDURE 9 of this manual.

WIRING HARNESS PROCEDURE 10

DETAIL A - GROUP 24 BATTERIES

Mounting

Screws

Wiring Harness

Bracket

Battery Box

Sub-Frame

REAR OF

CHAIR

Locknuts

Base

Frame

DETAIL B - GROUP 22 BATTERIES

Joystick

Cable

Wiring

Harness

FRONT OF

CHAIR

NOTE: Battery box sub-frame exploded away for clarification purposes only.

NOTE: Illustration depicts gearless/brushless motor.

Wiring harness is secured to the rear of the seat frame in the same manner for wheelchairs with conventional motor/gearbox assembly.

DETAIL “C” -SECOND GENERATION

WHEELCHAIRS

Mounting

Screws

Controller

Connector

Motor

Connector

Battery

Charger

Cable

Tie-Wrap

C

DETAIL “D” - SECOND GENERATION

WHEELCHAIRS WITH GEARLESS /BRUSHLESS

Controller

Connector

(BLUE)

MOTOR

Wiring

Harness

Connector

(BLUE)

Mounting

Screws

Charger

Mount

Bracket

Charger

Cable

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A

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Tie-Wrap

A

Wiring

Harness

Cable

Motor

Connector

Cable

Tie-Wraps

A and B

Controller

Connector

Controller

Connector

(BLUE)

Wiring Harness

Connector

(BLUE)

Motor

Connector

NOTE: There is no need to cut this

tie-wrap.

FIGURE 1 - REMOVING/INSTALLING THE WIRING HARNESS

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PROCEDURE 10 WIRING HARNESS

ADJUSTING LIMIT SWITCH

(FIGURE 2)

NOTE: The following procedure is for high back captains van seat model wheelchairs only.

WARNING

NEVER operate the wheelchair while in any recline position over 114 o

RELATIVE TO THE SEAT

FRAME. If the limit switch does not stop the wheelchair from operating in a recline position greater than 114 o


FRAME, DO NOT operate the wheelchair. Adjust the limit switch BEFORE using the wheelchair, otherwise injury or damage can occur.

1. Place the wheelchair on a level surface.

2. Recline the captains van seat back to a 24 the 114 o o to achieve

angle relative to the seat frame. Refer to AD-

JUSTING CAPTAINS VAN SEAT in PROCEDURE 4 of the owners manual, 1081227.

NOTE: The captains van seat frame is at a 5 tive to the seat, it will measure 61 o o angle relative to the ground. When the back angle is adjusted to 114 o rela-

relative to the ground.

NOTE: To determine 114 o back angle relative to the seat frame, place a magnetic protractor (available at any hardware store) on the back as shown in FIGURE 2 and adjust the back until the magnetic protractor reads 61 o .

3. Turn the wheelchair power switch on the joystick to the

ON position.

NOTE: The wheelchair should not operate.

4. IF wheelchair operates, proceed to the following steps to adjust the actuator on the upper limit switch bracket:

A. Fully recline the back. Refer to ADJUSTING CAP-

TAINS VAN SEAT in PROCEDURE 4 of the

Owners Manual, 1081227.

NOTE: This will make access to the limit switch easier.

B. Loosen, but do not remove, the two (2) phillips screws, washers and locknuts that secure the actuator to the upper limit switch bracket.

C. Slide the actuator UP (towards the top of the wheelchair).

CAUTION

DO NOT over tighten the phillips screws that secure the actuator to the upper limit switch bracket. Damage to the actuator can occur.

D. Only tighten the two (2) phillips screws, washers and locknuts that secure the actuator to the upper limit switch bracket until the actuator does not move.

E. Repeat STEPS 1-3 until the wheelchair does not operate when the captains van seat back is at a 24 angle.

o

Upper Limit

Switch

Bracket

Phillips

Screws,

Washers and

Locknuts

Actuator

24 o Back

Recline Angle

114 o

5-3/4 inches

Magnetic Protractor - (Will read 61 o recline angle is at 114 o

when back

relative to the seat frame)

FIGURE 2 - ADJUSTING LIMIT SWITCH

5 o Seat Angle

52

61 o

RETENTION STRAP/RETAINER PROCEDURE 11


Replacing Battery Box Retainer Bar/ Retainer Clip

-Group 24 Battery Base Frames

WARNING

B. FWD MODEL - Reinstall the mounting screw, washer, spacer, and locknut that secure the retainer clip to the battery box sub-frame. Use Loctite 242 and torque to 160-inch pounds.

5. Reinstall the battery boxes. Refer to INSTALLING/RE-

MOVING BATTERY BOXES - GROUP 24 BATTERY

BASE FRAMES in PROCEDURE 9 of this manual.



Replacing Retainer Bar

REPLACING BATTERY BOX

RETAINER BAR/RETAINER CLIP -

GROUP 24 BATTERY BASE FRAMES

(FIGURE 1)

1. Remove the battery box. Refer to INSTALLING/RE-

MOVING GROUP 24 BATTERY BOXES in PROCE-

DURE 9 of this manual.

Replacing Retainer Clip

1. Perform one (1) the following:

A. RWD AND MWD MODELS -Remove the two (2) mounting screws and spacers that secure the battery box retainer bar to the base frame.

B. FWD MODELS - Remove the two (2) mounting screws, spacers, washers, and locknuts that secure the retainer bar to the battery box sub-frame.

2. Pull up on the battery box retainer bar to remove it from the base frame.


A. RWD AND MWD MODELS - Remove the mounting screw that secures the retainer clip and shock (or rubber element) to the base frame.

3. Install the two (2) existing spacers through the mounting holes in the NEW battery box retainer bar.

WARNING

B. FWD MODEL - Remove the mounting screw, washer, spacer, and locknut that secure the retainer clip to the battery box sub-frame.

WARNING

The Battery Box Retainer Bar/Retainer Clip MUST be fastened securely in place before using the wheelchair. Use Loctite 242 and torque to 160-inch pounds.

2. Remove the existing retainer clip.


A. RWD AND MWD MODELS - Position the NEW retainer clip between the shock (or rubber element) and the battery box sub-frame as shown in FIGURE 1. Make sure the angled end of the retainer clip is facing up.


A. RWD AND MWD MODELS - Line up the NEW battery box retainer bar and spacers with the mounting holes in the battery box sub frame and the base frame.

B. FWD MODEL - Position the NEW retainer clip between the spacer and the battery box subframe as shown in FIGURE 1. Make sure the angled end of the retainer clip is facing upwards.

B. FWD MODELS - Line up the NEW battery box retainer bar and spacers with the mounting holes in the battery box sub frame.


The Battery Box Retainer Bar/Retainer Clip MUST

A. RWD AND MWD MODELS - Reinstall the mounting screws that secure the battery box retainer bar between battery box sub frame and the base frame.

Use Loctite 242 and torque to 160-inch pounds.

be fastened securely in place before using the wheelchair. Use Loctite 242 and torque to 160inch pounds.


B. FWD MODELS - Reinstall the mounting screws that secure the battery box retainer bar onto battery box sub frame. Use Loctite 242 and torque to 160inch pounds.

A. RWD AND MWD MODELS -Reinstall the mounting screw that secures the retainer clip and shock

(or rubber element) to the base frame. Use Loctite

242 and torque to 160-inch pounds.

53

6. Reinstall the both battery boxes. Refer to INSTALLING/

REMOVING GROUP 24 BATTERY BOXES in PRO-


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PROCEDURE 12

RWD AND MWD MODELS

Base Frame

Angled End

(Facing Upward)

Battery Box

Sub-frame

Shock

Assembly

Mounting

Screws

WHEELS/MOTORS

Retainer

Clip

Spacer

Top of Shock

Assembly

Retainer

Bar

FWD MODELS

Retainer Bar

Retainer

Clip

Spacer

Washers

ASSEMBLED VIEW

Spacer

Locknuts

Mounting Screws

Battery Box

Sub-Frame

FIGURE 1 - REPLACING BATTERY BOX RETAINER BAR/RETAINER CLIP - GROUP 24 BATTERY BASE FRAMES

54

WHEELS/ MOTORS PROCEDURE 12


Replacing Pneumatic Tires/Tubes - Drive Wheels/

Casters

Removing/Installing Drive Wheels

Removing/Installing Drive Wheel Hub

Installing Wheel Lock Bracket onto Wheelchair

Removing/Installing Casters

Replacing Forks

Motor Replacement

2. Remove the four (4) beveled hex nuts that secure the drive wheel assembly to the wheel hub assembly.

3. Remove existing drive wheel assembly from wheel hub.

Installing

1. Reinstall new/existing drive wheel assembly to the wheel hub assembly and torque the four (4) beveled hex nuts to 160-inch pounds.

2. Repeat procedure for opposite side of wheelchair, if necessary.

3. Reinstall the battery box(es). Refer to INSTALLING/


STALLING/REMOVING GROUP 22 BATTERY

BOXES in PROCEDURE 9 of this manual.

WARNING

After ANY adjustments, repair or service and BEFORE use, make sure all attaching hardware is tightened securely - otherwise injury or damage may result.

CAUTION

As with any vehicle, the wheels and tires should be checked periodically for cracks and wear and should be replaced.

REPLACING PNEUMATIC TIRES/

TUBES - DRIVE WHEELS/CASTERS

WARNING

DO NOT use your wheelchair unless it has the proper tire pressure (p.s.i.). DO NOT overinflate the tires. Failure to follow these suggestions may cause the tire to explode and cause bodily harm.

If tires are pneumatic, replacement of tire or tube

MUST be performed by an authorized Invacare dealer or qualified technician.

NOTE: If drive wheels or casters are pneumatic, under-inflation causes excessive wear which results in poor performance of the tires.

*Locknut

*NOTE: It is not required to remove the locknut and washer to remove the drive wheel.

GEARLESS/BRUSHLESS MOTOR

Drive Wheel

Assembly

REMOVING/INSTALLING DRIVE

WHEELS (FIGURE 1)

CONVENTIONAL MOTOR WITH GEARBOX

Gearbox Drive Shaft

Drive Wheel Assembly

Keystock

Four (4)

Beveled

Hex Nuts

*Washer

Wheel Hub

Assembly

CAUTION

Perform the following procedure in a designated work area to prevent damage to flooring (carpeting, tile, etc.).

Removing



STALLING/REMOVING GROUP 2 2 BATTERY


Wheel Hub

Assembly

Four (4) Beveled Hex Nuts

FIGURE 1 - REMOVING/INSTALLING DRIVE WHEELS

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55

PROCEDURE 12 WHEELS/MOTORS

L

S

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REMOVING/INSTALLING DRIVE

WHEEL HUB (FIGURE 1)

NOTE: This procedure can only be performed on second generation storm wheelchairs with the conventional motor/gearbox assembly. On second generation storm wheelchairs with the gearless/brushless motor, the drive wheel hub CANNOT be removed.

Return motor to manufacturer for service.

Removing

1. Remove the drive wheel from the wheelchair. Refer to

REMOVING/INSTALLING DRIVE WHEELS in this procedure of the manual.

2. Remove the locknut, washer, keystock and existing drive wheel hub from the drive shaft of the gearbox.

INSTALLING WHEEL LOCK BRACKET

ONTO WHEELCHAIR (FIGURE 2)

NOTE: This procedure only pertains to second generation storm wheelchairs with the conventional motor and gearbox. On second generation storm wheelchairs with the gearless/brushless motor, the wheel lock bracket is not required.

1. Remove the two (2) mounting screws closest to the large wheel that secure the gearbox to the suspension arm.

2. Line up mounting holes in the wheel lock mounting bracket with the gearbox mounting holes in the suspension arm.

3. Apply Loctite 242 to the two (2) mounting screws.

4. Reinstall the two (2) mounting screws into the mounting holes of the wheel lock mounting bracket and gear box and torque to 75-inch pounds.

5. Repeat STEPS 1-4 for opposite wheel lock bracket.

6. Adjust the wheel locks. Refer to ADJUSTING WHEEL

LOCKS in PROCEDURE 9 of the owners manual,

1081227.

Installing

1. Position the keystock on the gearbox drive shaft.

CAUTION

DO NOT apply more than a one (1)-inch (in length) thin film of anti-seize compound to the drive shaft.

Applying more than one (1)-inch (in length) can cause the anti-seize compound to leak resulting in damage to flooring (carpet, tile, etc.).

2. Apply a thin film of anti-seize compound one (1) inch in length to the end of the drive shaft.

3. Reinstall drive wheel hub onto the gearbox drive shaft.

NOTE: While installing the drive wheel hub onto the drive shaft, spin the drive wheel hub to evenly distribute the antiseize compound over the entire drive shaft.

4. Reinstall the washer and locknut and torque locknut to

45 foot pounds (540-inch pounds).

5. Reinstall the drive wheel assembly to the wheelchair.

Refer to REMOVING/INSTALLING DRIVE WHEELS in this procedure of the manual.

6. Repeat procedure for the opposite side of the wheelchair, if necessary.

Mounting

Screws

Gearbox

Wheel Lock

Mounting

Bracket

Suspension

Arm

FIGURE 2 - INSTALLING WHEEL LOCK BRACKET

ONTO WHEELCHAIR

56

WHEELS/MOTORS PROCEDURE 12

REMOVING/INSTALLING CASTERS

(FIGURE 3)

WARNING

DO NOT use your power wheelchair unless it has the proper tire pressure (p.s.i.). DO NOT over-inflate the tires. Failure to follow these suggestions may cause the tire to explode and cause bodily harm.

The recommended tire pressure is listed on the side wall of the tire.

Periodically, the tires will need to be replaced due to wear or puncture.

Removing Casters

1. Remove the mounting screw, spacers and locknut that secure the existing caster to the fork.

2. Remove the existing caster from the fork.

NOTE: Check bearing assemblies. Replace if necessary.

6. Ensure new fork slides completely into caster headtube.

7. Install nylon washer and secure with locknut.

WARNING

Improper positioning of the washer will prohibit the free movement of the forks.

8. Install the caster onto the new fork. Refer to REMOV-

ING/INSTALLING CASTERS in this procedure of the manual.

9. Adjust the forks. Refer to ADJUSTING FORKS in

PROCEDURE 9 of the owners manual, 1081227

Dust Cover

Locknut

Nylon Washer

Installing Casters

1. Position the new/existing caster into the fork.

2. Reinstall the mounting screw, spacers and locknut that secure the caster to the fork.

3. Torque locknut to 10-foot pounds (120-inch) pounds.

4. Loosen the locknut 1/8 of a turn.

5. Move the caster side to side.

NOTE: If the caster moves side to side, tighten the locknut slightly. Repeat STEP 4 until there is no side to side movement of the caster.

6-INCH

Locknut

8-INCH

Mounting

Screw


MOTOR (CONVENTIONAL MOTOR

WITH GEARBOX) (FIGURE 5)

Removing

Fork

Caster Headtube

FIGURE 4 - REPLACING FORKS

Locknut

RWD AND MWD MODELS.

1. Disconnect the right and/or left motor connector from the controller.

2. Remove the two (2) allen screws and washers that secure the motor to the gearbox.

Mounting

Screw Spacers

CAUTION

DO NOT damage the motor/gearbox coupling.

Spacers

3. Carefully pull the motor away from the gearbox.

FIGURE 3 - REMOVING/INSTALLING CASTERS

REPLACING FORKS (FIGURE 4)

1. Remove the caster from the existing fork. Refer to

REMOVING/INSTALLING CASTERS in this procedure of the manual.

2. Remove the head tube cap.

3. Remove the locknut and nylon washer.

4. Drop the existing fork out of the caster head tube.

5. Slide the new fork into the caster head tube.

ARROW FWD MODEL.


STALLING SIDE SHROUD ASSEMBLY in PROCE-


2. Remove the counterweight. Refer to REMOVING/

INSTALLING COUNTERWEIGHT in PROCEDURE

17 of this manual.

57




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PROCEDURE 12 WHEELS/MOTORS

4. Remove the two (2) mounting screws, spacers, and washers that secure the MKIV controller to the base frame. Set MKIV controller onto ground/floor.

NOTE: STEPS 5, 6, and 7 are necessary to obtain easier access to the motor/controller connection.

