Invacare Ranger II250, Ranger IIJR, Ranger IISTANDARD, Ranger IIBASIC User Manual

Page 1
Service Manual
Ranger II Storm Series
®
Wheelchairs
MWD/FWD
Ranger II
Ranger II
Ranger II
BASIC
STANDARD
JR
250 SERIES
DEALER: THIS MANUAL MUST BE GIVEN TO THE USER OF THE WHEELCHAIR.
USER: BEFORE USING THIS WHEELCHAIR, READ THIS MANUAL AND SAVE FOR FUTURE REFERENCE.
Page 2
W
A R N
N G
WARNING/SPECIAL NOTES
THE PROCEDURES IN THIS MANUAL SHOULD ONLY BE PERFORMED
DO NOT SERVICE OR OPERATE THIS EQUIPMENT WITHOUT FIRST
READING AND UNDERSTANDING THIS MANUAL AND THE OWNER’S
I
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
WARNING
BY A QUALIFIED TECHNICIAN.
DAMAGE MAY RESULT.
SPECIAL NOTES
S P E C
A L
N O T E S
WARNING/CAUTION notices as used in this manual apply to hazards or unsafe practices which could result in personal injury or property damage.
NOTICE
I
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
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 SEATING POSITIONING STRAP IS REQUIRED TO ENSURE THE SAFE OPERATION OF THIS EQUIPMENT BY THE USER. SERIOUS INJURY MAY OCCUR IN THE EVENT OF A FALL FROM A WHEELCHAIR.
SAVE THESE INSTRUCTIONS
2
Page 3
TABLE OF CONTENTS
The procedures in this manual refer to the following models: RANGER II MWD models: RANGER II BASIC RANGER II FWD models: RANGER II
BASIC
Weight Shift Basic Tilt.
SPECIAL NOTES................................................ 2
SPECIFICA TIONS ............................................... 4
PROCEDURE 1 - GENERAL GUIDELINES .......... 7
REPAIR OR SERVICE INFORMATION ................. 7
OPERATING INFORMATION ............................... 7
WARNING/CAUTION LABEL LOCATION ............ 8
PROCEDURE 2- TROUBLESHOOTING ........... 12
FIELD LOAD TEST .......................................... 12
USING HYDROMETER TO CHECK BATTERY
CELLS (LEAD ACID)..................................... 12
MOTOR TESTING ........................................... 13
MOTOR BRUSH INSPECTION ......................... 14
ELECTRO-MECHANICAL PARKING BRAKE
TESTING ..................................................... 14
PROCEDURE 3 - FRONT RIGGINGS ................ 15
ADJUSTING FLIP-UP REMOVABLE
FOOTBOARD ............................................. 16
ADJUSTING THE REMOVABLE FOOTBOARD . .. 16
PROCEDURE 4 - ARMS .................................... 18
REPLACING ARMREST PADS .......................... 18
REPLACING ARMREST PLATE ........................ 18
PROCEDURE 5 - SEA T/BACK ........................... 19
REPLACING SEAT POSITIONING STRAP .......... 19
REPLACING BACK UPHOLSTERY ................... 19
REPLACING CAPTAIN'S SEAT .......................... 20
PROCEDURE 6 - SEA T FRAME......................... 21
ADJUSTING SEAT DEPTH ................................ 21
ADJUSTING BACK HEIGHT .............................. 21
CHANGING BACK ANGLE ................................ 22
REPLACING BACK CANES .............................. 22
PROCEDURE 7 - ELECTRONICS ..................... 24
REPOSITIONING MKIV JOYSTICK ..................... 24
REMOVING/INSTALLING MKIV CONTROLLER . .. 24
PROCEDURE 8 - LIMIT SWITCH ...................... 27
DISCONNECTING/CONNECTING LIMIT
SWITCH ..................................................... 27
ADJUSTING LIMIT SWITCH ............................... 27
PROCEDURE 9 - WHEELS ............................... 29
REPLACING PNEUMATIC TIRES/TUBES -
DRIVE WHEELS/CASTERS ......................... 29
REMOVING/INSTALLING DRIVE WHEELS ......... 29
REMOVING/INSTALLING DRIVE WHEEL HUB . . 30
REPLACING CASTERS ................................... 32
REPLACING FORKS ....................................... 32
RANGER II STANDARD RANGER II 250
RANGER II
STANDARD
PROCEDURE 10 - SHROUDS ........................... 33
REMOVING/INSTALLING SHROUDS .................. 33
PROCEDURE 11 - CROSSBRACES ................ 37
ADJUSTING SEAT WIDTH - INTEGRATED
REPLACING CROSSBRACES - CAPTAIN’S
PROCEDURE 12 - BATTERIES ....................... 41
INSTALLING/REMOVING BATTERIES INTO/
PROCEDURE 13 - FWD WHEELCHAIRS .......... 46
ASSEMBLING RANGER II FWD ....................... 46
WHEN TO CHARGE BATTERIES ...................... 48
CHARGING BATTERIES ................................... 48
REPLACING BATTERIES ................................. 49
INSTALLING/REMOVING BATTERY BOXES ....... 50
BATTERY TRAY .............................................. 51
REPLACING WIRING HARNESS ..................... 55
REPOSITIONING MOTORS .............................. 59
REPLACING CLUTCH HANDLES - R2 REPLACING MOTOR/GEARBOX - R2 REPLACING MOTOR/GEARBOX -R2
PROCEDURE 14 - MWD WHEELCHAIRS ......... 64
ASSEMBLING RANGER II MWD ....................... 64
WHEN TO CHARGE BATTERIES ...................... 66
CHARGING BATTERIES ................................... 66
REPLACING BATTERIES ................................. 67
INSTALLING/REMOVING BATTERY BOXES ....... 68
BATTERY TRAY .............................................. 69
REPLACING WIRING HARNESS ..................... 71
STABILIZER IDENTIFICATION .......................... 73
ADJUSTING SPRINGS .................................... 73
ADJUSTING STABILIZERS FOR USER
REPLACING STABILIZER CYLINDERS .............. 75
REPLACING STABILIZER WHEELS ................... 76
REPLACING STABILIZER CYLINDER SPRINGS . . 77
REPOSITIONING MOTORS .............................. 78
REPLACING CLUTCH HANDLES
REPLACING MOTOR/GEARBOX -R2 REPLACING MOTOR/GEARBOX -R2
LIMITED WARRANTY ....................................... 83
3
TABLE OF CONTENTS
.