5. Remove the mounting screw and spacer that secure the top of the shock to the base frame.

6. Loosen, DO NOT remove, the mounting screw that secures the bottom of the shock to the suspension arm.

7. Rotate top of shock toward the inside of the wheelchair.

]

8. Disconnect the motor connector from controller.

9. Remove the two (2) allen screws and washers that secure the motor to the gearbox.

8. Install the battery box(es). Refer to INSTALLING/RE-



9. Install the counterweight. Refer to REMOVING/IN-

STALLING THE COUNTERWEIGHT in PROCE-


10. Install the front shroud. Refer to REMOVING/INSTALL-

ING FRONT SHROUD in PROCEDURE 17 of this manual.

ARROW FWD MODEL ONLY

Base

Frame

Mounting Screw

(REMOVE)

Locknut

Spacer

CAUTION

DO NOT damage the motor/gearbox coupling.

MKIV

Controller

10. Carefully pull the motor away from the gearbox.

Washer

Shock

Installing


A. For RWD and MWD perform STEPS 2-3.

B. For FWD ONLY perform STEPS 2-10.

2. Perform the following:

A. Inspect the coupling for wear and damage. If damage is evident, replace coupling.

B. Install coupling onto gearbox input shaft inserting coupling drive plate onto slot on shaft.

C. Carefully align motor and coupling and place motor against gearbox.

D. With motor against gearbox, turn gearbox drive shaft until the coupler seats into gearbox.

NOTE: When properly aligned, motor will be seated into gearbox.

E. Install two (2) allen screws. Use Loctite 242, tighten allen screws evenly and then torque to 75-inch lbs.

3. Reconnect right and/or left motor connector to controller.

4. Rotate the top of the shock of the shock toward the inside of the wheelchair.

5. Install the mounting screw and spacer that secure the top of the shock to the base frame. Torque to 156 - inch pounds.

6. Tighten the mounting screw that secures the bottom of the shock to the suspension arm. Torque to 156 - inch pounds.

7. Install the two mounting screws that secure the MKIV controller to the base frame. Torque to 156 - inch pounds.

58

Suspension

Arm

Mounting Screw

(Loosen, DO NOT

REMOVE)

Motor Connector

Motor

FIGURE 5 - REMOVING/INSTALLING THE MOTOR -

CONVENTIONAL MOTOR/GEARBOX FOR RWD,

MWD AND FWD MODELS

Mounting

Screws

RWD, MWD, AND ARROW FWD MODELS

Allen

Screw

Washer

Coupling

Slots*

Motor

Connector

Gearbox

*NOTE: The following slot locations must line up for proper installation: Slots on coupling of motor, the slots on the coupling and the slots on the gearbox.

WHEELS/MOTORS PROCEDURE 12


MOTOR (GEARLESS/BRUSHLESS

MOTOR) (FIGURE 6)

Removing



STALLING/REMOVING GROUP 2 2 BATTERY


2. Unthread the mounting screws that secure the wiring harness connector to the motor (DETAIL A).

3. Unplug the wiring harness connector from the motor.

4. If necessary, remove the group 22 battery box tray.

Refer to REMOVING/INSTALLING GROUP 22 BAT-

TERY BOX TRAY in PROCEDURE 16 of this manual.



6. Note the mounting position of the motor on the suspension arm before removing the motor.

7. Loosen adjustment screw that secures the motor lock lever in place on the brake release shaft.

NOTE: Alignment pin is located inside of bushing guide on the suspension arm.

8. Remove the mounting screw and washer that secure the alignment pin in place.

9. Slide the alignment pin back out of the end of the motor lock lever.

10. Remove the four (4) mounting screws and washers that secure the motor to the suspension arm.

11. Remove motor with motor lock lever from suspension arm.

12. If replacing motor, remove the motor lock lever from the brake release shaft of the existing motor.

3. Secure motor to the suspension arm with existing four (4) mounting screws. Torque to 13 foot/pounds.

4. Slide the motor lock lever along brake release shaft until the end is flush with the bushing guide.

5. Slide alignment pin, located inside of bushing guide, into the end of the motor lock lever and secure in place with existing mounting screw and washer. Securely tighten.

6. Secure motor lock lever in place on the brake release shaft with existing mounting screw.

7. Install the drive wheel from the wheelchair. Refer to


8. If necessary, install the group 22 battery box tray. Refer to REMOVING/INSTALLING GROUP 22 BAT-

TERY BOX TRAY in PROCEDURE 16 of this manual.

9. Plug the wiring harness connector into the motor.

10. Secure the wiring harness connector to the motor with the existing two (2) mounting screws.



STALLING/REMOVING GROUP 22 BATTERY


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Installing

NOTE: Do not tighten adjustment screw of motor lock lever until motor is secured in place on the suspension arm.

1. If necessary, install motor lock lever onto new brake release shaft of motor.

2. Position the new/existing motor with motor lock lever onto the suspension arm in the mounting position noted from STEP 4 of REMOVING THE GEARLESS/

BRUSHLESS MOTOR in this procedure of the manual.

59

PROCEDURE 12

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Motor

Suspension

Arm

DETAIL “A”

Brake Release Shaft

Washer

Mounting Screws

WHEELS/MOTORS

Guide

Bushing

*Alignment Pin

Washer

Mounting Screw

Washer

Mounting

Screw

Mounting

Screws

Motor Lock

Lever

Adjustment

Screw

Motor

Mounting

Screws

Wiring Harness

Connector

*NOTE: Alignment pin exploded away suspension arm for clarification purposes only.

FIGURE 2 - REMOVING/INSTALLING MOTOR - GEARLESS/BRUSHLESS

60

ELECTRONICS PROCEDURE 13


Repositioning MKIV Joystick - Van Seat Models

Removing/Installing MKIV Controller

WARNING


REPOSITIONING MKIV JOYSTICK -

VAN SEAT MODELS (FIGURE 1)

1. Turn the lever on the adjustment lock to release the adjustment lock from joystick mounting tube.

2. Remove the joystick mounting tube from wheelchair.

3. Remove the three (3) hex bolts, spacers and locknuts that secure joystick mounting bracket to armrest plate.

4. Remove the phillips screws that secures the front of the armrest pad to the armrest plate.

5. Remove the phillips screw that secures the rear of the armrest pad and armrest insert to the armrest plate.

6. Remove the armrest pad from the armrest plate.

7. Remove the lug bolt, washers and locknut that secure the existing armrest plate to the armrest weldment.

8. Repeat STEPS 4-7 for opposite side of the wheelchair.

9. Position armrest plate with joystick mounting holes on desired side of armrest weldment and secure with lug bolt, washers and locknut. Refer to FIGURE 1 for correct hardware orientation.

10. Position armrest plate without joystick mounting holes on opposite side of the armrest weldment and secure with lug bolt, washers and locknut. Refer to FIGURE

1 for correct hardware orientation.

Armrest Insert

Armrest Plate Lug Bolt (STEPS 7, 9)

Locknuts

(STEPS 3,16)

Phillips Screw

(STEPS 5, 13)

Locknut

(STEPS 7, 9)

Washer

(STEPS 7, 9)

Armrest

Pad

Hex Bolts

(STEPS 3, 16)

Joystick Mounting

Bracket (STEPS 3, 16)

Phillips

Screws

(STEPS 4,

14)

Washers

(STEPS 7, 9)

Armrest

Weldment Spacers

(STEPS 3, 16)

FIGURE 1 - REPOSITIONING MKIV JOYSTICK -

VAN SEAT MODELS

61

11. Position the armrest pad on the armrest plate.

12. Line up the mounting holes in the armrest insert, armrest plate and armrest pad.

13. Reinstall rear phillips screw through the armrest insert, armrest plate and armrest pad and tighten securely.

14. Reinstall the front phillips screw into the armrest plate and new armrest pad and tighten securely.

15. Repeat STEPS 11-14 for opposite side of wheelchair.

16. Install the three (3) hex bolts, spacers and locknuts that secure the joystick mounting bracket to the armrest plate.

17. Slide the joystick mounting tube through the joystick mounting bracket to the desired position.

18. Secure the adjustment lock to the joystick mounting tube by turning the lever on the adjustment lock.

REMOVING/INSTALLING MKIV

CONTROLLER (FIGURE 2)

RWD and MWD Models

REMOVING.

1. Remove the shroud that covers the MKIV controller.

2. Disconnect the left/right motor leads and battery leads.

3. Remove the two (2) hex bolts that secure the existing

MKIV controller to the wheelchair.

4. Remove existing MKIV controller from the wheelchair.

5. Remove the three (3) mounting screws that secure the mounting plate to the MKIV controller.

INSTALLING.

1. Install the three (3) mounting screws into the mounting plate and secure to the MKIV controller.

2. Secure the new/existing MKIV controller to the wheelchair with two (2) hex bolts.

3. Connect the left/right motor leads and battery leads

4. Install shroud over the MKIV controller.

Mounting

Plate

Base Frame

Mounting Screws

Hex

Bolts

MKIV Controller

NOTE: Controller for gearless/brushless motor removes in the same manner.

FIGURE 2 - REMOVING/INSTALLING MKIV

CONTROLLER

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PROCEDURE 13 ELECTRONICS

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Arrow Fwd Model

REMOVING.


STALLING FRONT SHROUD in PROCEDURE 17 of this manual.

2. Remove the counterweight. Refer to REMOVING/IN-

STALLING COUNTERWEIGHT in PROCEDURE 17 of this manual.




4. Disconnect the joystick cable from the top of the controller.

5. Disconnect the battery wiring harness and controller connection.

6. Remove the two (2) mounting screws, spacers, washers, and locknuts that secure the MKIV controller to the base frame. Set MKIV controller onto ground/floor.

7. Remove the mounting screw and spacer that secure the top of right shock to the base frame.

8. Loosen, DO NOT remove, the mounting screw that secure the bottom of the right shock to the suspension arm.

9. Rotate top of right shock toward inside of the wheelchair.

10. Disconnect right hand motor/controller connection.

11. Rotate top of right shock back into position.

12. Loosely install mounting screw through top of shock and into base frame. DO NOT tighten at this point.

13. To disconnect left hand motor/controller connection, perform STEPS 5-8 for opposite side of controller.

Locknut

INSTALLING.

1. Connect left hand motor/controller connection of NEW controller.

2. Rotate top of left shock into position.

3. Secure top of left shock to base frame with washer and mounting screw. Torque to 360 - inch pounds.

4. Remove mounting screw and washer that secure the top of the right shock to the base frame.

5. Rotate shock toward inside of wheelchair.

6. Connect right hand motor/controller connection.

7. Rotate shock back into position.

8. Secure top of right shock to base frame with washer and mounting screw. Torque to 156 - inch pounds.

9. Torque the bottom mounting screw of each shock to 160

- inch pounds.

10. Secure the MKIV controller to the base frame with the two (2) existing mounting screws, spacers, washers, and locknuts.

11. Connect the joystick cable to the top of the controller.

12. Connect the battery wiring harness and controller connection.

13. Install the battery box(es). Refer to INSTALLING/REMOV-

ING GROUP 24 BATTERY BOXES in PROCEDURE

9 of this manual.

14. Install the counterweight. Refer to REMOVING/INSTALL-

ING COUNTERWEIGHT in PROCEDURE 17 of this manual.

15. Install the front shroud. Refer to REMOVING/IN-

STALLING FRONT SHROUD in PROCEDURE 17 of this manual.

Top Mounting

Screw and

Washer

Base Frame

Spacer

Washer

Mounting

Screw

Shock

Bottom Mounting

Screw

Controller

FIGURE 2 - REMOVING/INSTALLING MKIV CONTROLLER - ARROW FWD MODEL

62

RECLINER PROCEDURE 14


Positioning Limit Switch

Adjusting Limit Switch

Replacing Recliner Cable Assemblies

Replacing/Adjusting Gas Cylinders

Changing Back Height

Changing Seat Depth

Changing Seat Width

Installing/Replacing Adjustable 16 to 19-inch Deep

Recliner Seat Frame onto Arrow or X Base

9. Secure limit switch sensor to the seat frame with the two (2) mounting screws and washers.

10. Secure the wire retainer onto the INSIDE of the seat frame with the mounting screw.

11. Tie wrap the limit switch wire to the seat frame.

12. Adjust the limit switch. Refer to ADJUSTING LIMIT

SWITCH in this procedure of the manual.

Mounting Screws (DO

NOT Over Tighten)

Limit Switch Sensor

Washers

WARNING


Tie

Wraps

Mounting

Screws

POSITIONING LIMIT SWITCH

(FIGURE 1)

NOTE: The battery charger connector, as well as, the limit switch are factory set on the RIGHT side of the wheelchair.

However, they can be positioned on either side for user convenience. The limit switch MUST BE positioned on the same side as the battery charger connector.

1. Cut the two (2) tie wraps that secure the limit switch wire to the seat frame.

2. Remove the two (2) mounting screws and washers that secure the actuator to the gas cylinder pivot block.

3. Position actuator on opposite gas cylinder pivot block.

Seat

Frame

Limit

Switch

Sensor

Gas Cylinder

Pivot Block

Washers

Wire

Retainer

Actuator

Actuator

Mounting Screws

(DO NOT

Overtighten)

FIGURE 1 - POSITIONING LIMIT SWITCH

ADJUSTING LIMIT SWITCH

(FIGURE 2)

CAUTION

DO NOT over tighten the mounting screws that secure the actuator to the pivot block. Damage to actuator will occur.

4. Secure the actuator to the pivot block with the two (2) mounting screws and washers. DO NOT overtighten.

5. Remove the mounting screw that secures the wire retainer to the inside of the seat frame.

6. Remove the two (2) mounting screws and washers that secure the limit switch sensor to the seat frame.

7. Turn limit switch sensor over so opposite side is facing up and the wire is on the INSIDE of the seat frame.

8. Position the limit switch sensor onto the opposite side of the seat frame.

CAUTION

DO NOT over tighten the mounting screws that secure the limit switch sensor to the seat frame.

Damage to the limit switch sensor will occur.

WARNING

NEVER operate the wheelchair while in any recline position over 105 o


FRAME. If the limit switch does not stop the wheelchair from operating in a recline position greater than 105 o

RELATIVE TO THE SEAT FRAME, do not operate the wheelchair. Adjust the limit switch

BEFORE using the wheelchair, otherwise injury or damage can occur.

63

1. Recline the back of the wheelchair until the gas cylinder rod measures 3-21/32 of an inch.

2. Turn the power of the joystick to the ON position.

NOTE: ALL segments of the bar graph on the joystick should start to flash on and off and the wheelchair should not operate.

3. IF the wheelchair operates, proceed to the following steps to adjust the actuator on the gas cylinder pivot block:

A. Loosen, but do not remove, the two (2) mounting screws and washers that secure the actuator to the gas cylinder pivot block.

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PROCEDURE 14 RECLINER

B. Slide actuator UP (towards top of the wheelchair).

CAUTION

DO NOT over tighten the mounting screws that secure the actuator to the pivot block. Damage to the actuator will occur.

C. Only tighten the two (2) mounting screws and washers that secure the actuator to the gas cylinder pivot block until the actuator does not move.

D. Repeat STEPS 1 and 2 until the wheelchair does not operate when the gas cylinder rod is 3-21/32inch long.

POSITION OVER

105

O

RELATIVE TO

THE SEAT FRAME Gas Cylinder

Rod Measures

3-21/32-inches

6. Remove the operator of the existing recliner cable assembly from the pivot block.

7. Make sure the threads of the gas cylinder rod are flush with the inside of the pivot block.

8. With the operator of the NEW recliner cable assembly on the inside of the recliner seat frame, line up the mounting hole in the operator of the new recliner cable assembly with the gas cylinder rod.

CAUTION

DO NOT force the gas cylinder rod into the operator of the recliner cable assembly.

DO NOT cross thread the operator of the recliner cable assembly with the gas cylinder.

If slack in the recliner cable or movement in the operator of the cable assembly can not be eliminated, DO NOT use the recliner cable assembly.

Mounting Screws and Washers

(DO NOT Over-Tighten)

Gas Cylinder

Pivot Block

Actuator

FIGURE 2 - ADJUSTING LIMIT SWITCH

REPLACING RECLINER CABLE

ASSEMBLIES (FIGURE 3)

9. Screw the NEW gas cylinder into the operator of the cable assembly until the jam nut sits on the pivot block, there is no slack in the recliner cable and there is no movement in the operator of the recliner cable assembly.

Pan Screw

Mounting Bracket

Handle

Mounting Screw

Washer

Nylon

Washers

Locknut

Gas Cylinder

NOTE: There are three (3) different cable lengths depending on back height:

Tie

Wraps

Cable

Operator

Back Cane

CABLE LENGTH

Short

Medium

Long

BACK HEIGHT

18-1/2 and 20-inches

22 and 24-inches

26-inches

WARNING

Replace ONE (1) recliner cable assembly at a time to avoid injury.