RANGER II
250 Series
and RANGER II with
SLING SEATS ............................................. 37
SEATS ........................................................ 39
FROM BATTERY BOXES ............................ 41
PREFERENCE ........................................... 74
-R2
BASIC
/R2
250 series
..................................................................... 78
SERIES
................. 60
BASIC
................ 61
BASIC
STANDARD
................. 79
BASIC
STANDARD
...... 62
........ 80
T A B L E
O
F
C O N
T E
N
T
S
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SPECIFICATIONS
S P E C
F
C A T
O N S
NOTE: All specifications are approximate.
I
Seat Width Range:
I
I
Seat Depth Range:
Back Height Range Std.: Opt. Headrest: Opt. Backrest Ext.:
Back Angle Range: Seat-to-Floor: Overall Width (No joystick): Overall Height:
Weight
3,6
W/O Batteries: W/Batteries (Gel Cell): Shipping:
Armrests:
Upholstery:
SPECIFICATIONS
RANGER II MWD - R2
INTEGRATED SLING SEAT
16, 18 or 20-inches 16, 17 or 18-in. - in 1-inch increments
(17 and 18-in. by extension)
16, 17, 18, 19 or 20-in. - In 1-in increments N/A N/A
90o to 105o - in 5o increments 18-1/4-inches
24-7/8-inches 34-3/8-in. - 18-in. Back Height
R2
/ R2
BASIC
250 series
110 to 114 lbs. 112 to 116 lbs. 178 to 182 lbs. 190 to 194 lbs. 134 to 153 lbs. 146 to 155 lbs.
Removable, Flip Back, Fixed or Adjustable Height - Desk and Full Length
Black Nylon
R2
STANDARD
BASIC
R2
STANDARD
R2
250 SERIES
CAPTAIN'S SEAT
BACK TYPE
LOW LOW SOLID SEA T HIGH
(LOB) (LOBSS) (HIB)
19-in. 19-in. 19-in. 17-in. 17-in. 17-in.
16-in. 18-in. 22-in.
N/A N/A 28-in.
23-in. N/A N/A
o
(55
- 114o)
2
(98o)
2
(35o - 170o)
22-in. 19-1/2-in. 22-in.
24-3/4-in. 24-3/4-in. 24-3/4-in.
35-in. 35-in. 39-in.
R2
BASIC
/ R2
250 series
R2
STANDARD
131 to 135 lbs. 138 to 142 lbs. 206 to 210 lbs. 213 to 217 lbs. 161 to 165 lbs. 168 to 172 lbs.
Flip Back - Adjustable Height - Full Length (Std.) Vinyl or Cloth with Vinyl (R2
trimmed w/ gray Vinyl)
250 SERIES
1
2
- Gray fabric
INTEGRATED SLING SEAT AND CAPTAIN'S SEAT
Overall Length (Drive wheel in Front Position -
Refer to PERCENT AGE OF
WEIGHT DISTRIBUTION in PROCEDURE
43-1/2-inches 35-1/2-inches
(With 8-in. rear casters (With 8-in. rear casters
and 93 front riggings) and no front riggings)
1 of this manual.)
Front Stabilizers Drive Wheels/Tires: Casters w/Precision Sealed Bearings:
7-inch Urethane 12-1/2 x 2-1/4-in. (Std.); 14-in.x 3-in. (Opt.) (Flat Free or Pneumatic)
8 x 1-3/4-in. Semi Pneumatic (Std.), 8 x 2-in. Pneumatic (Opt.) 6 x 2-in. Semi Pneumatic (Opt.)
Footrest/Legrest: Battery/Size (Not Supplied):
PERFORMANCE R2
Swingaway, Removable Adjustable Flip Up Removable Footboard R2
BASIC
BASIC
/R2
- 22NF Gel Cell (Two (2) Required); R2
STANDARD
R2
250 series
250-SERIES
R2
STANDARD
uses - U1 GEL CELL)
Speed (M.P.H.): 0 to 3.8 0 to 3.6 0 to 5.8 T urning Radius: > 23-inches > 23-inches > 23-inches Range (variable)4: 18-22 miles 12-14 miles 18-22 miles
L Weight Limitation5: 250 lbs. 250 lbs. 300 lbs.
L
NOTE: Refer to PERCENTAGE OF WEIGHT DISTRIBUTION in PROCEDURE 1 of this manual.
Footnotes:
1. High Back not available on model R2
250 SERIES
.
2. Low and High Back Types have an Infinite adjustment. Low Backs with Solid Seat have no adjustment.
3. 18-in. wide x 16-in. deep wheelchair with MKIV RII electronics.
4. Range will vary with battery conditions, surface, ter­rain and operators weight.
5. Includes seating systems and accessories.
6. Weight varies between motors. R2 R2
250 SERIES
have clutches. The R2
STANDARD
motor locks.
4
BASIC
AND
has
Page 5
SPECIFICATIONS
NOTE: All specifications are approximate.
Seat Width Range: Seat Depth Range:
Back Height Range Std.: Opt. Headrest: Opt. Backrest Ext.:
Back Angle Range: Seat-to-Floor: Overall Width (No joystick): Overall Height: Weight
2,5
W/O Batteries: W/Batteries (Gel Cell): Shipping:
Armrests:
Upholstery:
SPECIFICATIONS
RANGER II FWD -R2
INTEGRATED SLING SEAT
16, 18 or 20-inches 16, 17 or 18-in. - In 1-in. increments
(17 and 18-in. by extension)
16, 17, 18, 19 or 20-in. - In 1-in. increments N/A N/A
90o to 105o - in 5o increments 18-1/2-in. 24-5/8-in. 34-3/8-in. - 16-in. Back Height
R2
90 to 100 lbs. 105 to 115 lbs. 170 to 180 lbs. 185 to 195 lbs. 105 to 115 lbs. 120 to 130 lbs.
Removable, Flip Back, Fixed or Adjustable Height - Desk and Full Length
Black Nylon
BASIC
/ R2
250 series
R2
STANDARD
BASIC
R2
STANDARD
R2
250 SERIES
CAPTAIN'S SEAT
BACK TYPE
LOW LOW SOLID SEA T HI GH
(LOB) (LOBSS) (HIB)
19-in. 19-in. 19-in. 17-in. 17-in. 17-in.
16-in. 18-in. 22-in.
N/A N/A 28-in.
23-in. N/A N/A
(55o - 114o)
1
22-in. 19-1/2-in. 22-in.
24-3/4-in. 24-3/4-in. 24-3/4-in.
35-in. 35-in. 39-in.
R2
/ R2
BASIC
250 series
122 to 127 lbs. 138 to 142 lbs. 203 to 207 lbs. 218 to 222 lbs. 153 to 157 lbs. 168 to 172 lbs.