1. Cut the tie wraps that secure the existing recliner cable assembly to the back cane.

2. Remove the pan screw that secures the handle of the existing recliner cable assembly to the back cane.

3. Loosen the jam nut on the gas cylinder rod.

4. Remove the mounting screw, washer, nylon washers and locknut that secure the TOP of the gas cylinder to the mounting bracket on the back cane.

5. Unscrew the gas cylinder from the operator of the existing recliner cable assembly but do not remove the gas cylinder from the pivot block.

64

Gas Cylinder

Rod

Jam

Nut

Pivot

Block

NO Movement in Operator of the Recliner Cable

Assembly

No Slack in Cable

Cable

Snapped into Slot

Handle

Cable Fitting

Seated Properly

FIGURE 3 - REPLACING RECLINER CABLE ASSEMBLIES


10. Visually inspect the handle to make sure that the cable is snapped completely into slot in handle and cable fitting is seat properly in the handle.

11. Reinstall the mounting screw through the mounting bracket of the back cane, nylon washer, gas cylinder, nylon washer, mounting bracket and washer and securely tighten with the existing locknut. Torque to 75inch pounds.

12. Line up the mounting hole in the handle of the recliner cable assembly with the mounting hole in the back cane.

13. Insert the pan screw through the handle of the recliner cable assembly and the back cane and torque to 9-inch pounds.

14. Tie wrap the recliner cable assembly to the recliner back cane.

15. Adjust the gas cylinder. Refer to ADJUSTING GAS

CYLINDERS in this procedure of the manual.

REPLACING/ADJUSTING GAS

CYLINDERS (FIGURE 4)

WARNING

Replace ONE (1) gas cylinder at a time to avoid injury.

Both gas cylinders MUST be operational and adjusted properly BEFORE using the recliner. DO NOT operate the recliner if only one (1) of the gas cylinders is operational or adjusted properly.

Replacing Gas Cylinder

1. Remove the mounting screw, washer, nylon washers and locknut that secure the TOP of the gas cylinder to mounting bracket on back cane.

2. Loosen the jam nut on existing gas cylinder rod.

3. Unscrew the existing gas cylinder from the operator of the recliner cable assembly and the pivot block and remove the existing gas cylinder from the wheelchair.

4. Screw cylinder rod of the NEW gas cylinder into the pivot block until the threads of the cylinder rod are flush with inside of pivot block (FIGURE 4).

5. With the operator of the recliner cable assembly on the inside of the recliner seat frame, line up the mounting hole in the operator of the recliner cable assembly with the new gas cylinder rod.

CAUTION

DO NOT force the gas cylinder rod into the operator of the recliner cable assembly.

DO NOT cross thread the operator of the recliner cable assembly with the gas cylinder.

If slack in the recliner cable or movement in the operator of the cable assembly can not be eliminated, DO NOT use the recliner cable assembly.

6. Screw the NEW gas cylinder into the operator of the cable assembly until the jam nut sits on the pivot block, there is no slack in recliner cable and there is no movement in the operator of the recliner cable assembly.

7. Visually inspect the handle to make sure that the cable is snapped completely into slot in handle and cable fitting is seat properly in the handle.

8. Press the operator of the recliner cable assembly to extend the NEW gas cylinder.

9. Line up the mounting holes of the NEW gas cylinder and the bracket of the back cane.

10. Reinstall the mounting screw through the mounting bracket of the back cane, nylon washer, NEW gas cylinder, nylon washer, mounting bracket and washer and securely tighten with the existing locknut. Torque to 75-inch pounds.

11. Adjust the NEW gas cylinders. Refer to ADJUSTING

GAS CYLINDERS in this procedure of the manual.

Nylon Washer

Handle

Mounting Bracket

Gas Cylinder

Rod

Jam Nut

Mounting

Screw

Washer

Locknut

No Slack in Cable

Gas

Cylinder

Gas Cylinder

Rod Threads

Cable

Snapped into Slot

Pivot Block

NO Movement in Operator of the Recliner Cable

Assembly

Cable Fitting

Seated Properly

Handle

FIGURE 4 - REPLACING/ADJUSTING GAS CYLINDERS

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Adjusting Gas Cylinder

1. To adjust the LEFT gas cylinder: Squeeze the handle of the RIGHT recliner cable assembly and try to recline the back. The back should not recline.

2. If the LEFT side of the back releases without squeezing the handle of the LEFT recliner cable assembly, perform the following steps:

A. Finger tighten the jam nut on the rod of the gas cylinder until it bottoms out on the rod of the cylinder (FIGURE 4).

B. Turn the jam nut on the LEFT gas cylinder

COUNTERCLOCKWISE approximately onehalf (1/2) revolution.

NOTE: The gas cylinder rod will turn.

C. Repeat STEP 1.

D. Repeat STEP B until the LEFT side of the back

DOES NOT recline.

3. To adjust the RIGHT gas cylinder: Repeat STEPS

1 and 2 for the LEFT handle of the cable assembly.

CAUTION

Damage to the gas cylinder rod WILL occur if the following steps are NOT followed when the jam nut is torqued against the pivot block.

4. Using NO LARGER than 1/4-inch wide, fine toothed pliers, wrap masking tape around the teeth of the pliers two (2) or (3) revolutions.

5. Using NO excessive force, hold the gas cylinder rod just above the jam nut.

6. While holding the gas cylinder rod and using a 17mm wrench, turn the jam nut CLOCKWISE and torque the RIGHT and LEFT jam nuts against the RIGHT and LEFT pivot blocks to 156-inch pounds.

6. Turn the spreader bar on the existing back canes

CLOCKWISE (toward back upholstery) and remove the spreader bar from the existing back canes.

7. Loosely install the spreader bar onto the NEW back cane handles by rotating the spreader bar COUN-

TERCLOCKWISE (away from the back canes).

NOTE: If the spreader bar does not thread onto the back canes, do not force. Turn the spreader bar around and repeat STEP 7.

8. Line up two (2) bottom mounting holes of back canes with the two (2) mounting holes in the seat frame.

WARNING

The back canes MUST be fastened securely to the seat frame BEFORE using the wheelchair. Torque mounting screws to

156-inch pounds.

9. Reinstall the mounting screw, washer and locknut through the back cane and seat frame mounting holes and torque to 156-inch pounds.

10. Reinstall the mounting screw through the mounting bracket of the back cane, nylon washer, mounting hole in the TOP of the gas cylinder, nylon washer, mounting bracket and washer and securely tighten with the existing locknut. Torque to 75-inch pounds.

11. Reinstall the recliner cable assemblies onto the back canes. Refer to REPLACING RECLINER CABLES in this procedure of the manual.

Headrest

Extension

Tube

Back Cane

CHANGING BACK HEIGHT

(FIGURE 5)

1. Press the push pins on the headrest extension tubes in and remove headrest extension from back canes.

2. Remove the recliner cables from the back canes.

Refer to REPLACING RECLINER CABLE ASSEM-

BLIES in this procedure of the manual.

3. Remove the mounting screws, washers and locknuts that secure the TOP of the gas cylinders to the mounting bracket on the back canes.

4. Remove the mounting screws, washers and locknuts that secure the back canes to the seat frame.

5. Remove the existing recliner back assembly from the wheelchair.

Spreader

Bar

Push

Pin

Mounting

Bracket

Mounting

Screw

Washers

Locknut

Mounting

Screw

Seat Frame

66

NOTE: Upholstery not shown for clarity.

FIGURE 5 - CHANGING BACK HEIGHT


NOTE: There are three (3) different cable lengths depending on back height:

BACK HEIGHT (in inches) 18-1/2, 20 22, 24 26

CABLE LENGTH Short Medium Long

NOTE: New recliner cables will be needed if back height is changed to a height not within the length of the original cable.

12. Install the NEW back upholstery onto the back canes.

13. Install the ten (10) or twelve (12) mounting screws

(depending on back height) that secure the back upholstery to the recliner back canes.

14. Reinstall headrest extension onto recliner back canes.

15. Adjust the tautness of the back and headrest upholstery. Refer to ADJUSTING BACK OR HEADREST

UPHOLSTERY in this procedure of the manual.

Seat Pan Removal/Replacement Procedures:

1. Remove the seat cushion from the wheelchair.

2. Remove the six (6) mounting screws and locknuts that secure seat pan, seat positioning strap to the seat frame.

3. Install new 1-inch deeper/shorter seat pan onto seat frame.

4. Reinstall the mounting screws, spacers and locknuts and torque to 75-inch pounds.

5. Remove the protective strips on the seat pan and reinstall the seat cushion onto the seat pan.

NOTE: Clean upholstery with a warm damp cloth and mild detergent to remove superficial soil.

CHANGING SEAT DEPTH (FIGURE 6)

NOTE: 16-inch, 17-inch, 18-inch or 19-inch seat depths CAN

NOT be increased to 20-inches or deeper. If needing to increase to a seat depth of 20-inches or deeper, the base frame

MUST be converted from a STANDARD base frame to a

LONG base frame as well.

NOTE: 20-inch, 21-inch or 22-inch seat depths CAN NOT be decreased to 19-inches or less. If needing to decrease to a seat depth of 19-inches or less, the base frame MUST be converted from a LONG base frame to a STANDARD base frame.

To adjust seat depth of wheelchair, use following guidelines:

If the current seat depth is an ODD number, i.e., 17-inches,

19-inches or 21-inches, the seat depth CANNOT be IN-

CREASED without changing the seat frame. Refer to IN-

STALLING/REPLACING ADJUSTABLE 16 TO 19-INCH

DEEP RECLINER SEAT FRAME ONTO ARROW OR X

BASE FRAMES in this procedure of the manual.

If the current seat depth is an ODD number, i.e., 17-inches,

19-inches or 21-inches, the seat depth can be DECREASED by 1-inch by installing a 1-inch shorter seat pan. Refer to the following procedures:

If the current seat depth is an EVEN number, i.e., *16-inches,

18-inches, 20-inches or 22-inches, the seat depth CANNOT be DECREASED without changing the seat frame. Refer to

INSTALLING/REPLACING ADJUSTABLE 16 TO 19-INCH

DEEP RECLINER SEAT FRAME ONTO ARROW OR X

BASE FRAME in this procedure of the manual.

*NOTE: 16-inch seat depth is the smallest seat depth available on recliner seat frames.

If the current seat depth is an EVEN number, i.e., 16-inches,

18-inches, 20-inches or *22-inches, the seat depth can be

INCREASED by 1-inch by installing a 1-inch deeper seat pan. Refer to the following procedures:

*NOTE: 22-inch seat depth is the deepest seat depth available on recliner seat frames.

WARNING

Laundering or moisture will reduce the flame retardation of the upholstery.

Hex Screws

Seat

Positioning

Strap

CHANGING SEAT WIDTH

Seat Pan

Seat

Frame

Locknuts

FIGURE 6 - CHANGING SEAT DEPTH

67

To change seat width, the seat frame must be changed to the desired width. Refer to INSTALLING/REPLACING AD-

JUSTABLE 16 TO 19-INCH DEEP RECLINER SEAT

FRAME ONTO ARROW OR X BASE FRAME in this procedure of the manual.

NOTE: If changing the seat width of the wheelchair, the back and headrest upholstery, seat pan and cushion also need to be changed.

NOTE: If changing the seat width of the wheelchair, the back canes, spreader bar and headrest pillow may also need to be changed. Refer to the following charts:

BACK CANES AND SPREADER BAR SEAT WIDTH

RANGES

14-17-INCHES OR 18-24-INCHES

HEADREST PILLOWS SEAT WIDTH RANGES (IN

INCHES)

14-15, 16-18, 19-20 OR 21-24

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If the seat width required is within the range of the original back canes, spreader bar and headrest pillow, the original components can still be used.

If the seat width required is NOT within the range of the original back canes, spreader bar and headrest pillow, the original components can not be used.

10. Perform instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING SEAT FRAME


CAPTAINS VAN SEAT) in PROCEDURE 6 of this manual:

EQUIPMENT OPTION

INSTALLING/REPLACING

ADJUSTABLE 16 TO 19-INCH DEEP

RECLINER SEAT FRAME ONTO

ARROW OR X BASE FRAME

(FIGURE 7)

1. Perform instructions outlined in PREPARATIONS FOR

REMOVING/INSTALLING SEAT FRAME (STANDARD

FRAME, ADJUSTABLE FRAME, AND CAPTAINS VAN

SEAT) in PROCEDURE 6 of this manual:

2. Perform one (1) of the following in PROCEDURE 7 of this manual:


FRAME SUBASSEMBLY.



NENT REPLACEMENT.


REMOVING CAPTAINS VAN SEAT ASSEMBLY.

3. Remove seat pan on recliner.

4. Install new recliner seat assembly onto seat mount plates.

5. Secure recliner seat assembly to seat mount plates with the mounting screws, spacers and locknuts. Torque the mounting screws to 156-inch pounds.

NOTE: There are three (3) types of seat mount plates; low, medium, and high heights. The seat mount plate shown in this illustration represents the medium height. Refer to

MOUNTING PLATE - SEAT ANGLE ADJUSTMENT AND

INSTALLATION ORIENTATION in PROCEDURE 6 of this manual for illustrations of the low and high heights.

6. Position limit switch onto wheelchair. Refer to POSITION-

ING LIMIT SWITCH in this procedure of the manual.

7. Reinstall recliner seat pan with existing six (6) mounting screws.

8. Install the two (2) warnings labels onto the two (2) suspension arm assemblies. Refer to FIGURE 7 for correct label placement.

9. Install battery box(es). Refer to INSTALLING/REMOV-

ING BATTERY BOXES- GROUP 24 BATTERY

BASE FRAMES or INSTALLING/REMOVING BAT-

TERY BOX - GROUP 22 BATTERY BASE FRAMES in PROCEDURE 9 of this manual.

Recliner

Seat Assembly

Seat Mount

Plate

Inside of

Suspension Arm

Assembly

Mounting

Screws

Spacer

Base

Frame

Locknuts

Warning Label

68

FIGURE 7 - INSTALLING/REPLACING ADJUSTABLE 16

TO 19-INCH DEEP RECLINER SEAT FRAME ONTO

ARROW OR X BASE

MWD WHEELCHAIRS PROCEDURE 15


Removing/Installing Group 24 Battery Box Sub-Frame

Removing/Installing Group 22 Battery Box Tray

Converting Group 22 Batteries To Group 24 Batteries

Shock Replacement

Shock Spring Replacement

Replacing Stabilizer Fork Assembly

Replacing Stabilizer Wheels

Replacing Stabilizer Cylinder Springs

Adjusting Weight Distribution

Adjusting Stabilizers

Installing/Removing Gearbox

Replacing Suspension Arm

2. Reinstall the four (4) mounting screws that secure the shocks, retainer bar, spacers and retainer clips to the base frame. Refer to REPLACING BATTERY BOX

RETAINER/RETAINER CLIP - GROUP 24 BATTERY


Use Loctite 242 and torque mounting screws to 160inch pounds.


MOVING GROUP 24 BATTERY BOXES in PRO-

CEDURE 9 of this manual. Use Loctite 242 and torque mounting screws to 160-inch pounds.

Mounting

Screws

Wiring Harness w/Bracket

WARNING



FRONT OF

CHAIR

Locknuts

Sub-Frame

REAR OF CHAIR

REMOVING/INSTALLING GROUP 24

BATTERY BOX SUB-FRAME (FIGURE 1)

REAR OF

CHAIR

Battery Box Sub-frame

Removing

1. Remove the battery boxes. Refer to INSTALLING/RE-



2. Remove the two (2) mounting screws and locknuts that secure the wiring harness w/bracket and the rear of the existing sub-frame to the base frame. Refer to

REMOVING/INSTALLING WIRING HARNESS in


3. Remove the four (4) mounting screws that secure the shocks, retainer bar, spacers and retainer clips to the base frame. Refer to REPLACING BATTERY BOX



Battery Box

Retainer

Bar

Spacer

Retainer Clip

BOX SUB-FRAME

Mounting

Screws

FRONT OF CHAIR

FIGURE 1 - REMOVING/INSTALLING GROUP 24 BATTERY

REMOVING/INSTALLING GROUP

22 BATTERY BOX TRAY (FIGURE 2)

Removing

4. Remove the existing sub-frame assembly.

Installing

1. Remove battery box. Refer to INSTALLING/REMOV-

ING GROUP 22 BATTERY BOX in PROCEDURE 9 of this manual.