Flip Back - Adjustable Height - Full Length (Std.) Vinyl or Cloth with Vinyl (R2
trimmed w/ gray Vinyl)
(98o)
1
R2
STANDARD
250 SERIES
(35o - 170o)
- Gray fabric
S P E C
I
F
I C A T
1
I O N S
INTEGRATED SLING SEAT AND CAPTAIN'S SEAT
LDRIVE WHEEL POSITION
Overall Length
REAR POSITION MIDDLE POSITION FORW ARD POSITION
With 8-in. rear casters and 93 front riggings:
47-1/4-inches 48-1/4-inches 49-1/4-inches
With 8-in. rear casters and no front riggings:
40-1/2-inches 40-1/2-inches N/A
L
NOTE: Refer to PERCENTAGE OF WEIGHT DISTRIBUTION in PROCEDURE 1 of
this manual.
Drive Wheels/Tires: Casters w/Precision Sealed Bearings:
12-1/2 x 2-1/4-in. (Std.); 14-in.x 3-in. (Opt.) (Flat Free or Pneumatic) 8 x 1-3/4-in. Semi Pneumatic (Std.), 8 x 2-in. Pneumatic (Opt.)
6 x 2-in. Semi Pneumatic (Opt.)
Footrest/Legrest: Battery/Size (Not Supplied):
PERFORMANCE R2
Swingaway, Removable Adjustable Flip Up Removable Footboard 22NF Gel Cell (Two (2) Required); R2
BASIC
R2
250-SERIES
250 SERIES
uses - U1 GEL CELL)
R2
STANDARD
Speed (M.P.H.): 0 to 3.8 0 to 3.6 0 to 4.0 Turning Radius: > 25.8-inches > 25.8-inches > 25.8-inches Range (variable)3: 17-22 miles 12-14 miles 12-16 miles
L Weight Limitation4: 250 lbs. 250 lbs. 300 lbs.
L
NOTE: Refer to PERCENTAGE OF WEIGHT DISTRIBUTION in PROCEDURE 1 of this manual.
Footnotes:
1. Low and High Back Types have an Infinite adjustment. Low Backs with Solid Seat have no adjustment.
2. 18-in. wide x 16-in. deep wheelchair with MKIV RII elec­tronics.
3. Range will vary with battery conditions, surface, ter­rain and operators weight.
4. Includes seating systems and accessories.
5. Weight varies between motors. R2 R2
250 SERIES
have clutches. The R2
BASIC
STANDARD
motor locks.
5
AND
has
Page 6
S P E C
F
C A T
O N S
SPECIFICATIONS
NOTE: All specifications are approximate.
Seat Width Range: 14-inches
I
I
I
Seat Depth Range: 16 to 18-inches - In 1-inch increments (17 and 18-inch by extension) Back Height Range: 16 to 20-inches - In 1-inch increments Back Angle Range: 90 Seat-to-Floor: 18-1/2-inches Overall Width
(No joystick): 20-5/8-inches Overall Height: 34-3/8-inches - 16-inch Back Height
Overall Length LREAR DRIVE POSITION With 8-inch rear casters
and 93 front riggings: 43-1/2-inches
SPECIFICATIONS
RANGER II FWD - R2
INTEGRATED SLING SEAT
o
to 105o - in 5o increments
JR
With 8-inch rear casters and no front riggings: 32-1/2-inches
L
NOTE: Refer to PERCENTAGE OF WEIGHT DISTRIBUTION in
PROCEDURE 1 of this manual.
Drive Wheels/Tires 12-1/2 X 2-1/4-inch (Pneumatic-Standard, Flat Free - Optional) Caster w/Precision
Sealed Bearings: 8 x 1-3/4-inch Semi Pneumatic (Std.), 8 x 2-inch Pneumatic (Opt.)
6 x 2-inch Semi Pneumatic (Opt.)
Footrests/Legrests: Swingaway, Removable Weight
W/O Batteries: 83 lbs. W/Batteries (Gel Cell): 153 lbs.
Shipping: 98 lbs. Armrests: Removable, Flip Back, Fixed or Adjustable Height - Desk and Full Length Upholstery: Black Nylon
Batteries: U1 Gel Cell
1
PERFORMANCE
Speed (M.P.H.): 0 to 3.6 Turning Radius: 24-inches Range (variable)2: 14 miles
L Weight Limitation3: 200 lbs.
L
NOTE: Refer to PERCENTAGE OF WEIGHT DISTRIBUTION in PROCEDURE 1 of this manual.
Footnotes:
1. 14-in. wide x 16-in. deep wheelchair with MKIV RII electronics.
2. Range will vary with battery conditions, surface, terrain and operators weight.
3. Includes seating systems and accessories.
6
Page 7
GENERAL GUIDELINES PROCEDURE 1
This Procedure Includes the Following: Repair or Service Information Operating Information
WARNING
CONTROLLER SETTINGS FOR R2 Set-up of the Electronic Control Unit is to be performed ONLY by qualified technicians.
Factory setting of the controller MUST be used for daily activities. Reprogramming the controller to reflect aggressive settings (i.e. increased acceleration, turning, braking etc..) could cause the wheelchair to tip over resulting in serious injury to the user and/or dam­age to the surrounding property.
REPAIR OR SERVICE INFORMATION Set-up of the Electronic Control Unit is to be performed ONLY by qualified technicians. The final tuning adjustments of the controller may affect other activities of the wheelchair. Damage to the equipment could occur under these circumstances. If any individual other than a qualified technician performs any work on these units, the warranty is void.
OPERATING INFORMATION
JR
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.
G
E N E R A L
G
U
I D E L
I N E S
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.
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 unti.
The use of rubber gloves and safety glasses is recommended when working with batteries. Carefully read battery/battery charger information prior to installing, servicing or operat-
ing your wheelchair. 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.
7
Page 8
GENERAL GUIDELINESPROCEDURE 1
WARNING/CAUTION LABEL LOCATION - MWD MODELS
G
E
N
E R A
L G
U
I
D
E
L
I
N
E S
(R2
BASIC
/R2
STANDARD
/R2
CAUTION
HIGH BACK CAPTAIN'S SEATS ONLY - Disconnect limit switch BEFORE re­moving seat - damage to seat can occur.
250 SERIES
)
NOTE: This warning label is found on mod­els built before 3/1/00. For warning label locations on chairs built after 3/1/00, refer to the warning label on page 11.
Stabilizers may vary depending
on manufacturing date of the
wheelchair
Crossbrace
Push Bracket
Wiring Harness for Battery Box
Lid
8
Page 9
GENERAL GUIDELINES PROCEDURE 1
WARNING/CAUTION LABEL LOCATION - FWD MODELS
(R2
BASIC
Controller
(Back View)
/R2
HIGH BACK CAPTAIN'S SEATS ONLY - Disconnect limit switch BEFORE removing seat - dam­age to seat can occur.
STANDARD
WARNING
Replacement con­troller MUST be SAME part number.
CAUTION
/R2
250 SERIES
NOTE: Caution Label is located on side shroud.
)
Side Frame
G
E
N
E R A
L G
U
I
D
E
L
I
N
E S
Motor
Assembly
Wiring Harness for
Battery Box Lid
CAUTION
Repositioning the motors WILL af­fect the stability and/or perfor­mance of the wheelchair. Refer to PERCENTAGE OF WEIGHT DISTRIBU­TION in the Owner's Manual BEFORE repositioning motors. 1080267
Crossbrace
Push Bracket
NOTE: This warning label is found on models built before 3/1/
00. For warning label locations on chairs built after 3/1/00, refer to the warning label on page 11.
9
Page 10
GENERAL GUIDELINESPROCEDURE 1
WARNING/CAUTION LABEL LOCATION - FWD MODELS (R2JR)
G
E
N
E R A
L G
U
I
D
E
L
I
N
E S
Controller
(Back View)
WARNING
Replacement con­troller MUST be SAME part number.
Side Frame
Motor
Assembly
Battery
Tray
Side Frame
WARNING
Pinch Point
CAUTION
Repositioning the motors WILL af­fect the stability and/or perfor­mance of the wheelchair. Refer to PERCENTAGE OF WEIGHT DISTRIBU­TION in the Owner's Manual BEFORE repositioning motors. 1080267
Wiring Harness
for Battery
Box Lid
10
Page 11
GENERAL GUIDELINES PROCEDURE 1
BATTERY WARNING LABEL LOCATION
WARNING
This POSITIVE (+) RED Battery Cable MUST connect to the POSITIVE (+) Battery Terminal(s)/Post(s), otherwise serious damage will occur to the electrical sys­tem. Refer to the Owners Manual. DO NOT remove this label. 1095558
WARNING
DO NOT allow battery cable(s) to contact the opposite battery terminal(s)/post(s). Re­place cable(s) immediately if cable(s) insu­lation becomes damaged. Failure to observe these warnings may result in an electrical short with serious personal injury resulting. DO NOT remove this label. 1095561
G
E
N
E R A
L G
U
I
D
E
L
I
N
E S
This NEGATIVE (+) BLACK Battery Cable MUST connect to the NEGATIVE (+) Bat­tery Terminal(s)/Post(s), otherwise serious damage will occur to the electrical sys­tem. Refer to the Owners Manual. DO NOT remove this label. 1095559
NOTE: Only U1 battery box top is show for clarity. Warning Labels are located on the group 22 battery box top in the same manner.
NOTE: These warning labels are found on models built after 3/1/00. For warning label locations on chairs built before 3/1/00, refer to specific drive system for the wheelchair.
WARNING
11
Page 12
TROUBLESHOOTINGPROCEDURE 2
This Procedure Includes the Following: Field Load Test
T R O U B
L
E S H O O
T
I N G
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 ONL Y qualified ser-
7. 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.
vice 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. Place a one (1) piece of wood taller than the axle of the drive wheels between the wheelchair and a wall, workbench or other stationary object.
4. Remove the footrests from the wheelchair and place the stabilizer wheels or the front of the wheelchair against the piece of wood.
5. 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.
6. Have two (2) individuals (one [1] on each arm) apply as much downward pressure as possible on the arms of the wheelchair.
The use of rubber gloves and safety glasses is recommended when testing the battery cells.
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.
12
Page 13
TROUBLESHOOTING PROCEDURE 2
WARNING
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 one (1) of the fol­lowing:
FWD WHEELCHAIRS ­BATTERY BOXES in PROCEDURE 13 of this manual.
MWD WHEELCHAIRS ­BATTERY BOXES in PROCEDURE 14 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
INSTALLING/REMOVING
INSTALLING/REMOVING
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 one (1) of the follow­ing:
FWD WHEELCHAIRS -
INSTALLING/REMOVING
BATTERY BOXES in PROCEDURE 13 of this manual.
MWD WHEELCHAIRS -
INSTALLING/REMOVING
BATTERY BOXES in PROCEDURE 14 of this manual.
MOTOR TESTING (FIGURE 3)
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.
T R
O
U B L E S
H O O
T
I
N G
0 Discharged 1 25% Charged 2 50% Charged 3 75% Charged 4 100% Charged
* 5 Overcharged
* Check charging system.
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
Balls Will Vary
According to Charge
Ohmmeter
Motor Connector
FIGURE 3 - MOTOR TESTING
FIGURE 2 - USING A HYDROMETER TO
CHECK BATTERY CELLS (LEAD ACID)
13
Page 14
TROUBLESHOOTINGPROCEDURE 2
MOTOR BRUSH INSPECTION (FIGURE 4)
T R O U B
S H O O
N G
There are two (2) contact brushes on the 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
L
sent to Invacare Technical Services for inspection/repair.
E
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.
T
I
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)
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 (). A read­ing of 0 ohms () 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 should NOT damage a motor.
Cap
Motor
Cap
Motor
4 Pin Motor Connector
FIGURE 4 - MOTOR BRUSH INSPECTION
4 Pin Motor Connector
Ohmmeter
FIGURE 5 - ELECTRO-MECHANICAL
PARKING BRAKE TESTING
14
Page 15
FRONT RIGGINGS
PROCEDURE 3
This Procedure Includes the Following: Adjusting Flip-Up Removable Footboard Adjusting the Removable Footboard
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.
ADJUSTING FLIP-UP REMOVABLE FOOTBOARD
NOTE:This footboard assembly is located on models built BEFORE 3/1/00. Refer to ABLE FOOTBOARD for the footboard assembly on models built AFTER 3/1/00 in this procedure of the manual.
NOTE: The following procedures are for both FWD and MWD wheelchairs, unless otherwise noted.
Angle (FIGURE 1)
NOTE: This procedure is for FWD wheelchair only. NOTE: Angle availability is limited when the motors are in
the forward-most position.
1. Remove the caplug caps.
2. Remove the front hex screw and caplug washer that secure the footboard mounting bracket and bushing to the wheelchair.
3. Repeat STEPS 1-2 for the opposite front hex screw and caplug washer.
4. Move the footboard mounting brackets to one (1) of three (3) positions.
NOTE: To ensure the existing hex screws tighten securely, apply Loctite 242
5. Reinstall the two (2) hex screws and caplug washers through the two (2) footboard mounting brackets and bushings and into the wheelchair.
®
onto the threads.