1. Install the two (2) mounting screws and locknuts that secure the wiring harness w/bracket and the back of the NEW sub-frame to the base frame. Refer to RE-

MOVING/INSTALLING THE WIRING HARNESS in

PROCEDURE 10 of this manual. Use Loctite 242 and torque mounting screws to 160-inch pounds.

2. Remove the two (2) mounting screws and locknuts that secure rear of battery box tray to the base frame.

3. Remove the two (2) front locknuts that secure the battery box tray to battery mount brackets.

69

4. Remove the battery box tray.

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PROCEDURE 15 MWD WHEELCHAIRS

Installing

1. Install battery box tray onto base frame.

2. Secure the front of the battery box tray to battery mount brackets with existing locknuts. Torque to

160-inch pounds.

3. Secure the rear of the battery box tray to the base frame with existing mounting screws and locknuts.


4. Reinstall the battery box. Refer to INSTALLING/REMOV-


3. Disconnect the right and left motor connectors from the controller connectors.

4. Remove the two (2) mounting screws that secure the charger cable to the mount bracket.

5. Remove the charger cable from the mount bracket.

5. Cut the tie-wrap that secures the wiring harness to the seat frame.


7. Remove the four (4) mounting screws that secure the battery mount brackets to the base frame and remove the battery mount brackets.

Tie Wrap

Front Locknuts

FRONT OF

CHAIR

Battery Mount

Bracket

Mounting

Screws

Charger Cable/

Bracket

Motor

Connector

Battery

Box Tray

Base

Frame

REAR OF

CHAIR

Rear Locknuts

Motor Connector

FIGURE 2 - REMOVING/INSTALLING GROUP 22

BATTERY BOX TRAY

Mounting

Screws

Spacer

Locknut


CONVERTING GROUP 22 BATTERY

BOX TRAY TO GROUP 24 BATTERY

BOX SUB FRAME

NOTE: The battery box tray and battery mount brackets will not be used with this option. Keep for future use.

Removing Group 22 Components (FIGURE 3)


MOVING GROUP 22 BATTERY BOX in PROCE-


2. Remove the existing battery box tray. Refer to REMOV-

ING/INSTALLING THE GROUP 22 BATTERY BOX

TRAY in this procedure of the manual.

Base Frame

Shock

Battery Mount Bracket

FIGURE 3 - REMOVING GROUP 22 COMPONENTS

Installing Group 24 Components (FIGURE 4)

1. Align the mounting holes of the NEW wiring harness w/bracket, the NEW battery box sub-frame and the mounting holes in the base frame.

2. Install the two (2) mounting screws through all three (3) parts and secure with locknuts. Torque to 160-inch pounds.

70


WARNING

The Battery Box Retainer/Retainer Clip

MUST be fastened securely in place before using the wheelchair. Use Loctite 242 and torque to 160-inch pounds.

3. Position the NEW retainer clip between the NEW battery box sub-frame and shock making sure the retainer clip mounting hole is towards the bottom and the closed end of the clip is against the battery box retainer bar.

STEPS 1-2

FRONT OF

CHAIR

Locknuts

Mounting

Screws


Battery Box

Sub-Frame

4. Install the mounting screw that secures the retainer clip to the battery box sub-frame. Use Loctite 242 and torque to 160-inch pounds.

5. Align the NEW battery box retainer and spacers with the mounting holes in the base frame making sure the closed end of the battery box retainer is pointing up.

6. Reinstall the mounting screws that secure the battery box retainer to the base frame. Use Loctite 242 and torque to 160-inch pounds.

7. Install charger cable to existing mounting bracket secure with existing two (2) mounting screws.

8. Tie-wrap NEW wiring harness to the seat frame.

9. Connect the following cables: a. The right and left motor connectors to the controller connectors.

b. The battery harness/charger cable (BLUE) to the controller connector (BLUE).

10. Install the NEW battery boxes. Refer to INSTALLING/

REMOVING GROUP 22 BATTERY BOX in PROCE-


REAR OF CHAIR

Base Frame

STEPS 3-6

REAR OF

CHAIR

Battery Box

Sub-frame

Spacer

Mounting Screws

Shock

Retainer

Clip

Closed End

FRONT OF

CHAIR

Battery Box

Retainer

Bar

SHOCK REPLACEMENT


1. Remove the front battery box. Refer to INSTALLING/



2. Remove the drive wheel assembly. Refer to REMOV-

ING/INSTALLING THE DRIVE WHEEL in PROCE-


3. Loosen the mounting screw that secures the battery box retainer between the battery box sub frame assembly and the base frame.

4. Remove the mounting screw that secures the top of the shock and retainer clip between the battery box sub frame assembly and the base frame.

NOTE: Remove and hold onto the retainer clip for installation of the NEW shock.

5. Remove the mounting screw, two (2) flat washers, two (2) spring washers, two (2) inner link spacers, and locknut that secures the bottom of the shock, suspension arm, and stabilizer bracket together.

6. Remove the existing shock.

7. Install the NEW shock.

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FIGURE 4 - INSTALLING GROUP 24 COMPONENTS

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8. Secure the bottom of the NEW shock, suspension arm, and stabilizer bracket together with the mounting screw, two (2) flat washers, two (2) spring washers, two (2) inner link spacers, and locknut. Torque to 160-inch pounds.

Base Frame

Battery Box

Sub- Frame

Battery Box

Retainer Bar

Stabilizer

Assembly*

Mounting Screw

Loosen, DO NOT

REMOVE (STEPS

3,11)

Shock

Battery Box Sub-Frame

Retainer Clip

Top of Shock

WARNING



9. Position retainer clip between shock and battery box sub-frame making sure the retainer clip mounting hole is towards the bottom and the closed end of clip is against battery box retainer.

10. Secure top of shock and retainer clip between battery box sub frame and base frame. Apply Loctite 242 and torque to 160-inch pounds.

11. Apply Loctite 242 and torque the mounting screw that secures the battery box retainer between the battery box sub frame and base frame. Torque to 160-inch pounds.

12. Reassemble large wheel to hub assembly and Torque to 160-inch pounds.

13. Repeat this procedure for the opposite shock.

14. Reinstall the front battery box. Refer to INSTALLING/



Spring

Washer

Mounting

Screw

NOTE: Top of stabilizer* exploded away for clarity only.

Base

Frame

Shock

Mounting

Screw

Inner Link

Spacer Suspension

Arm

Locknut

Flat Washer Stabilizer

Bracket

NOTE: The spacer and retainer are not shown for clarity.

*NOTE: The spring shown on the stabilizer is for wheelchair models built before 7/1/1999

FIGURE 5 - SHOCK REPLACEMENT - GROUP 24

BATTERY BASE FRAMES

72





2. Remove the four (4) nuts that secure the large wheel assembly to the to the hub assembly and remove the large wheel assembly.

3. Loosen the mounting screw that secures the spacer between battery mount bracket and the base frame.

4. Remove mounting screw that secures top of the shock between battery mount bracket and base frame.

5. Remove the mounting screw, two (2) flat washers, two (2) spring washers, two (2) inner link spacers, and locknut that secures the bottom of the shock, suspension arm, and stabilizer bracket together.

6. Remove the existing shock.


8. Secure the bottom of the NEW shock, suspension arm, and stabilizer bracket together with the mounting screw, two (2) flat washers, two (2) spring washers, two (2) inner link spacers, and locknut. Torque to 160-inch pounds.

9. Secure the top of shock between battery mount bracket and base frame. Apply Loctite 242 and torque to 160-inch pounds.


10. Apply Loctite 242 and torque the mounting screw that secures the spacer between the battery mount bracket and base frame. Torque to 160-inch pounds.

11. Reassemble large wheel to hub assembly and Torque to 160-inch pounds.

12. Repeat this procedure for the opposite shock.

13. Reinstall the battery box. Refer to INSTALLING/RE-



Battery Mount Bracket

Base Frame

Mounting

Screw

Flat Washer

Mounting

Screw

Suspension

Arm

Spring

Washer

Inner Link Spacer

Shock

Stabilizer*

Locknut

Stabilizer Bracket

NOTE: Top of stabilizer exploded away for clarity only.

*NOTE: The spring shown on the stabilizer is for wheelchair models built before 7/1/1999

FIGURE 6 - SHOCK REPLACEMENT - GROUP 22

BATTERY BASE FRAMES

SHOCK SPRING REPLACEMENT

(FIGURE 7)

NOTE: Heavy Duty Models Only. Shock springs on standard models cannot be individually replaced. A new shock assembly must be installed. Refer to SHOCK REPLACE-

MENT in this procedure of the manual.

1. Remove the front battery box. Refer to INSTALLING/




A. (Group 24 Battery Base Frames) Loosen the mounting screw that secures the battery box retainer between the battery box sub frame assembly and the base frame.

B. (Group 22 Battery Base Frames) Loosen the mounting screw that secures the battery box spacer between the battery box tray mount bracket and the base frame.

3. Remove the mounting screw that secures the top of the stabilizer cylinder to the base frame.


A. (Group 24 Battery Base Frames) Remove the mounting screw that secures the top of the shock between the battery box sub-frame and the base frame.

B. (Group 22 Battery Base Frames) Remove the mounting screw that secures the top of the shock between retainer clip and the battery box tray mount bracket and the base frame.

NOTE: (Group 24 Battery Base Frames Only) Remove and hold onto the retainer clip for reinstallation of shock.

5. Swing the top of both the stabilizer cylinder and the shock forward.

6. Hold the spring retainer and turn the shock eyelet assembly COUNTERCLOCKWISE to unthread it from the shock.

7. Remove the spring retainer and spring.

8. Place the NEW spring onto the shock.

9. Reinstall the shock eyelet assembly and the spring retainer onto the NEW spring.

10. While holding the spring retainer, torque the shock eyelet assembly to 245-inch pounds.

11. (Group 24 Battery Base Frames) Position the retainer clip between the shock and the battery box subframe making sure the retainer clip mounting hole is towards the bottom and the closed end of the clip is against the battery box retainer.


A. (Group 24 Battery Base Frames) Apply Loctite

242 and torque the mounting screw that secures the battery box retainer to the base frame to 160inch pounds.

B. (Group 22 Battery Base Frames) Apply Loctite

242 and torque the mounting screw that secures the battery mount bracket to the base frame to

160-inch pounds.

13. Secure the top of the shock and retainer clip (Group

24) to base frame. Apply Loctite 242 and torque to

160-inch pounds.

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14. Reinstall the front battery box. Refer to INSTALLING/



Shock Eyelet

Assembly

Spring

Retainer

Shock

Spring

2. Remove the mounting screw, two (2) washers, two

(2) spring washers, two (2) outer link spacers, two

(2) flat washers, and locknut that secure the stabilizer fork assembly, stabilizer bracket, and stabilizer wheel together.

3. Secure NEW stabilizer fork assembly to stabilizer bracket and stabilizer wheel with existing mounting screw, two (2) washers, two (2) spring washers, two (2) outer link spacers, two (2) flat washers, and locknut. Securely tighten.

4. Secure top of stabilizer fork assembly to base frame with existing mounting screw and locknut. Torque to

40 in/lbs.

Spring

Base

Shock

FIGURE 7 - SHOCK SPRING REPLACEMENT

REPLACING STABILIZER FORK

ASSEMBLY (FIGURE 8)

1. Remove the mounting screw and locknut that secures the top of the stabilizer fork assembly to the base frame.

REPLACING STABILIZER WHEELS

(FIGURE 8)

1. Remove the mounting screw, two (2) washers, two

(2) spring washers, two (2) outer link spacers, two

(2) flat washers, and locknut that secure the stabilizer wheel, stabilizer bracket, and stabilizer fork assembly together.

2. Secure NEW stabilizer wheel to stabilizer bracket and stabilizer fork assembly with existing mounting screw, two (2) washers, two (2) spring washers, two (2) outer link spacers, two (2) flat washers, and locknut. Securely tighten.

Base Frame

Locknut

Mounting Screw

NOTE: Remove this mounting screw and locknut only when replacing the stabilizer fork assembly.

Mounting Screw

Stabilizer

Bracket Stabilizer

Fork

Assembly*

Flat

Washer

Locknut

Washer

Spring Washer Outer Link Spacers Stabilizer Wheel

Washer

*NOTE: The spring shown on the stabilizer fork assembly is for wheelchair models built before 7/1/1999

FIGURE 8 - REPLACING STABILIZER FORK ASSEMBLY/REPLACING STABILIZER WHEELS

74


REPLACING STABILIZER

CYLINDER SPRING (FIGURE 9)

NOTE: Stabilizer springs are only on wheelchair models built before 7/1/1999.

1. Remove mounting screw and locknut that secures top of the stabilizer fork assembly to the base frame.

2. Unthread adjustment barrel and remove from stabilizer rod.

3. Unthread jam nut and remove from stabilizer rod.

4. Unthread adjustment nut and remove from stabilizer rod.

5. Remove spring retainer from stabilizer rod.

6. Remove existing stabilizer spring.

7. Install NEW stabilizer spring.

8. Reinstall spring retainer.

9. Reinstall adjustment nut.

10. Reinstall jam nut.

11. Reinstall adjustment barrel.

12. Adjust stabilizer. Refer to ADJUSTING STABILIZERS in this procedure of the manual.

Base Frame

ADJUSTING WEIGHT DISTRIBUTION

(FIGURE 10)

NOTE: The seat mount plates and seat support brackets allow seat frame to be repositioned along the base frame.

NOTE: The position of the seat support brackets is factory set at 5-1/2-inches from the front end of the base frame.

Use the following chart as a starting point.

Weight of

User

Distance of Seat

Support Bracket* under 200-lbs over 200-lbs

5-7-inches

6-8-inches

* Distance measured from the front of the base frame to the front of the seat support bracket.

NOTE: Following the above chart will put 85-90% of the total weight of the chair and user over the large wheels.

However, these settings may not be the most desirable in terms of maneuverability and comfort for the user.

Adjustment for Optimum Performance

1. Loosen the four (4) mounting screws that secure the seat support brackets to the base frame.

2. Adjust seat back until one (1) of the following occurs:

A. The clearance of the front riggings and the stabilizers is at a minimum or

B. The rear stop is contacted.

Mounting

Screw

WARNING

DO NOT adjust seat beyond limit stops.

Locknut

Stabilizer

Spring

Adjustment

Barrel

Jam Nut

Adjustment

Nut

Spring

Retainer

Stabilizer

Rod

FIGURE 9 - REPLACING STABILIZER CYLINDER SPRING

75

3. Retighten mounting screws securing the seat support brackets to the base frame.

4. Test wheelchair for handling.

5. If handling of the power wheelchair is drifting, repeat this procedure moving seat up in small increments until the chair handles properly.

6. Once the seat is adjusted to the point of proper handling, comfort adjustments can be made

7. Check distance the stabilizer wheels are off the floor.

A. If distance is between 3/8 and 1/2-inches off of the floor the user will experience a normal amount of rocking when stopping or negotiating steeper inclines, depending on the amount of braking.

B. If distance is greater than 1/2-inches off of floor the amount of rocking the user experiences when stopping or negotiating steeper inclines will increase.

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NOTE: This setting would allow the wheelchair to roll better on thicker carpeting and minimize scuffing.

C. If distance is between 0 and 3/8-inch, along with an increase in spring compression, the amount of rocking the user experiences will decrease. Although, this setting would minimize rocking, obstacles protruding from the ground as well as negotiating steeper inclines will be more difficult.

8. Adjust the stabilizers to the desired setting determined in STEP 7. Refer to ADJUSTING STABILIZERS in this procedure of the manual.

Seat Support Bracket

Front of

Base Frame

WARNING

The threaded rod must be engaged in the adjustment barrel at least eight (8) full threads.

Otherwise, injury or damage may occur.

5. Realign the top of stabilizer fork assembly with the mounting hole in the base frame noted earlier.

NOTE: Further height adjustment can be accomplished by using the alternate mounting hole in the base frame.

See DETAIL A.

6. Secure stabilizer to base frame with existing mounting screw and locknut.

7. To increase spring compression, refer to ADJUST-

ING SPRING COMPRESSION in this procedure of the manual.

NOTE: Adjust both stabilizers equally to maintain proper handling.