ADJUSTING THE REMOV-
Wheelchair Frame
6. Torque the two (2) hex screws to 156-in/lbs.
7. Reinstall the two (2) caplug caps.
Height (FIGURE 2)
1. If necessary, remove the four (4) caplug caps.
2. Remove the hex screw, two (2) spacers, washers and locknut that secure one (1) of the footboard pivots to the footboard mounting bracket.
3. Repeat STEP 2 for opposite side of the wheelchair.
4. Move the footboard pivots to one (1) of the following: MWD WHEELCHAIRS: one (1) of seven (7) positions.
FWD WHEELCHAIRS: one (1) of five (5) positions.
HEIGHT - FWD WHEELCHAIRS
Footboard Mounting
Bracket
Flip Up Footboard
Five (5) Mounting Positions
Caplug
Cap
HEIGHT - MWD WHEELCHAIRS
Footboard
Mounting
Bracket
Hex
Screw
Locknut
Footboard Pivot
Hex
Screw
Washer
Seven (7)
Mounting Positions
Washer
F R O N
T R
I G G
I N G S
Bushing
Caplug
Washer
Hex
Caplug
Cap
FIGURE 1 - ADJUSTING FLIP-UP
REMOVABLE FOOTBOARD (ANGLE)
Screw
Footboard
Mounting
Bracket
Locknut
Footboard Pivot
FIGURE 2 - ADJUSTING FLIP-UP
REMOVABLE FOOTBOARD (HEIGHT)
Loctite - Registered Trademark of Loctite Corporation.
15
Flip Up Footboard
Page 16
PROCEDURE 3
FRONT RIGGINGS
F R O N
T R
G G
N G
S
5. Resecure the two (2) footboard pivots to the footboard mounting brackets with the hex screws, spacers, washers and locknuts. Refer to FIGURE 2 for the cor- rect hardware orientation.
6. Torque the two (2) hex screws to 156in/lbs. and back off the hex screws 1/8-1/4 of a revolution.
7. If necessary, reinstall the four (4) caplug caps.
ADJUSTING THE REMOVABLE
I
FOOTBOARD
NOTE:This footboard assembly is available on models
I
built AFTER 3/1/00. Refer to ADJUSTING THE FLIP-UP REMOVABLE FOOTBOARD for the footboard assem­bly on models built BEFORE 3/1/00 in this procedure of the manual.
NOTE: The following procedures are for both FWD and MWD fwheelchairs, unless otherwise noted.
Depth (FIGURE 3)
NOTE: There is no footboard depth adjustment for 16­inch wide MWD wheelchairs.
1. Remove the four (4) flat head screws and barrel nuts that secure the removable footboard to the two (2) footplate clamps.
2. Move the removable footboard to one (1) of the four (4) positions.
Flat Head Screws
Footplate
Clamps
Proper
Footplate
Clamp
Position for
FWD
Wheelchairs
ADJUSTING DEPTH
Removable
Footboard
Mounting Positions
Barrel Nut
Barrel Nut
DET AIL "A"
Proper
Footplate
Clamp
Position for
MWD
Wheelchairs
NOTE: Before reinstalling the four (4) flat head screws, make sure the footplate clamps are in the proper position as shown in DETAIL "A".
3. Reinstall the four (4) flat head screws and barrel nuts that secure the removable footboard to the two (2) footplate clamps. Tighten securely.
Angle ADJUSTING FOOTBOARD ANGLE (FIGURE 3).
1. Loosen, but do not remove, the four (4) flat head screws and barrel nuts that secure the removable footboard to the two (2) footplate clamps.
NOTE: Because of the two (2) support tubes, the angle of the removable footboard can be adjusted downward ONLY.
2. Grasp the front of the removable footboard and rotate it DOWNWARD until the desired angle is reached.
3. While holding the removable footboard in place, tighten the four (4) flat head screws and barrel nuts securely.
ADJUSTING FOOTBOARD ANGLE
Removable
Footboard
FRONT
Footplate
Clamp
FIGURE 3 - ADJUSTING FLIP-UP
REMOVABLE FOOTBOARD
Barrel Nut
Angle Can Be Adjusted
Downward ONLY
Head
Screw
Flat
16
Page 17
FRONT RIGGINGS
PROCEDURE 3
ADJUSTING FOOTBOARD MOUNTING BRACKET ANGLE - FWD MODELS ONLY (FIGURE 4).
NOTE: Angle availability is limited when the motors are in the forward-most position.
1. Remove the caplug cap.
2. Remove the front hex screw and caplug washer that secure the footboard mounting bracket and bushing to the wheelchair.
3. Repeat STEPS 1-2 for the opposite footboard mount­ing bracket.
4. Move the footboard mounting brackets to one (1) of three (3) positions.
NOTE: To ensure the existing hex screws tighten securely, apply Loctite 242 onto the threads.
5. Reinstall the two (2) hex screws and caplug washers through the two (2) footboard mounting brackets and bushings and into the wheelchair.
6. Torque the two (2) hex screws to 13-ft/lbs.
7. Reinstall the two (2) caplug caps.
Battery
Tray
4. Remove the nut, flat washer and that secure the threaded arm on the height adjustment bracket to the footboard bracket. Refer to DETAIL “B”.
5. Perform one (1) of the following: A. MWD WHEELCHAIRS - Move the height adjust-
ment bracket to one (1) of seven (7) height positions.
B. FWD WHEELCHAIRS - Move the height adjustment
bracket to one (1) of five (5) height positions.
6. Reinstall the flat washer and nut that secures the threaded arm on the height adjustment bracket to the footboard bracket. Refer to DETAIL “B”.
7. Reinstall mounting screw, caplug washer, flat washer and nut that secures the two (2) large washers and support tube to the height adjustment bracket and footboard
bracket. Refer to DETAIL “A”.
8. Reinstall the caplug caps.
9. Repeat STEPS 2-8 for the opposite footboard bracket.
10. Reinstall the removable footboard plate. Refer to ING/INSTALLING THE REMOVABLE FOOTBOARD ONTO/FROM THE WHEELCHAIR in PROCEDURE 3 of the Owners Manual.
REMOV-
Nut
Height Adjustment
Bracket
Caplug
Washer
Flat Washer
Two (2) Large
Washers
F R O N
T R
I G G
I N G S
3 Mounting
Positions
Bushing
Caplug
Cap
Footboard
Mounting
Bracket
Front Hex
Screw
Caplug
Washer
FIGURE 4 - ADJUSTING
REMOVABLE FOOTBOARD - ADJUSTING
FOOTBOARD MOUNTING BRACKET ANGLE
Height (FIGURE 5)
1. Remove the removable footboard plate. Refer to PREPARING REMOVABLE FOOTBOARD FOR WHEELCHAIR TRANSPORTATION in PROCE­DURE 3 of the Owners Manual.
2. Remove the caplug cap.
3. Remove the mounting screw, caplug washer, flat washer and nut that secures the two (2) large washers and sup­port tube to the height adjustment bracket and footboard bracket. Refer to DETAIL “A”.
Footboard
Pivot
Assemblies
Caplug
Cap
Mounting
Screw
Footboard
DETAIL “A”
DETAIL “B”
Bracket
Support Tube
Nut
Footboard
Bracket
Flat Washer
Mounting Positions
Height
Adjustment
Bracket
Threaded Arm
NOTE: MWD footboard bracket shown for clarity. Footboard bracket on FWD models adjusts in the same manner.
FIGURE 5 - ADJUSTING FLIP-UP
REMOVABLE FOOTBOARD - HEIGHT
17
Page 18
ARMSPROCEDURE 4
A R M S
This Procedure Includes the Following: Replacing Armrest Pads Replacing Armrest Plate
NOTE: The following procedures are for Captain's seats only.
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 (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.
REPLACING ARMREST PLATE (FIGURE 2)
1. If necessary, remove the three (3) hex bolts, spacers and locknuts that secure the joystick mounting bracket to the armrest plate.
2. Remove armrest pad. Refer to REST PADS in this procedure of the manual.
3. Remove the lug bolt, washers and locknut that secure the existing armrest plate to the seat frame assembly.
4. Position the new armrest plate on the seat frame as­sembly and secure with the lug bolt, washers and lock­nut. Refer to FIGURE 2 for correct hardware orienta­tion.
5. Reinstall armrest pad. Refer to REST PADS in this procedure of the manual.
6. If necessary, reinstall the three (3) hex bolts, 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.
Armrest Plate
Armrest Insert
Armrest Pad
REPLACING ARM-
REPLACING ARM-
Lug Bolt
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.
FRONTREAR
Armrest
Insert
Mounting
Screw
FIGURE 1 - REPLACING ARMREST PADS
Armrest Plate
Armrest
Pad
Mounting
Screw
Phillips Screw
Locknuts
Washers
Hex Bolts
Washers
Seat Frame
Assembly
Joystick Mounting Bracket
FIGURE 2 - REPLACING ARMREST PLATE
Locknuts
Spacers
Phillips
Screw
18
Page 19
PROCEDURE 5SEAT/BACK
This Procedure Includes the Following: Replacing Seat Positioning Strap Replacing Back Upholstery Replacing Captain's seat
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 SEAT POSITIONING STRAP
Captain's Seats (FIGURE 1)
1. Remove the Captain's seat from the wheelchair. Refer to
REMOVING/INSTALLING CAPTAIN'S SEAT in PRO-
CEDURE 5 of the owner's manual, part number
1080722.
2. Remove the two (2) hex bolts, washers and locknuts that secure the seat positioning strap to the seat frame assembly.
3. Remove the two (2) halves of the seat positioning strap from the seat frame assembly.
4. Position the two (2) new seat positioning strap halves on the inside of the seat frame assembly as shown in FIGURE 1.
7. Reinstall the Captain's seat onto the wheelchair. Re­fer to
REMOVING/INSTALLING CAPTAIN'S SEAT in
PROCEDURE 5 of the owner's manual, part number
1080722.
REPLACING BACK UPHOLSTERY (FIGURE 2)
NOTE: The following procedure is for Integrated sling seat wheelchairs only.
1. Flip the armrests up and out of the way. Refer to US­ING/ADJUSTING FLIP BACK ARMRESTS in PRO­CEDURE 4 of the owner's manual, part number
1080722.
2. Cut the tie-wraps that secure the bottom of the exist­ing back upholstery to the wheelchair frame.
3. Remove the two (2) phillips screws and washers that secure the existing back upholstery to the back canes.
4. Remove the two (2) hex bolts, washers and locknuts that secure one (1) back cane to the wheelchair frame.
NOTE: It is necessary to remove only one (1) back cane to replace the back upholstery.
5. Pull the loose back cane out of the existing back upholstery.
6. Pull the existing back upholstery up and over the mounted back cane.
7. Install new back upholstery over mounted back cane.
S E A
T
/
B A C K
5. Position the mounting holes in the two (2) new seat po­sitioning strap halves with the mounting holes in the seat frame assembly.
6. Reinstall the two (2) hex bolts, washers and locknuts that secure the seat positioning strap to the seat frame assembly and tighten securely.
Seat Positioning
Strap
Washer
Locknut
Hex Bolt
FIGURE 1 - REPLACING SEAT POSITIONING
STRAP - CAPTAIN'S SEATS
Seat Frame
Assembly
Washer
Phillips
Screw
Tie Wrap Mounting Holes
Back Cane
Washers
Hex Bolts
(Apply Loctite
242 and torque
to 75-inch
pounds)
FIGURE 2 - REPLACING BACK UPHOLSTERY
Back Upholstery
Locknuts
19
Page 20
PROCEDURE 5 SEAT/BACK
S E A
B A C K
8. Slide the loose top half of the back cane through the new back upholstery.
9. Using the mounted back cane as a guide, reinstall the two (2) hex bolts that secure the top half of the back cane to the bottom half of the back cane.
NOTE: Make sure the back canes are mounted to the same height.
T
WARNING
/
The top and bottom half of the back canes MUST be tightened securely together BE­FORE using the wheelchair, otherwise in­jury or damage may occur. Use Loctite 242 on the hex bolts and torque to 75-inch pounds.
10. Use Loctite 242 on the hex bolts and torque into the back canes to 75-inch pounds.
11. While holding the hex bolt, reinstall the locknut and torque to 75-inch pounds.
12. Repeat STEP 11 for the other hex bolt and locknut.
REPLACING CAPTAIN'S SEAT (FIGURE 3)
1. Remove the Captain's seat from the wheelchair. Refer
to REMOVING/INSTALLING CAPTAIN'S SEAT in PRO- CEDURE 5 of the owner's manual part number
1080722.
2. Remove the four (4) hex screws and washers that secure the existing captain's seat to the seat frame assembly.
3. Line up mounting holes in the new captain's seat with mounting holes in the seat frame assembly.
4. Apply Loctite 242 to the hex screws.
5. Install the four (4) hex screws and washers through the seat frame assembly and into the new captain's seat. Tighten securely.
6. Install the new captain's seat onto the wheelchair. Re-
REMOVING/INSTALLING CAPTAIN'S SEAT in
fer to PROCEDURE 5 of the owner's manual, part number
1080722.