8. Repeat for opposite stabilizer.

9. Test wheelchair for handling/maneuverability.

10. Repeat STEPS 1-7 until desired comfort and maneuverability is achieved

Mounting Screws

(Two (2) on each bracket)

ADJUSTING STABILIZERS

(FIGURE 11)

Front of Seat

Support Bracket

FIGURE 10 -ADJUSTING WEIGHT DISTRIBUTION

NOTE: Adjust the stabilizers to the desired handling/maneuverability determined in ADJUSTING WEIGHT DIS-

TRIBUTION in this procedure of the manual.

Adjusting Spring Compression

1. Perform one (1) of the following

A. To increase spring compression, turn adjustment nut CLOCKWISE two (2) to four (4) revolutions.

B. To decrease spring compression, turn adjustment nut COUNTERCLOCKWISE two (2) to four (4) revolutions.

Base

Frame

Alternate Mounting Hole

Mounting Screw

Top of

Stabilizer Fork

Assembly

NOTE: Note the mounting position of the stabilizer to the base frame for proper reinstallation.

Height Adjustment DETAIL A

Locknut

1. Remove the mounting screw and locknut that secures the top of the stabilizer fork assembly to the base frame.

2. Swing top end of stabilizer fork assembly forward.

3. Loosen jam nut, located below adjustment barrel.


Turn the adjustment barrel CLOCKWISE to raise the stabilizer wheel.

Turn the adjustment barrel COUNTERCLOCKWISE to lower the stabilizer wheel.

76

Top of Stabilizer

Fork Assembly

Adjustment Nut

Spring

Adjustment

Barrel

Jam Nut

Threaded

Rod

FIGURE 11 - ADJUSTING STABILIZERS


2. Count the number of exposed threads and repeat this procedure for the opposite shock.

3. Proceed to STEP 9 in HEIGHT ADJUSTMENT OF

STABILIZERS in this procedure of the manual.

REMOVING/INSTALLING GEARBOX

(FIGURE 12)

CAUTION


Removing

1. Remove the drive wheels from the wheelchair. Refer to

REMOVING/INSTALLING DRIVE WHEELS in PRO-


2. Remove the drive wheel hub from the existing gearbox drive shaft. Refer to REMOVING/INSTALLING DRIVE

WHEEL HUBS in PROCEDURE 12 of this manual.

NOTE: Note the mounting position of gearbox to the suspension arm before gearbox disassembly.

3. Remove the four (4) mounting screws that secure the motor/gearbox to the suspension arm.

4. If necessary, remove existing motor from gearbox. Refer to REMOVING/INSTALLING THE MOTOR in PRO-


5. If necessary, install existing motor onto NEW gearbox.

Refer to REMOVING/INSTALLING THE MOTOR in


Installing

WARNING

When reinstalling the gearbox ALWAYS use the mounting holes furthest back on the suspension arm. DO NOT reposition the motors.

2. When reassembling the gearbox to the suspension arm, use Loctite 242 and torque mounting screws to 160inch pounds.

NOTE: Replace any parts that show signs of wear or damage.

3. Reinstall the drive wheel hub to the new gearbox drive shaft. Refer to REMOVING/INSTALLING DRIVE


4. Reinstall the drive wheels onto the wheelchair. Refer to



5/16-18 x 1-1/4-inch

Mounting Screws

WARNING

5/16-18 x 2-1/2-inch

Mounting Screws

When reinstalling the gearbox ALWAYS use the mounting holes furthest back on the suspension arm. DO NOT reposition the motors.

Motor

Gearbox

Suspension Arm

FIGURE 12 - REMOVING/INSTALLING GEARBOX

CAUTION

The FRONT mounting screws that secure the gearbox to the suspension arm MUST be 5/

16-18 x 2-1/2-inches long and the REAR hex screws that secure the gearbox to the suspension arm MUST be 5/16-18 x 1-1/4-inches long. Otherwise damage to the gearbox casting can result.

1. Position the NEW gearbox with the mounting holes furthest back on the suspension arm.

REPLACING SUSPENSION ARM

(FIGURE 13)





A. (GROUP 24) - Loosen the mounting screws that secures the wiring harness and the battery subframe to the base frame assembly.

B. (GROUP 22) - Loosen the two (2) mounting screws that secures the rear of the battery tray to the sub-frame assembly.

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3. Remove gearbox from the existing suspension arm. Refer to REMOVING/INSTALLING GEARBOX in this procedure of the manual.

4. Remove the mounting screw, two (2) flat washers, two (2) spring washers, two (2) inner link spacers, and locknut that secures the bracket end of the suspension arm, the bottom of the shock, and stabilizer bracket together.

5. Remove plug button from the middle of base frame.

6. Remove the mounting screw and the beveled washers that secures the tubular end of the suspension arm assembly to the base frame.

7. Remove the suspension arm from the wheelchair.

8. Position bracket end of NEW suspension arm around shock.

9. Thread existing mounting screw through stabilizer bracket, bracket end of suspension arm, and bottom of shock with mounting screw, two (2) flat washers, two (2) spring washers, two (2) inner link spacers, and locknut. See DETAIL A for proper hardware orientation.

Bracket End of Suspension Arm

Tubular End of

Suspension Arm

NOTE: When installing the tubular end of the NEW suspension arm, the beveled washer MUST be placed on the inside and outside of the base frame, with the bevels facing each other.

10. Secure tubular end of the NEW suspension arm assembly to base frame with existing mounting screw.

11. Torque suspension arm mounting screw (1/2 x 7inches) to 85 FOOT pounds (approximately 1,020inch pounds) and replace plug buttons.

12. Reinstall the gearbox onto the existing suspension arm.

Refer to REMOVING/INSTALLING GEARBOX in this procedure of the manual.


A. (GROUP 24) - Tighten the mounting screws that secures the wiring harness and the battery subframe to the base frame assembly.

B. (GROUP 22) - tighten the two (2) mounting screws that secures the rear of the battery tray to the sub-frame assembly.

14. Reinstall the drive wheel onto the wheelchair. Refer to REMOVING/INSTALLING DRIVE WHEELS in


15. Repeat STEPS 1-14 for the opposite side of the wheelchair, if necessary.

Tubular End of

Suspension Arm

(STEPS 6,10)

Beveled

Washer

(STEPS

6,10)

STEPS 4,8, AND 9

Bracket End of

Suspension Arm

Inner Link

Spacer

Base Frame

NOTE: Top of shock and stabilizer exploded away for clarification purposes only. Removal from base frame is not required.

Mounting

Screw

Hex Nut

(STEPS 6,11)

Spring Washer

Bottom of Shock

Mounting Screw (STEPS 6,10)

Plug Button (STEP 5)

FIGURE 13 - REPLACING SUSPENSION ARM

78

Flat

Washer

Stabilizer Bracket

Locknut

RWD WHEELCHAIRS PROCEDURE 16


Removing/Installing Group 24 Battery Box Sub-Frame

Removing/Installing Group 22 Battery Box Tray

Converting Group 22 Batteries to Group 24 Batteries

Shock Replacement


Rubber Element Replacement

Converting Torque and X Rubber Elements to Shocks

Anti-Tipper Wheel Replacement

Removing/Installing Gearbox


Repositioning Motor/Gearbox Assembly

Repositioning Gearless/Brushless Motor

Replacing Suspension Arm for Wheelchairs with

Motor/Gearbox assembly

Replacing Suspension Arm for Wheelchairs with

Gearless/Brushless Motor

Removing/Installing the Anti-tip Assembly

2. Reinstall the four (4) mounting screws that secure the shocks, retainer bar, spacers and retainer clips to the base frame.

Refer to REPLACING BATTERY BOX RETAINER/RE-

TAINER CLIP - GROUP 24 BATTERY BASE FRAMES in


3. Reinstall the battery boxes. Refer to INSTALLING/REMOV-

ING GROUP 24 BATTERY BOXES in PROCEDURE 9 of this manual. Use Loctite 242 and torque mounting screws to 160-inch pounds.

Mounting

Screws


WARNING



REAR OF

CHAIR

Locknuts

Sub-Frame

FRONT OF CHAIR

REMOVING/INSTALLING GROUP 24

BATTERY BOX SUB-FRAME (FIGURE 1)

FRONT OF

CHAIR

Battery Box

Sub-frame

Removing




2. Remove the two (2) mounting screws and locknuts that secure the wiring harness w/bracket and the rear of the existing sub-frame to the base frame. Refer to

REMOVING/INSTALLING THE WIRING HARNESS in PROCEDURE 10 of this manual.

Battery Box

Retainer

Bar Spacer

Mounting

Screws

REAR OF CHAIR

Retainer Clip

FIGURE 1 - REMOVING/INSTALLING GROUP 24 BATTERY

BOX SUB-FRAME

3. Remove the four (4) mounting screws that secure the shocks, retainer bar, spacers and retainer clips to the base frame. Refer to REPLACING BATTERY BOX



REMOVING/INSTALLING GROUP

22 BATTERY BOX TRAY (FIGURE 2)

Removing

4. Remove the existing sub-frame assembly.

Installing

1. Install the two (2) mounting screws and locknuts that secure the wiring harness w/bracket and the back of the NEW sub-frame to the base frame. Refer to RE-

MOVING/INSTALLING THE WIRING HARNESS in


79

1. Remove the battery box. Refer to INSTALLING/REMOV-


2. Remove the two (2) rear locknuts that secure the battery box tray to battery mount brackets.

3. Remove the two (2) front bolts and locknuts that secure the battery box tray to the base frame.

4. Remove the battery tray from the base frame.

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PROCEDURE 16 RWD WHEELCHAIRS

Installing

1. Install battery tray onto base frame.

2. Secure the rear of the battery tray to battery mount brackets with existing locknuts. Torque to 160-inch pounds.

3. Secure the front of the battery tray to the base frame with existing mounting screws and locknuts. Torque to 160-inch pounds.


ING BATTERY BOX - GROUP 22 BATTERY BASE

FRAMES in PROCEDURE 9 of this manual.

4. Remove the four (4) mounting screws that secure the battery mount brackets to the base frame.

5. Remove the battery mount brackets.

Spacer

Battery Mount

Bracket

Mounting

Screws

Base

Frame

Locknuts Bolts

*Rubber Element

(or Shock Assembly)

*NOTE: Illustration depicts rubber element. Battery

Mount Brackets remove in the same manner for the shock assembly.

FIGURE 3 - REMOVING GROUP 22 COMPONENTS

*Rubber

Element

Battery Tray


Base

Frame

*NOTE: Illustration depicts the rubber element. Battery Box

Tray removes in the same manner for shock assembly.

FIGURE 2 - REMOVING/INSTALLING GROUP 22

BATTERY BOX TRAY

Installing Group 24 Components (FIGURE 4)

1. Line up the mounting holes in the front of the NEW battery box sub-frame and the NEW wiring harness w/bracket with the mounting holes in the base frame

(FIGURE 5).

2. Install the two (2) mounting screws through the wiring harness w/bracket, battery box sub-frame, and base frame (FIGURE 5).

3. Install the locknuts onto mounting screws. Torque to

160-inch pounds (FIGURE 5).

CONVERTING GROUP 22 BATTERY

BOX TRAY TO GROUP 24 BATTERY

BOX SUB FRAMA ASSEMBLY

WARNING



Removing Group 22 Components (FIGURE 3)


MOVING GROUP 22 BATTERY BOX/BATTERIES in PROCEDURE 9 of this manual.

2. Remove the battery box tray. Refer to REMOVING/

INSTALLING THE GROUP 22 BATTERY BOX TRAY in this procedure of the manual.

3. Remove the wiring harness. Refer to REMOVING/

INSTALLING THE WIRING HARNESS in PROCE-


NOTE: The battery box tray and the battery mount brackets will not be reused. Mounting screws and spacers will be reused.

80

4. Position the retainer clip between the NEW battery box sub-frame and the top of the rubber element or shock assembly making sure the retainer clip mounting hole is towards the bottom and the closed end of the clip is against the battery box retainer bar (FIGURE 5).

NOTE: Make sure the closed end of the battery box retainer clip is pointing up.

5. Install the mounting screw that secures the retainer clip to the battery box sub-frame. Use Loctite and torque to 160-inch pounds (FIGURE 5).

® 242

6. Line up the NEW battery box retainer bar and spacers with mounting holes in the base frame (FIGURE 5).


7. Reinstall the mounting screws that secure the battery box retainer bar to the base frame. Use Loctite

242 and torque to 160-inch pounds (FIGURE 5).

8. Perform STEPS 2-7 of REMOVING/INSTALLING

THE WIRING HARNESS in PROCEDURE 10 of this manual to complete the wiring harness installation.

9. Install the group 24 battery boxes. Refer to INSTALL-

ING/REMOVING GROUP 24 BATTERY BOXES in


STEPS 1 - 3

Mounting

Screws


Battery Box

Sub-Frame

REAR OF

CHAIR

Base

Frame

Locknuts FRONT OF

CHAIR

FRONT OF

CHAIR

Spacer

STEPS 4 - 7

Mounting Screws

Battery Box

REAR OF

CHAIR

Battery Box

Retainer

Bar

Retainer

Clip

Shock Assembly

(or Rubber Element)

Closed End

FIGURE 4 -INSTALLING GROUP 24 COMPONENTS

SHOCK REPLACEMENT (FIGURE 5)

1. Remove the group 22 battery box or group 24 battery boxes. Refer to INSTALLING/REMOVING GROUP

22 BATTERY BOX or INSTALLING/REMOVING

GROUP 24 BATTERY BOXES in PROCEDURE 9 of this manual.

2. Remove the drive wheel from the wheel hub. Refer to

REMOVING/INSTALLING THE DRIVE WHEELS in


3. GROUP 24 BATTERIES ONLY - Loosen the hex screw that secures the battery box retainer bar to the base frame.

4. Remove the mounting screw that secures the top of the shock to the base frame.

5. Remove the mounting screw and locknut from the bottom of the suspension arm.

6. Remove the shock from the base frame.



A. GROUP 24 BATTERIES -

● Position retainer clip between shock and battery box sub-frame making sure the retainer clip mounting hole is towards the bottom and the closed end of clip is against battery box retainer bar.

● Secure the top of shock and retainer clip to base frame. Apply Loctite 242 and torque to 160-inch pounds.

● Apply Loctite 242 and torque the hex screw that secures the battery box retainer bar to the base frame to 160-inch pounds.

B. GROUP 22 BATTERIES - Secure the top of shock to base frame. Apply Loctite 242 and torque to 160-inch pounds.

9. Secure the bottom of the new shock to the suspension arm with the existing mounting screw and locknut. Apply Loctite 242 and torque to 160-inch pounds.

10. Install the drive wheel from the wheel hub. Refer to

REMOVING/INSTALLING THE DRIVE WHEELS in





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GROUP 24 BATTERIES

Battery Box

Sub-frame

TOP OF SHOCK


FRONT OF

CHAIR

Shock

REAR OF

CHAIR

Mounting Screw

(LOOSEN)

Spacer

Mounting

Screw

Suspension

Arm

Top of

Shock

Battery Box

Retainer

Bar

Retainer Clip

(Closed End)

NOTE: Suspension arm for conventional motor shown.

Shock removes in the same manner for gearless/ brushless motor.

BOTTOM OF SHOCK

GROUP 22 AND GROUP 24 BATTERIES

Locknut

Shock

Mounting

Screw

Suspension

Arm

NOTE: Suspension arm shown is for conventional motors. Shock removes in the same manner for gearless/ brushless motor.

FIGURE 5 - SHOCK REPLACEMENT

82



(FIGURE 6)




2. GROUP 24 BATTERIES ONLY - Loosen the mounting screw that secures the battery box retainer bar to the base frame.

3. Remove the mounting screw that secures the top of the shock to the suspension arm.

4. Swing the top of the shock rearward.

5. Hold the spring retainer and turn the shock eyelet assembly counterclockwise to unthread it from the shock.





10. Position the retainer clip between the shock and the battery box sub-frame making sure the retainer clip mounting hole is towards the bottom and the closed end of the clip is against the battery box retainer.

11. Secure top of shock and retainer clip to base frame.

Apply Loctite 242 and torque to 160-inch pounds.

12. GROUP 24 BATTERIES ONLY - Apply Loctite 242 and torque the hex screw that secures the battery box retainer bar to the base frame to 160-inch pounds.

13. Reinstall the group 22 battery box or group 24 battery boxes. Refer to INSTALLING/REMOVING GROUP



Mounting

Screw


Shock

Suspension

Arm

NOTE: Shock exploded away for clarity. There is no need to remove shock from suspension arm.