13. Securely tighten the new back upholstery to the back canes with the two (2) phillips screws and washers.
14. Secure the bottom of the new back upholstery to the wheelchair frame with tie-wraps.
NOTE: Clean upholstery with warm DAMP cloth and mild detergent to remove superficial soil.
WARNING
Laundering or moisture will reduce flame retardation of the upholstery.
Captain's Seat
Seat Frame
Assembly
Washers
Hex Screws (Apply
FIGURE 3 - REPLACING CAPTAIN'S SEAT
Seat Frame
Assembly
Loctite 242)
20
Page 21
PROCEDURE 6SEAT FRAME
This Procedure Includes the Following: Adjusting Seat Depth Adjusting Back Height
Changing Back Angle Replacing Back Canes
NOTE: The instructions in this procedure are for IN­TEGRATED SLING SEAT wheelchairs ONLY.
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.
ADJUSTING SEAT DEPTH (FIGURE 1)
1. Remove the existing seat upholstery from the wheel­chair. Refer to REPLACING SEAT UPHOLSTERY in PROCEDURE 5 of the owner's manual, part number
1080722.
NOTE: If adjusting seat depth of the wheelchair, the seat upholstery MUST be changed as well.
2. Remove the two (2) plug buttons from the ends of the crossbraces that are towards front of wheelchair.
NOTE: Make sure to line up the mounting holes in the seat extension tubes with the new seat upholstery.
5. Install plug buttons into ends of the seat extension tubes.
ADJUSTING BACK HEIGHT (FIGURE 2)
1. Remove the two (2) hex bolts, washers and locknuts that secure the top half of the back cane to the bottom half of the back cane.
2. Reposition the back cane to one (1) of five (5) pairs of height adjustment holes:
HOLE P AIR # 1 2345
Back Height (in inches) 16 17 18 19 20
Holes numbered from bottom to top for reference only.
(There are no numbers on the back canes.)
3. Reinstall the two (2) hex bolts that secure the top half of the back cane to the bottom half of the back cane.
WARNING
The top and bottom half of the back canes MUST be tightened securely together BE­FORE using the wheelchair, otherwise in­jury or damage may occur. Use Loctite 242 on the hex bolts and torque to 75-inch pounds.
S E A
T
F R A M E
NOTE: The two (2) plug buttons will be used in the ends of the seat extensions.
3. Install the two (2) seat extension tubes into the ends on
the crossbraces. Line up the second mounting hole from the rear of the seat extension tube with the front mounting hole in the crossbrace.
4. Install the new seat upholstery onto the wheelchair. Refer to CEDURE 5 of the owner's manual, part number
1080722.
Phillips
Screws
Crossbrace
Seat Extension Tube
REPLACING SEAT UPHOLSTERY in PRO-
Washer
Plug Button
4. Use Loctite 242 on the hex bolts and torque into the back canes to 75-inch pounds.
5. While holding the hex bolt, reinstall the locknut and torque to 75-inch pounds.
6. Repeat STEP 5 for the other hex bolt and locknut.
7. Repeat STEPS 1-6 for the opposite back cane.
HOLE
PAIR #
5 4 3 2 1
Hex Bolts (Apply
Loctite 242 and torque
to 75-inch pounds)
FIGURE 2 - ADJUSTING BACK HEIGHT
Top Half of
Back Cane
Locknuts
Bottom Half
of Back Cane
FIGURE 1 - ADJUSTING SEAT DEPTH
21
Page 22
SEAT FRAMEPROCEDURE 6
S E A
T
F R A M E
CHANGING BACK ANGLE (FIGURE 3)
1. Flip the armrests up and out of the way. Refer to US­ING/ADJUSTING FLIP BACK ARMRESTS in PRO­CEDURE 4 of the owner's manual, part number
1080722.
2. Remove the TOP hex bolt, two (2) washers and lock­nut that secure the back cane to the mounting plate on the wheelchair frame.
3. Refer to DETAIL "B" in FIGURE 3 to determine the mounting plate hole for the desired back angle.
4. Reposition the back cane to the position determined in STEP 3.
5. Reinstall TOP hex bolt, two (2) washers and locknut. Refer to FIGURE 3 for correct hardware orientation.
WARNING
The back canes MUST be tightened se­curely to the wheelchair frame BEFORE using the wheelchair, otherwise injury or damage may occur. Use Loctite 242 on the hex bolt and torque to 75-inch pounds.
6. Use Loctite 242 on the hex bolt and torque the hex bolt to 75-inch pounds.
7. Repeat STEPS 2-6 for opposite side of wheelchair.
Washers
TOP Hex Bolt
(Apply Loctite
242 and torque
to 75-inch
pounds)
O
90
DETAIL "B"
O
95
100
O
Locknut
Washers
105
O
REPLACING BACK CANES (FIGURE 4)
Top Half of Back Canes
1. Flip the armrests up and out of the way. Refer to ING/ADJUSTING FLIP BACK ARMRESTS in PRO­CEDURE 4 of the owner's manual, part number
1080722.
NOTE: If the back height of the wheelchair is staying the same, note the position of the existing top half of the back cane(s) before removing from the wheelchair.
2. Remove the phillips screw and washer that secure the back upholstery to the existing top half of the back cane.
3. Slide the back upholstery up to expose the two (2) hex bolts, washers and locknuts.
4. Remove the two (2) hex bolts, washers and locknuts that secure the existing top half of the back cane to the bottom half of the back cane.
5. Remove the existing top half of the back cane from the bottom half of the back cane.
6. Perform one (1) of the following: A. Install the new top half of the back cane through
the back upholstery and into the bottom half of the back cane at the existing position noted.
B. Install the new top half of the back cane through the
back upholstery and into the bottom half of the back cane to one (1) of the following new positions:
HOLE P AIR # 12345
Back Height (in inches) 16 17 18 19 20
Holes numbered from bottom to top for reference only.
(There are no numbers on the back canes.)
7. Reinstall the two (2) hex bolts that secure the new top half of the back cane to the bottom half of the back cane.
WARNING
The top and bottom half of the back canes MUST be tightened securely together BE­FORE using the wheelchair, otherwise in­jury or damage may occur. Use Loctite 242 on the hex bolts and torque to 75-inch pounds.
US-
FIGURE 3 - CHANGING BACK ANGLE
8. Use Loctite 242 on the hex bolts and torque into the back canes to 75-inch pounds.
9. While holding the hex bolt, reinstall the locknut and torque to 75-inch pounds.
10. Repeat STEP 9 for the other hex bolt and locknut.
22
Page 23
PROCEDURE 6SEAT FRAME
11. Securely tighten back upholstery to the new top half of the back cane with the phillips screw and washer.
12. Repeat STEPS 2-11 for the opposite side of the wheel- chair, if necessary.
Bottom Half of Back Canes
1. Flip the armrests up and out of the way. Refer to ING/ADJUSTING FLIP BACK ARMRESTS in PRO­CEDURE 4 of the owner's manual, part number
1080722.