Spacer

Shock Eyelet

Assembly

Shock Eyelet

Assembly

Hex

Screws

Battery Box

Retainer

Bar

Retainer Clip

Spring

Retainer

Shock

Spring

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Spring

Base

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Shock


PROCEDURE 16

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RUBBER ELEMENT REPLACEMENT

(FIGURE 7)

NOTE: Rubber elements are only found on Storm

Torque and Storm X wheelchairs.



2. Remove the battery box tray. Refer to REMOVING THE

BATTERY BOX TRAY in this procedure of the manual.

3. Loosen the mounting screw that secures the battery mount bracket to the base frame, but do not remove.

4. Remove the mounting screw that secures the top of the rubber element and battery mount bracket to the base frame.

6. Remove the three (3) mounting screws and locknuts that secure the bottom of the rubber element to the rubber element mount bracket.

7. Remove the existing rubber element and install the new rubber element.

8. Resecure the bottom of the rubber element to the rubber element mount bracket with the existing three (3) mounting screws. Use Loctite 242 and torque to 160inch pounds.

9. Reinstall the hex screw that secures the top of the rubber element and battery mount bracket to the base frame.


10. Torque the hex screw that secures the battery mount bracket to the base frame to 160-inch pounds.

11. Reinstall the battery box tray onto the hanger bracket and torque the locknut to 160-inch pounds.



Spacer

Battery Mount

Bracket

Mounting

Screw

Base

Frame


CONVERTING TORQUE AND X

RUBBER ELEMENTS TO ARROW

SHOCKS (FIGURE 8)



2. Remove the existing Torque and X rubber element. Refer to RUBBER ELEMENT REPLACEMENT -

TORQUE AND X BASE FRAMES in this procedure of the manual.

3. Line up the bottom of the new Storm Arrow shock with the BOTTOM hole in the rubber element mount plate.

4. Install the new hex screw and locknut through the bottom hole of the mount bracket and shock. Torque to

160-inch pounds.

NOTE: The original hardware that secured the BOTTOM of the Torque and X rubber element to the shock mount bracket will not be used with this option. Keep for future use.

5. Reinstall the hex screw that secures the top of the shock assembly and battery mount bracket to the base frame.


6. Torque the hex screw that secures the battery mount bracket to the base frame to 160-inch pounds.

7. Reinstall the battery box tray onto the battery mount bracket and torque the locknut to 160-inch pounds.



Shock Hex Screw

Battery Mount

Bracket

Mounting Screw

(LOOSEN) FIGURE 8 - CONVERTING TORQUE AND X RUBBER

ELEMENTS TO ARROW SHOCKS

Rubber Element

FIGURE 7 - RUBBER ELEMENT REPLACEMENT

RWD WHEELCHAIRS

84



GEARBOX

(FIGURE 10)

CAUTION


5/16-18 x

2-1/2-inch

Hex

Screws

5/16-18 x

1-1/4-inch

Hex

Screws

Removing




2. Remove the drive wheel hub from the existing gearbox drive shaft. Refer to REMOVING/INSTALLING DRIVE


NOTE: Note mounting position of gearbox to suspension arm before disassembly.

NOTE: To reposition the gearbox on the suspension arm,

refer to WEIGHT DISTRIBUTION in this procedure of the manual.

3. Remove the four (4) hex screws that secure the existing motor/gearbox to the suspension arm.

4. Remove existing motor from gearbox. Refer to MOTOR

REPLACEMENT in PROCEDURE 12 of this manual.

Suspension

Arm

Gearbox

Motor

FIGURE 10 - REMOVING/INSTALLING GEARBOX

ADJUSTING WEIGHT

DISTRIBUTION (FIGURE 11)

5. Install existing motor onto new gearbox. Refer to MOTOR

REPLACEMENT in PROCEDURE 12 of this manual.

Installing

NOTE: Seat mount plates and seat support brackets allow the seat frame to be repositioned along the base frame.

The range is determined by position of the seat stop screws. The front seat stop screw is positioned at 4-inches and the rear seat stop screw is positioned at 10-inches.

Both seat stop screw positions are measured from the front of the base frame.

CAUTION

The REAR hex screws that secure the gearbox to the suspension arm MUST be 5/16-

18 x 2-1/2-inches long and the FRONT hex screws that secure the gearbox to the sus-

NOTE: The position of the seat support brackets is factory set at 7-inches, this measured from the front of the base frame to the front of the seat support bracket. This will put about 70% of the total weight of the chair and user over the large wheels. However, this setting may not be the most desirable in terms of maneuverability, front rigging clearance and comfort for the user.

pension arm MUST be 5/16-18 x 1-1/4-inches long. Otherwise damage to the gearbox

Adjustment Options casting can result.

1. Position NEW gearbox with noted mounting holes.

NOTE: This section will provide the user with some knowledge of what to expect if the following adjustments are made.

2. When reassembling gearbox to suspension arm, use

Loctite 242 and torque hex screws to 160-inch pounds.


3. Reinstall the drive wheel hub to the new gearbox driveshaft. Refer to REMOVING/INSTALLING DRIVE


4. Reinstall the drive wheels onto the wheelchair. Refer to



85

1. Moving the seat forward.

Advantage: This adjustment allows more clearance for front riggings and a more stable

feel for the user.

Disadvantage: More weight is put on front casters and makes turning more difficult.

NOTE: This option can also be accomplished by moving the motor backward on the suspension arm. Refer to RE-

POSITIONING GEARBOX in this procedure of the manual.

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2. Moving the seat rearward.

Advantage: Makes turning easier and provide better traction for the large wheels.

Disadvantage: This adjustment, however, allows less clearance for front riggings and the user will experience more engagement of the anti-tippers.

NOTE: This option can also be accomplished by moving the motor forward on the suspension arm. Refer to REPO-

SITIONING GEARBOX in this procedure of the manual.

MOTOR/GEARBOX ASSEMBLY

Standard -

Approximately 65% of weight over rear wheels

1 - Inch Forward -


Adjusting Weight Distribution Procedure

1. Loosen the four (4) mounting screws that secure the seat support brackets to the base frame.

WARNING

DO NOT adjust seat beyond limit stops.

2. Adjust seat forward or back to the position determined from the previous section ADJUSTMENT OPTIONS.

3. Retighten the four (4) mounting screws securing the seat support brackets to the base frame.

4. Test wheelchair maneuverability, comfort, and handling.

5. Repeat STEPS 1-4 for further adjustment, if necessary.



FIGURE 12 - REPOSITIONING MOTOR/GEARBOX

Washer

REPOSITIONING THE MOTOR/

GEARBOX (FIGURE 12)

Mounting Screws

WARNING

When using a recliner/high back van seat, the motor/gearbox or motor MUST use most

REARWARD mounting holes on the suspension arm assembly.

Seat Support

Bracket

Base

Frame

FIGURE 11 - ADJUSTING WEIGHT DISTRIBUTION

1. Determine the desired position for the gearbox on the wheelchair.




3. Remove gearbox from the suspension arm. Refer to

REMOVING/INSTALLING GEARBOX in this procedure of the manual.

4. Move gearbox to the position determine in STEP 1.

NOTE: The motor/gearbox assembly can be repositioned to lengthen or shorten the wheelbase by 2-inches in 1-inch increments.

NOTE: If the wheelchair is equipped with 9-inch casters on a standard or heavy duty base, the 2-inch forward position CAN

NOT be utilized.

STANDARD POSITION - LENGTHENS the wheelbase and gives you the most stability and standard maneuverability.

1 - INCH FORWARD - CENTERS the wheelbase and gives you standard stability and maneuverability.

2 - INCH FORWARD - SHORTENS the wheelbase and increases maneuverability and distributes additional weight on rear wheels.



6. Repeat STEPS 3-5 for opposite side of the wheelchair.

86

7. Reinstall the drive wheel onto the wheelchair. Refer to




REPOSITIONING THE GEARLESS/BRUSHLESS MOTOR (FIGURE 13,14)

Acceptable mounting positions for the gearless/brushless motor.

NOTE: The motor/gearbox assembly or gearless/brushless motor can be repositioned to lengthen or shorten the wheelbase by 2-inches in 1-inch increments.

ARROW AND STORM X

NOTE: These mounting positions apply to the Arrow and Storm X with fixed back or recliner and torque with manual recline option

TORQUE

NOTE:These mounting positions apply to the Torque with fixed back.

STANDARD POSITION - LENGTHENS the wheelbase and gives you the most stability and standard maneuverability.

1-INCH FORWARD - CENTERS the wheelbase and gives you standard stability and maneuverability.

2-INCH FORWARD - SHORTENS the wheelbase and increases maneuverability and distributes additional weight on rear wheels.

STANDARD POSITION - SHORTENS the wheelbase and increases maneuverability and distributes additional weight on rear wheels.

1-INCH REARWARD - CENTERS the wheelbase and gives you standard stability and maneuverability.

2-INCH REARWARD - LENGTHENS the wheelbase and gives you the most stability and standard maneuverability.

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Standard -






2 - Inch Rearward -


1 - Inch Rearward -


Standard -


FIGURE 13 - REPOSITIONING THE GEARLESS/BRUSHLESS MOTOR

87

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PROCEDURE 16

1. Determine the desired mounting position of the gearless/brushless motor. Refer to ACCEPTABLE

MOUNTING POSITIONS FOR THE GEARLESS/

BRUSHLESS MOTOR in this procedure of the manual.

2. Remove the group 22 battery box or group 24 battery boxes. Refer to INSTALLING/REMOVING BATTERY

BOX - GROUP 22 BATTERY BASE FRAMES or IN-

STALLING/REMOVING BATTERY BOXES - GROUP

24 BATTERY BASE FRAMES in PROCEDURE 9 of this manual.

3. If necessary, remove the battery box tray. Refer to RE-

MOVING THE BATTERY BOX TRAY in this procedure of the manual.


REMOVING/INSTALLING DRIVE WHEELS in PROCE-


5. Loosen the adjustment screw that secures the motor release handle to the brake release shaft.

6. Remove the four (4) mounting screws and washers that secure the motor to the suspension arm.

7. Slide the motor forward or backward to the desired mounting position.

8. Secure the motor to the mounting position determined in STEP 1 and secure with the four (4) existing mounting screws and washers. Torque to 13 foot/pounds.

9. Securely tighten adjustment screw.

Motor Brake Release

Shaft

Motor Release

Lever

Adjustment

Screw

10. Reinstall the drive wheel to the wheelchair. Refer to RE-

MOVING/INSTALLING DRIVE WHEELS in PROCE-


11. Repeat STEPS 1-9 for opposite side of wheelchair.

12. If necessary, reinstall the battery box tray. Refer to RE-

MOVING THE BATTERY BOX TRAY in this procedure of the manual.

13. Remove the group 22 battery box or group 24 battery boxes. Refer to INSTALLING/REMOVING BATTERY

BOX - GROUP 22 BATTERY BASE FRAMES or IN-

STALLING/REMOVING BATTERY BOXES - GROUP

24 BATTERY BASE FRAMES in PROCEDURE 9 of this manual.

REPLACING SUSPENSION ARM FOR

WHEELCHAIRS WITH MOTOR/

GEARBOX ASSEMBLY (FIGURE 15)


REMOVING/INSTALLING DRIVE WHEELS in PROCE-


2. Loosen the hex screws that secure wiring harness to sub-frame assembly.

3. Remove gearbox from the existing suspension arm. Refer to REMOVING/INSTALLING GEARBOX in this procedure of the manual.

4. Remove plug buttons from the middle of the base frame.

5. Remove the hex screws and the beveled washers that secure the suspension arm assembly to the base frame.

6. Remove existing suspension arm from the wheelchair.

NOTE: When installing the NEW suspension arm, the beveled washers MUST be placed on the inside and outside of the base frame, with the bevels facing each other.

7. Install the NEW suspension arm assembly onto the base frame.

Suspension Arm

RWD WHEELCHAIRS

Beveled

Washers

Suspension Arm

Washer

FIGURE 14 - REPOSITIONING THE GEARLESS/

BRUSHLESS MOTOR

Plug

Button

Mounting

Screws

88

Suspension Arm Hex Screw

(1/2 x 7-inches)

FIGURE 15 - REPLACING SUSPENSION ARM FOR

WHEELCHAIRS WITH MOTOR/GEARBOX ASSEMBLY


8. Torque suspension arm hex screws (1/2 x 7-inches) to

85 FOOT pounds (approximately 1,020-inch pounds) and replace plug buttons.



10. Tighten the hex screws that secure wiring harness to sub-frame assembly securely.

11. Reinstall the drive wheel onto the wheelchair. Refer to



12. Repeat STEPS 1-12 for the opposite side of the wheelchair, if necessary.

12. Install the shock onto the new suspension arm. Refer to REMOVING/INSTALLING THE SHOCK ASSEM-

BLY in this procedure of the manual.

13. Install the motor onto the new suspension arm. Refer to REMOVING/INSTALLING THE MOTOR in PRO-


14. Install anti-tip assembly onto the rear of the new suspension arm. Refer to REMOVING/INSTALLING THE

ANTI-TIP ASSEMBLY in this procedure of the manual.


A. Remove the seating system. Refer to the seating systems owners manual for removal/installation instructions.

B. Remove the seat pan. Refer to REMOVING/IN-

STALLING THE SEAT PAN in PROCEDURE 6 of this manual.


FOR WHEELCHAIRS WITH

GEARLESS/BRUSHLESS MOTORS

(FIGURE 16)

Suspension Arm


A. Remove the seating system. Refer to the seating systems owners manual for removal/installation instructions.

B. Remove the seat pan. Refer to REMOVING/IN-

STALLING THE SEAT PAN in PROCEDURE 6 of this manual.

2. Remove the motor. Refer to REMOVING/INSTALLING

THE MOTOR in PROCEDURE 12 of this manual.

3. Cut the tie-wrap(s) that secure the wiring harness/ charger cable to the suspension arm.

4. Remove the anti-tip assembly from the rear of the suspension arm. Refer to REMOVING/INSTALLING THE

ANTI-TIP ASSEMBLY in this procedure of the manual.

5. Remove the shock from the suspension arm. Refer to

REMOVING/INSTALLING THE SHOCK ASSEMBLY in this procedure of the manual.

6. Remove the plug buttons from the side of the base frame.

7. Remove the mounting screw and beveled washers that secure the front of the suspension arm to the base frame.

8. Remove the existing suspension arm from the base frame.

9. Install the new suspension arm onto the base frame.

10. Install mounting screw and beveled washers that secure the front of the suspension arm to the base frame.

11. Install the plug buttons into the side of the base frame

89

Beveled

Washers

Plug

Button

ANTI-TIPPER WHEEL

REPLACEMENT (FIGURE 9)

Anti-Tipper Wheel

Spacer

Suspension Arm Hex Screw

FIGURE 16 - REPLACING SUSPENSION ARM FOR

WHEELCHAIRS WITH GEARLESS/BRUSHLESS MOTOR

1. Remove the locknuts, hex screws and spacers that secure the anti-tipper wheels to the shock mount plates.

2. Replace anti-tipper wheel(s) and torque existing hardware to 30-35-inch pounds. DO NOT overtighten.

Hex Screw

(1/2 x 7-inches)

Locknut

Shock Mount Plates

FIGURE 9 - ANTI-TIPPER WHEEL REPLACEMENT

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ANTI-TIP ASSEMBLY

Removing

1. Remove the mounting screw, washers, and spacers that secure the top of the anti-tip bracket to the suspension arm.

2. Remove the mounting screw and locknut that secure the extension spring in place.

3. Remove the mounting screw, washers, and spacers that secure the bottom of the anti-tip bracket to the suspension arm.

Installing

1. Align top mounting hole of anti-tip bracket with top mounting slot in rear of suspension arm.

Top

Mounting

Hole

Anti-Tip

Bracket Spacers

2. Secure top of anti-tip bracket to suspension arm with existing mounting screw, washers, spacers, and locknut. Securely tighten.

3. Align lower mounting hole of the anti-tip mounting bracket with the lower slot of the suspension arm.

4. Secure the anti-tip bracket to the suspension arm with the existing mounting screw, washers, spacers, and locknuts. Securely tighten.

5. Hook one end of the extension spring around mounting screw.

6. Install mounting screw through lower mounting hole in suspension arm, other end of extension spring and opposite side of suspension arm. Securely tighten with locknut.

Washers Locknuts

DO NOT

USE THIS

MOUNTING

HOLE

Lower

Mounting

Hole

Locknut

DO NOT

USE THIS

MOUNTING

HOLE

Extension

Spring

Mounting

Screws

Lower

Mounting

Hole

Suspension

Arm

DO NOT

USE THIS

MOUNTING

SLOT

Lower

Mounting

Slot

Mounting

Screw

DO NOT use this mounting hole. This mounting hole is used to secure the shock assembly.

NOTE: Suspension arm shown is for gearless/brushless motor. The Anti-tip assembly removes/installs in the same manner on the suspension arm used with the conventional motor/gearbox assembly.

FIGURE 17 - REMOVING/INSTALLING THE ANTI-TIP ASSEMBLY

90

FWD WHEELCHAIRS PROCEDURE 17


Removing/Installing Rear Shroud

Removing/Installing Front Shroud

Removing/Installing Side Shroud Assembly

Removing/Installing Counterweight

Replacing Group 24 Battery Box Sub-Frame

Removing/Installing Shocks


Tie Rod Replacement

Removing/Installing Gearbox

Sensor Cable Assembly Replacement

Replacing Suspension Arm

Removing/Installing The Wiring Harness


WARNING

After ANY adjustments, repair or service and BEFORE use, make sure that all attaching hardware is tightened securely otherwise injury or damage may result.

REMOVING/INSTALLING REAR

SHROUD (FIGURE 1)

Removing

1. Turn the two (2) wing nuts COUNTERCLOCKWISE and lift up on the rear shroud.

REMOVING/INSTALLING FRONT

SHROUD (FIGURE 2)

Removing

1. Turn the two (2) wing nuts on the TOP of the front shroud COUNTERCLOCKWISE.

2. Turn the wing nut on the BOTTOM of the front shroud

COUNTERCLOCKWISE and lift up on the front shroud.

Installing

1. Position the front shroud on the wheelchair frame.

2. Align the wing nut on the BOTTOM of the front shroud with the mounting bracket on the wheelchair frame.

3. Align the two (2) wing nuts on the TOP of the front shroud with the mounting holes in the wheelchair frame.

4. Turn the wing nut on the BOTTOM of the front shroud

CLOCKWISE to secure front shroud in place.

5. Turn the two (2) wing nuts on the TOP of the front shroud CLOCKWISE to secure front shroud in place.

Front

Shroud

Wing Nut

Installing

1. Position the rear shroud on the wheelchair frame aligning the two (2) wing nuts with the mounting brackets.

2. Turn the two (2) wing nuts CLOCKWISE to secure rear shroud in place.

Wing

Nut

Wing

Nut

Mounting

Bracket

Wing Nut

FIGURE 2 - REMOVING/INSTALLING FRONT

SHROUD

REMOVING/INSTALLING SIDE

SHROUD ASSEMBLY (FIGURE 3)

Rear

Shroud

FIGURE 1 - REMOVING/INSTALLING REAR

SHROUD

91

Removing

1. Remove the rear shroud. Refer to REMOVING/INSTALL-

ING REAR SHROUD in this procedure of the manual.

2. Remove the drive wheel from the wheelchair. Refer to REMOVING/INSTALLING DRIVE WHEEL in PRO-


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PROCEDURE 17 FWD WHEELCHAIRS

3. Remove the two (2) socket screws that secure the side shroud bracket to the suspension arm.

4. Remove the mounting screw and washer that secures the REAR of the side shroud to the suspension arm.

5. Remove the side shroud assembly.

Installing

1. Position the side shroud on the wheelchair frame.

2. Install the two (2) socket screws that secure the side shroud bracket into the mounting holes of the suspension arm. Securely tighten.

3. Install the mounting screw and washer that secures the REAR of the side shroud to the suspension arm.

4. Repeat STEPS 1-3 for the opposite side shroud assembly, if necessary.

5. Reinstall the drive wheel from the wheelchair. Refer to REMOVING/INSTALLING DRIVE WHEEL in PRO-


6. Reinstall the rear shroud. Refer to REMOVING/IN-

STALLING REAR SHROUD in this procedure of the manual.

Socket

Screws

Front

Mounting

Hole

Mounting

Screw

Rear

Mounting

Hole


COUNTERWEIGHT (FIGURE 4)

WARNING

The sensor on the wheelchair should prevent the wheelchair from operating without the counterweight secured to the rear of the wheelchair. If the wheelchair operates without the counterweight, DO NOT operate the wheelchair. Have the wheelchair serviced by a dealer or qualified technician.

The counterweight weighs 42 pounds. Use proper lifting techniques (lift with your legs) to avoid injury.

Removing



2. While using proper lifting techniques, use ONE hand to firmly grasp the handle and the OTHER hand to firmly grasp the OUTSIDE LOWER EDGE of the counterweight.

3. Pull the outside lower edge toward you, releasing the bottom shoulder screws on the counterweight from the bottom slots in the mounting brackets.

4. Lift the counterweight up and remove the top shoulder screws from the top slots in the mounting brackets.

Washer

Side Shroud Bracket

Suspension Arm

FIGURE 3 - REMOVING/INSTALLING SIDE

SHROUD ASSEMBLY

Installing

1. While using proper lifting techniques, use ONE hand to firmly grasp the handle and the OTHER hand to firmly grasp the OUTSIDE LOWER EDGE of the counterweight.

2. Hold the counterweight at an angle (DETAIL C) and position the top shoulder screws into the top slots on the mounting brackets.

3. Lower the counterweight down until the bottom shoulder screws engage in the bottom slots on the mounting brackets.

4. Push in the bottom rear of the counterweight to secure the counterweight to the wheelchair until it locks into place (DETAIL A).

5. Install the rear shroud. Refer to REMOVING/INSTALL-


92


DETAIL “A” - REMOVING - STEP 2;

INSTALLING - STEP 5

REPLACING GROUP 24 BATTERY

BOX SUB-FRAME (FIGURE 5)

Handle

Removing

Outside

Lower Edge

Counterweight

DETAIL “B” - REMOVING - STEP 3;

Counterweight

INSTALLING - STEPS 3, 4

Bottom Shoulder Screw

Mounting Bracket

DETAIL “C” - REMOVING - STEP 4;

INSTALLING - STEP 2

Counterweight

Top Shoulder

Screw

Bottom Shoulder Screw

Top Slot in

Mounting

Bracket

FIGURE 4 - REMOVING/INSTALLING

COUNTERWEIGHT

Bottom

Slot

Bottom Slot in Mounting Bracket

93



2. Remove the counterweight. Refer to REMOVING/INSTALL-

ING COUNTERWEIGHT in this procedure of the manual.




4. Cut tie wrap A, which secures the sensor cable AND the LEFT motor cable to the battery box sub-frame.

5. Cut tie-wrap B, which secures the battery charger cable

AND the RIGHT motor cable to the battery box sub-frame.

6. Remove the two (2) mounting screws and locknuts that secure the wiring harness w/bracket to the battery box sub-frame.

7. Remove the wiring harness w/bracket from the battery box sub-frame.

8. Remove the four (4) mounting screws and washers that secure the battery box sub-frame to the mounting brackets.

9. Remove the EXISTING sub-frame assembly.

10. Remove the four (4) mounting screws and washers that secure the two (2) mounting brackets to the sub-frame.

11. Install the four (4) mounting screws and washers that secure the two (2) NEW mounting brackets to the sub-frame.

12. Install the four (4) mounting screws that secure the

NEW battery box sub-frame to the mounting brackets. Use Loctite 242 and torque mounting screws to

156-inch pounds.

13. Install the two (2) mounting screws and locknuts that secure the wiring harness w/bracket to the NEW battery box sub-frame. Use Loctite 242 and torque mounting screws to 160-inch pounds.

14. Secure the sensor cable AND the LEFT motor cable to the NEW battery box sub-frame using tie wrap A.

Refer to FIGURE 5 for tie wrap positioning.

15. Secure the battery charger cable AND the RIGHT motor cable to the NEW battery box sub-frame using tie wrap B. Refer to FIGURE 5 for tie wrap positioning.




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17. Reinstall the counterweight. Refer to REMOVING/IN-

STALLING COUNTERWEIGHT in this procedure of the manual.

Mounting Screw

(STEPS 8 and 12)

Battery Box

Sub-frame



Washer (STEP 8 and 12)

Position

Tie Wrap

A Here

REAR OF

CHAIR

Wiring Harness

W/ Bracket

Mounting

Screw

(STEPS 10 and 11) Mounting

Screw

(STEPS 6 and 13)

Mounting

Bracket (Only

One (1) Shown

For Clarity)

Locknut

Position

Tie Wrap

B Here

Washer

(STEP 10 and 11)

Sub-Frame

FRONT OF

CHAIR

FIGURE 5 - REMOVING/INSTALLING GROUP 24 BATTERY BOX SUB-FRAME

REMOVING/INSTALLING SHOCKS

(FIGURE 6)

Removing


STALLING FRONT SHROUD in this procedure of the manual.

2. Remove the rear shroud. Refer to REMOVING/IN-







5. Remove the mounting screw and washer that secures the top of the EXISTING shock to the base frame.

6. Remove the mounting screw and locknut that secures the bottom of the EXISTING shock to the suspension arm.

7. Remove the EXISTING shock.

94

Installing

1. Secure the top of the NEW shock to base frame using the existing washer and mounting screw. Apply

Loctite 242 and torque to 156-inch pounds.

2. Secure the bottom of the NEW shock to the suspension arm with the existing mounting screw and locknut. Apply Loctite 242 and torque to 160-inch pounds.








6. Reinstall the front shroud. Refer to REMOVING/IN-

STALLING FRONT SHROUD in this procedure of the manual.


Base Frame

Washer

7. Secure top of shock and spring retainer to base frame.

Apply Loctite 242 and torque to 160-inch pounds.

8. Reinstall the shock. Refer to REMOVING/INSTALL-

ING SHOCKS in this procedure of this manual.

Mounting Screw

TIE ROD REPLACEMENT (FIGURE 8)

Locknut


(FIGURE 7)

1. Remove the shock. Refer to REMOVING/INSTALL-


2. Hold the spring retainer and turn the shock eyelet assembly counterclockwise to unthread it from the shock.





Shock

Suspension Arm

Mounting Screw

FIGURE 6 - REMOVING/INSTALLING SHOCKS

Removing

1. Remove the front shroud. Refer to REMOVING/INSTALL-

ING FRONT SHROUD in this procedure of the manual.








5. Remove the shocks. Refer to REMOVING/INSTALL-


6. Remove the MKIV controller. Refer to REMOVING/

INSTALLING MKIV CONTROLLER in PROCEDURE

13 of this manual.

7. Remove the locknut, small washer, larger washer and mounting screw that secures the tie rod to the suspension arm.

8. Remove the locknut, small washer, large washer and mounting screw that secures the tie rod to the base frame.

9. Remove the tie rod from the wheelchair.

NOTE: In order to ensure that the replacement tie rod(s) are adjusted properly, it is necessary to remove ALL of the tie rods from the wheelchair and install both the

NEW and the EXISTING tie rods as described in the section below.

10. Repeat STEPS 7-9 to remove the three (3) remaining tie rods.

Shock Eyelet

Assembly

Spring

Retainer

Spring

Spring

Base

Shock


Adjusting/Installing

95

1. Before installing, adjust the collar on one (1) tie rod until the length of the tie rod is approximately five (5) inches (DETAIL A).

NOTE: The length of the tie-rod is measured from the center of one eyelet to the center of the opposite eyelet.

NOTE: Turn the collar CLOCKWISE to shorten the tie rod and COUNTER-CLOCKWISE to lengthen the tie rod.

2. Lock the collar on the tie rod into place by turning the nut on the tie rod until it is FLUSH against the collar (DETAIL A).

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3. Install the tie rod onto the base frame using the mounting screw, large washer, small washer and locknut.

HAND TIGHTEN ONLY.

4. Install the tie rod in the suspension arm using the mounting screw, large washer, small washer and locknut. HAND TIGHTEN ONLY.

5. Repeat STEPS 1-4 to install the three (3) remaining tie rods.

NOTE: To complete proper tie rod adjustment, Perform STEPS 6-7 on the TOP TWO (2) tie rods ONLY.

6. Turn the collar COUNTER-CLOCKWISE for one (1) complete revolution on the TOP TWO (2) tie rods.

7. Lock the collar on the TOP TWO (2) tie rods into place by turning the nuts on the TOP TWO (2) tie rods until they are FLUSH against the collars.

Center 5 inches

8. Securely tighten the tie rods to the base frame AND to the suspension arm. Apply Loctite 242 and torque to

360-inch pounds.

9. Reinstall the MKIV controller. Refer to REMOV-

ING/INSTALLING MKIV CONTROLLER in PRO-


10. Reinstall the shocks. Refer to REMOVING/INSTALL-







13. Reinstall the rear shroud. Refer to REMOVING/INSTALL-


14. Reinstall the front shroud. Refer to REMOVING/INSTALL-

ING FRONT SHROUD in this procedure of the manual.

Tie Rod

Nut

Collar

(Turn CLOCKWISE To

Shorten And COUNTER-

CLOCKWISE To Lengthen)

Center


GEARBOX (FIGURE 9)

CAUTION


DETAIL “A”

Tie Rod

Locknut

Small

Washer

Large

Washer

Base

Frame

Mounting

Screw

Suspension

Arm

Mounting

Screw

Suspension Arm

FIGURE 8 - TIE ROD ASSEMBLIES

Removing








4. Remove the drive wheel from the wheelchair. Refer to REMOVING/INSTALLING DRIVE WHEELS in


5. Remove the side shroud assembly. Refer to REMOV-

ING/INSTALLING THE SIDE SHROUD in this procedure of the manual.

6. Remove the six (6) socket screws that secure the existing motor/gearbox to the suspension arm.

7. Remove existing motor from gearbox. Refer to MO-

TOR REPLACEMENT in PROCEDURE 12 of this manual.

96


Installing

CAUTION

The longer socket screws MUST be positioned in the mounting holes on the OUT-

SIDE of the suspension arm, and the SHORTER socket screws MUST be positioned in the mounting holes on the INSIDE of the suspension arm. Otherwise, damage to the gearbox may result.

1. Install the EXISTING motor onto the NEW gearbox.

Refer to MOTOR REPLACEMENT in PROCEDURE

12 of this manual.

2. Secure the gearbox to the suspension arm using the six (6) socket screws. Use Loctite 242 and torque the socket screws to 75-inch pounds.


3. Reinstall the side shroud assembly. Refer to REPLAC-

ING THE SIDE SHROUD in this procedure of the manual.

4. Reinstall the drive wheels onto the wheelchair. Refer to REMOVING/INSTALLING DRIVE WHEELS in


Suspension

Arm

LONG

Socket

Screw

SHORT

Socket

Screw

Motor

Gearbox

FIGURE 9 - REMOVING/INSTALLING

GEARBOX






7. Reinstall the rear shroud. Refer to REMOVING/INSTALL-


97

SENSOR CABLE ASSEMBLY

REPLACEMENT (FIGURE 10)








4. Cut tie-wrap A, which secures the EXISTING sensor cable to the sensor bracket (DETAIL A).

5. Cut tie-wrap B, which secures the EXISTING sensor cable AND the LEFT motor cable to the battery box sub-frame (DETAILB).

6. Cut tie-wrap C, which secures the EXISTING Lego block connector of the sensor cable and the Lego block connector of the battery wiring harness to the base frame.

7. Disconnect the EXISTING Lego block connector of the sensor cable from the Lego block connector of the battery wiring harness (DETAIL C).

]

8. Remove the two (2) mounting screws, washers and locknuts that secure the EXISTING sensor to the sensor bracket (DETAIL D).

9. Remove the EXISTING sensor cable assembly.

10. Install the two (2) mounting screws, washers and locknuts to secure the NEW sensor to the sensor bracket

(DETAIL D). Securely tighten.

11. Connect the NEW Lego block connector of the sensor cable assembly to the Lego block connector of the wiring harness (DETAIL C).

12. Secure the two (2) Lego block connectors to the base frame with a NEW tie wrap (DETAIL C).

13. Secure the NEW sensor cable AND the LEFT motor cable to the battery box sub-frame with a NEW tie wrap (DETAILB).

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14. Secure the NEW sensor cable to the sensor bracket with a NEW tie wrap (DETAIL A).

15. Reinstall the battery boxes. Refer to INSTALLING/







Sensor

Bracket

Tie Wrap A

DETAIL A

Sensor

Cable

Battery Box

Sub-Frame

Base Frame

Base

Frame

Lego

Block

Connector

Of The

Sensor

Cable

Tie Wrap C

DETAIL C

Lego

Block

Connector

Of The

Battery

Wiring

Harness

FRONT OF

CHAIR

Locknut

Sensor

Bracket

REAR OF

CHAIR

Tie Wrap B

Battery

Box Sub-

Frame

Sensor

Washer

Mounting

Screw

DETAIL D

LEFT Motor

Cable

NOTE: Seat frame and drive wheels removed for clarification purposes ONLY.

FIGURE 10 - SENSOR CABLE ASSEMBLY REPLACEMENT

Sensor

Cable

DETAIL B


(FIGURE 11)



98



FWD WHEELCHAIRS




4. Remove the drive wheel from the wheelchair. Refer to REMOVING/INSTALLING DRIVE WHEELS in


5. Remove the shock. Refer to REMOVING/INSTALL-


6. Remove the tie rods from the EXISTING suspension arm. Refer to TIE ROD REPLACEMENT in this procedure of the manual.

7. Remove the side shroud assembly. Refer to RE-

PLACING SIDE SHROUD ASSEMBLY in this procedure of the manual.

8. Remove the gearbox from the EXISTING suspension arm. Refer to REMOVING/INSTALLING GEARBOX in this procedure of the manual.

9. Remove the locknut, two (2) spacers, two (2) washers and the mounting screw that secures the EXIST-

ING suspension arm to the base frame.

10. Remove EXISTING suspension arm from the base frame.

11. Secure the NEW suspension arm to the base frame using the mounting screw, two (2) washers, two (2) spacers and the locknut. Torque the locknuts to 85

-inch pounds.

12. Reassemble the wheelchair by reversing STEPS 1-8.

Washer

Mounting

Screw

Locknut

Washer

Base

Frame

Spacer

REMOVING/INSTALLING WIRING

HARNESS (FIGURE 12)

Removing




2. Remove the two (2) mounting screws that secure the battery charger port to the mounting bracket and remove the battery charger port (DETAIL A).

3. Remove the two (2) mounting screws and locknuts that secure the wiring harness w/bracket to the battery box sub-frame (DETAIL B).

4. Cut tie-wrap A, which secures the Lego block connectors to the base frame (DETAIL C).

5. Disconnect the Lego block connector of the battery wiring harness from the Lego block connector of the sensor cable assembly (DETAIL C).

6. Cut tie-wrap B, which secures the battery charger cable and the RIGHT motor cable to the battery box sub-frame (DETAIL D).

7. Disconnect the battery harness/charger cable

(BLUE) from the controller connector (BLUE)

(DETAILE).


Installing

1. Connect the battery harness/charger cable (BLUE) to the controller connector (BLUE) (DETAILE).

2. Connect the Lego block connector of the battery wiring harness to the Lego block connector of the sensor cable assembly (DETAIL C).

3. Secure the Lego block connectors to the base frame with a NEW tie wrap (DETAIL C).

4. Install the two (2) mounting screws and locknuts that secure the wiring harness w/bracket to the battery box sub-frame. Use Loctite 242 and torque mounting screws to 160-inch pounds (DETAIL B).

5. Secure the battery charger cable and the RIGHT motor cable to the battery box sub-frame with a NEW tie wrap (DETAIL D).

Spacer

PROCEDURE 17

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Suspension Arm

FIGURE 11 - REPLACING THE SUSPENSION ARM

99

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6. Reinstall the mounting screw that secures the battery charger port to the mounting bracket (DETAILA). Securely Tighten.




Mounting Screws

Base Frame

Wiring

Harness W/

Bracket Battery

Box Sub-

Frame

Locknuts

DETAIL B

Mounting

Bracket

Battery

Charger

Port

Mounting

Screw

Lego

Block

Connector

Of The

Sensor

Cable

Lego Block

Connector

Of The

Battery

Wiring

Harness

Tie Wrap A

DETAIL C

DETAIL A

Tie Wrap B

Battery

Box Sub-

Frame

RIGHT

Motor

Cable

Battery Charger

Cable

DETAIL D

Battery

Harness/

Charger

Cable (Blue)

DETAIL E

FIGURE 12 - REMOVING/INSTALLING WIRING HARNESS

100

Controller

Connector

(Blue)


ADJUSTING WEIGHT

DISTRIBUTION (FIGURE 13)

NOTE: Depending on the seat depth ordered, the position of the seat support brackets is factory set between 2.25 and

6 inches (measured from the front of the base frame to the front of the seat support brackets). This will put approximately

65% of the total weight of the chair and user over the drive wheels (large wheels), allowing for the best performance of the chair.

In order to achieve maximum comfort and maneuverability for the end user, it may be necessary to adjust the seat support brackets slightly forward or backward. It is recommended that the seat support brackets be set as close to

2.25 - 6 inch mark (depending on seat depth) as possible, while allowing maximum comfort and maneuverability to the end user.

Adjusting Weight Distribution For New Seat

Depth

NOTE: When changing the seat depth of the chair, it is necessary to adjust the seat support brackets in order to achieve optimum weight distribution (65%). Perform the following procedure to adjust the seat brackets:

1. Refer to the following chart to determine the correct position of the two (2) seat support brackets to achieve optimum weight distribution (65%).

Seat

Depth

(Inches)

14 to 16 inches

17 to 18 inches

19 to 20 inches

Position Of The Seat Support

Brackets (Inches) To Achieve

Optimum Weight Distribution (65%)

2.25-inches

4.25-inches

6-inches

2. Loosen the four (4) mounting screws that secure the two (2) seat support brackets to the base frame.

3. Adjust the two (2) seat support brackets forward or backward until the position determined in STEP 1 is achieved.

NOTE: When the front of the seat aligns with the controller, approximately 65% of the total weight of the chair and user is over the drive wheels (large wheels).

4. Adjust the two (2) seat brackets slightly forward or backward, until maximum comfort and maneuverability for the end user is acheived.

5. Retighten the four (4) mounting screws securing the two (2) seat support brackets to the base frame.

Seat Support

Brackets

Mounting Screws

Front Of

Base

Frame

2.25 Inches (For a seat depth of 14 to

16 inches)

NOTE: Seat/seat frame not shown for clarity.

FIGURE 13 - ADJUSTING WEIGHT

DISTRIBUTION

INSTALLING 90

o

FOOTBOARD

(FIGURE 14)

WARNING

DO NOT remove detent pin from footrest assembly. Otherwise, injury may result.

1. Remove the existing footrests. Refer to FRONT RIG-

GINGS in PROCEDURE 3 of the Owners manual, part number 1081227.

2. Remove the telescoping front rigging supports. Refer to ADJUSTING/REPLACING TELESCOPING

FRONT RIGGING SUPPORT in PROCEDURE 3 of the Owners Manual, part number 1081227.

3. Remove existing front and rear shrouds. Refer to RE-

MOVING/INSTALLING THE REAR SHROUD and

REMOVING/INSTALLING THE FRONT SHROUD in this procedure of the Manual.

4. Remove the seat. Refer to REMOVING/INSTALLING

THE SEAT FRAME in PROCEDURE 6 of this Manual.

5. Position the 90 o in FIGURE 14.

footboard on the base frame as shown

6. Loosely install one (1) mounting screw into the back of the footboard and into the base frame.

7. Loosely install two (2) mounting screws and washers through the top of the footboard and into the base frame.

8. Torque all three (3) mounting screw between 15 and

19-foot pounds.

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101

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9. Adjust angle of footrest. Refer to FOOTREST ANGLE

ADJUSTMENTS in this procedure of the Manual.

10. Install the seat. Refer to REMOVING/INSTALLING

THE SEAT FRAME in PROCEDURE 6 of this manual.

11. Install NEW front shroud and existing rear shroud.

Refer to REMOVING/INSTALLING THE REAR

SHROUD and REMOVING/INSTALLING THE

FRONT SHROUD in this procedure of the Manual.

12. Install the two (2) end caps provided into the ends of the seat frame where the telescoping front rigging supports were mounted.

13. Adjust footboard. Refer to DEPTH/HEIGHT/ANGLE

ADJUSTMENT in this procedure of the manual.

Mounting

Screw (STEP 6)

Mounting

Screws

(STEP 7)

Washer

90 o Footrest

Support

FOOTBOARD ADJUSTMENTS-

DEPTH/HEIGHT/ANGLE

(FIGURE 15)

WARNING


Depth

1. Remove the four (4) flat screws, washers and locknuts that secure 90 o footboard to the two (2) half clamps.

NOTE: Observe the angle of the footboard for reinstallation.

2. Move footboard to one (1) of two (2) mounting positions.

3. Secure the footboard to the half clamps with the four

(4) flat screws, washers and locknuts. Securely tighten.

Angle

1. Loosen, but do not remove the four (4) flat screws, washers and locknuts that secure the footplate to the half clamps.

2. Position the 90 o footboard to the desired angle.

3. Retighten four (4) flat screws, washers and locknuts.

90 o

Footboard

Flat Screws

Washers

Locknuts

FIGURE 14 - INSTALLING 90 o

FOOTBOARD

Height

1. Remove the two (2) hub caps.

2. Remove the mounting screw, washers, caplug washers, and locknut that secure the footboard to the footrest support.

3. Adjust footboard to desired height.

4. Secure the footboard with the mounting screw, washers, caplug washers, and locknut. Tighten mounting screw and locknut to 12 foot pounds. See

FIGURE 15 for hardware orientation.

102


Two (2)

Mounting

Positions

Footrest

Support

DEPTH

ANGLE/HEIGHT

Side View Of 90 o Footboard

Flat Screws

(Loosen

Here)

Half Clamp

Washer

Flat Screws

Washers

Locknuts

Footboard

Washer/

Locknut

Hub Cap

Locknut

Flat Screws

Washers

Locknuts

Footboard

Caplug Mounting Screw

FIGURE 15 - DEPTH/HEIGHT/ANGLE

ADJUSTMENT

FOOTREST ANGLE ADJUSTMENTS

WARNING


Footrest Angle Adjustment Relative to the

Vertical Position of the Front Shroud

(FIGURE 16)

NOTE: The angle of the footrest relative to the vertical position of the front shroud can be increased or decreased by adjusting both cams located at the top of the footrest support.

1. Loosen the mounting screw and locknut that secure the cams to the upper mounting bracket. Refer to

DETAIL A.

NOTE: Both cams MUST be rotated to the same position to keep the footrest square to the base.

2. Rotate both cams either direction until footrest is at desired angle. Refer to DETAIL B and C

3. Tighten mounting screw and locknut to 12 foot pounds.

Footrest Angle Adjustment Relative to the

Horizontal Position of the Front Shroud

(FIGURE 16)

NOTE: The footrest is factory set to be square to the base when installed. The footrest can be positioned to be out of square by adjusting only one (1) of the cams located at the top of the footrest support.

1. Loosen the mounting screw and locknut that secure the cams to the upper mounting bracket. Refer to DETAIL

A.


NOTE: Right and Left are determined by sitting in the wheelchair.

A. Turning the right cam will rotate the footrest counterclockwise. Refer to DETAIL D.

B. Turning the left cam will rotate the footrest clockwise. Refer to DETAIL D.

3. When footrest is at desired position, tighten mounting screw and locknut to 12 foot pounds.

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FWD WHEELCHAIRS

DETAIL “A”

Cams

Mounting

Screw

Locknut

Upper

Mounting

Bracket

NOTE: Angle is increased or decreased depending on direction of footrest rotation

Cam

DETAIL “C” - SIDE VIEW OF FOOTREST

DETAIL “B”

PROCEDURE 17

Vertical Position of Front Shroud

Direction of

Footrest

Rotation

DETAIL “D” - TOP VIEW OF FOOTREST

Horizontal Position of Front Shroud

Right

Cam

Left

Cam

CLOCKWISE

Footrest

COUNTER-

CLOCKWISE

Direction of

Footrest Rotation

FIGURE 16 - FOOTREST ANGLE ADJUSTMENTS

104

NOTES

NOTES

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NOTES

NOTES

106

LIMTIED WARRANTY

LIMITED WARRANTY

PLEASE NOTE: THE WARRANTY BELOW HAS BEEN DRAFTED TO COMPLY WITH FEDERAL LAW

APPLICABLE TO PRODUCTS MANUFACTURED AFTER JULY 4, 1975.

This warranty is extended only to the original purchaser/user of our products.

This warranty gives you specific legal rights and you may also have other legal rights which vary from state to state.

Invacare warrants seat frame to be free from defects in materials and workmanship for a period of three (3) years from date of purchase; that electrical components are warranted for a period of one (1) year; gearbox/motors for a period of 18 months; and gearless/brushless motors for five (5) years from the date of purchase; and the base frame for the life of the product; all remaining components (including gas cylinders and motor lock pads) for one (1) year from the date of purchase except upholstered materials, padded materials and tires/wheels. If within such warranty period any such product shall be proven to be defective, such product shall be repaired or replaced, at

Invacare's option. This warranty does not include any labor or shipping charges incurred in replacement part installation or repair of any such product. Invacare's sole obligation and your exclusive remedy under this warranty shall be limited to such repair and/or replacement.

This warranty pertains to Arrow Series, Ranger X Series and Torque Series Only!

For warranty service, please contact the dealer from whom you purchased your Invacare product. In the event you do not receive satisfactory warranty service, please write directly to Invacare at the address at the bottom of the back cover. Provide dealer’s name, address, date of purchase, indicate nature of the defect and, if the product is serialized, indicate the serial number. Do not return products to our factory without our prior consent.

LIMITATIONS AND EXCLUSIONS: THE FOREGOING WARRANTY SHALL NOT APPLY TO SERIAL

NUMBERED PRODUCTS IF THE SERIAL NUMBER HAS BEEN REMOVED OR DEFACED, PROD-

UCTS SUBJECTED TO NEGLIGENCE, ACCIDENT, IMPROPER OPERATION, MAINTENANCE OR

STORAGE, COMMERCIAL OR INSTITUTIONAL USE, PRODUCTS MODIFIED WITHOUT

INVACARE'S EXPRESS WRITTEN CONSENT INCLUDING, BUT NOT LIMITED TO, MODIFICA-

TION THROUGH THE USE OF UNAUTHORIZED PARTS OR ATTACHMENTS; PRODUCTS DAM-

AGED BY REASON OF REPAIRS MADE TO ANY COMPONENT WITHOUT THE SPECIFIC CON-

SENT OF INVACARE, OR TO A PRODUCT DAMAGED BY CIRCUMSTANCES BEYOND

INVACARE'S CONTROL, AND SUCH EVALUATION WILL BE SOLELY DETERMINED BY INVAC-

ARE. THE WARRANTY SHALL NOT APPLY TO PROBLEMS ARISING FROM NORMAL WEAR OR

FAILURE TO ADHERE TO THESE INSTRUCTIONS.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS WARRAN-

TIES. IMPLIED WARRANTIES, IF ANY, INCLUDING THE IMPLIED WARRANTIES OF MERCHANT-

ABILITY AND FITNESS FOR A PARTICULAR PURPOSE, SHALL NOT EXTEND BEYOND THE DURA-

TION OF THE EXPRESS WARRANTY PROVIDED HEREIN AND THE REMEDY FOR VIOLATIONS OF

ANY IMPLIED WARRANTY SHALL BE LIMITED TO REPAIR OR REPLACEMENT OF THE DEFEC-

TIVE PRODUCT PURSUANT TO THE TERMS CONTAINED HEREIN. INVACARE SHALL NOT BE

LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES WHATSOEVER.

THIS WARRANTY SHALL BE EXTENDED TO COMPLY WITH STATE/PROVINCIAL LAWS AND RE-

QUIREMENTS.

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I

107

Invacare Corporation www.invacare.com

U S A

One Invacare Way

Elyria, Ohio USA

44036-2125

800-333-6900

Canada

5970 Chedworth Way

Mississauga, Ontario

L5R 3T9, Canada

905-890-8838

Invacare, Storm Series, and Arrow are registered trademarks of

Invacare Corporation.

Yes, You can., Ranger X, and Torque are trademarks of

Invacare Corporation.

Loctite is a registered trademark of Loctite Corporation.

©

2001 Invacare Corporation

Form No. 98-266 Part No. 1081229 Rev C (1)-4/01

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