2. Remove phillips screw and washer that secure back upholstery to the existing top half of the back cane.
3. Slide the back upholstery up to expose the two (2) hex bolts, washers and locknuts.
4. Remove the two (2) hex bolts, washers and locknuts that secure the top half of the back cane to the existing bottom half of the back cane.
5. Remove the top half of the back cane from the existing bottom half of the back cane.
US-
NOTE: If the back angle of the wheelchair is staying the same, note the position of the existing bottom half of the back cane(s) before removing from the wheelchair.
6. Remove the two (2) hex bolts, four (4) washers and two (2) locknuts that secure the bottom half of the back cane to the wheelchair.
7. Remove the existing bottom half of the back cane from the wheelchair.
NOTE: The existing insert will be reused.
12. Use Loctite 242 on the hex bolts and torque the hex bolts to 75-inch pounds.
13. Securely tighten back upholstery to the top half of the back cane with the phillips screw and washer.
14. Repeat STEPS 2-13 for the opposite side of the wheel- chair, if necessary.
HOLE
PAIR #
5 4 3 2 1
Washers
Top Half of
Back Cane
Locknuts
Hex Bolts (Apply
Loctite 242 and
torque to 75-inch
pounds)
Bottom Half
of Back
Cane
Insert
Locknuts
Washers
Wheelchair
Washers
Frame
S E A
T
F R A M E
8. Remove the insert from the existing bottom half of the back cane.
9. Install the insert into the new bottom half of the back cane and line up the mounting holes.
10. Install the new bottom half of the back cane onto the wheelchair at the position noted.
NOTE: If the back angle needs to be changed, refer to
CHANGING BACK ANGLE
11. Reinstall the two (2) hex bolts, four (4) washers and two (2) locknuts that secure the new bottom half of the back cane to the wheelchair.
in this procedure of the manual.
WARNING
The back canes MUST be tightened se­curely to the wheelchair frame BEFORE using the wheelchair, otherwise injury or damage may occur. Use Loctite 242 on the hex bolts and torque to 75-inch pounds.
FIGURE 4 - REPLACING BACK CANES
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PROCEDURE 7
ELECTRONICS
E
L E C
T R O N
C S
This Procedure Includes the Following: Repositioning MKIV Joystick Removing/Installing MKIV Controller
WARNING
After ANY adjustments, repair or service and BEFORE use, make sure all attaching hardware is tightened securely - other­wise injury or damage may result.
REPOSITIONING MKIV JOYSTICK
Captain’s Seats (FIGURE 1)
I
1. Turn the lever on the adjustment lock to release the adjustment lock from joystick mounting tube.
2. Remove the joystick from the wheelchair.
3. Remove the three (3) hex bolts, spacers and locknuts that secure joystick mounting bracket to armrest plate.
4. Remove the phillips screw 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 seat frame assembly.
8. Repeat STEPS 4-7 for opposite side of wheelchair.
9. Position armrest plate with joystick mounting holes on desired side of seat frame assembly and secure with lug bolt, washers and locknut. Refer to FIGURE 1.
10. Position armrest plate without joystick mounting holes on opposite side of seat frame assembly and secure with lug bolt, washers and locknut. Refer to FIGURE 1.
Armrest Plate
Armrest Insert
Phillips Screw
(STEPS 5, 13)
Locknuts
(STEPS 7, 9)
Washers
(STEPS 7, 9)
Hex Bolts
(STEPS 3, 16)
Adjustment Lock
Washers
Seat Frame Assembly
FIGURE 1 - REPOSITIONING MKIV JOYSTICK
(STEPS 7, 9)
- CAPTAINS SEATS
Armrest Pad
(STEPS 7, 9)
(STEPS 3, 17)
(STEPS 4, 14)
(STEPS 3, 17)
Lug Bolt
Locknuts
Phillips Screw
Spacers
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 armrest pad and tighten securely.
15. Repeat STEPS 11-14 for opposite side of wheelchair.
16. Install Loctite 242 onto the three (3) hex bolts.
17. Install the three (3) hex bolts, spacers and locknuts that secure joystick mounting bracket to armrest plate.
18. Slide the joystick mounting tube through the joystick mounting bracket to the desired position.
19. Secure adjustment lock to joystick mounting tube by turning lever on adjustment lock.
REMOVING/INSTALLING MKIV CONTROLLER
WARNING
Replacement controller MUST be same part number as factory installed controller ­Otherwise, injury or damage may result.
16, 18, or 20-inch Wide Models (FIGURE 2) REMOVING.
1. If necessary, remove the rear shroud and rear compart­ment (if equipped). Refer to SHROUDS in PROCEDURE 10 of this manual.
2. Remove the battery boxes. Refer to INSTALLING THE BATTERY BOXES for one (1) of the following:
FWD WHEELCHAIRS - in PROCEDURE 13 of this manual.
MWD WHEELCHAIRS - in PROCEDURE 14 of this manual.
3. Disconnect the following connections: A. The right hand motor and controller connection. B. The left hand motor and controller connection. C. Battery wiring harness and controller connection.
4. Remove the two (2) locknuts that secure the existing MKIV controller and washer(s) to the wheelchair.
5. Remove existing MKIV controller from the wheelchair.
INSTALLING.
1. Install washer(s) onto rear mounting stud.
2. Install new/existing MKIV controller onto wheelchair frame.
REMOVING/INSTALLING
REMOVING/
24
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PROCEDURE 7ELECTRONICS
3. Secure the new/existing MKIV controller to the wheel­chair with NEW locknuts. Torque to 156-in/lbs.
4. Connect the following connections: A. The right hand motor and controller connection. B. The left hand motor and controller connection. C. Battery wiring harness and controller connection.
5. Install the battery boxes. Refer to ING THE BATTERY BOXES for one (1) of the follow­ing:
FWD WHEELCHAIRS - in PROCEDURE 13 of this manual.
MWD WHEELCHAIRS - in PROCEDURE 14 of this manual.
6. If necessary, install the rear shroud and rear compart­ment (if equipped). Refer to SHROUDS in PROCEDURE 10 of this manual.
REMOVING/INSTALL-
REMOVING/INSTALLING
Mounting Stud on
Wheelchair Frame
Washer
MKIV
Controller
4. Disconnect the following connections: A. The right hand motor and controller connection. B. The left hand motor and controller connection. C. Battery wiring harness and controller connection.
5. Cut the tie-wrap that secure the the left hand motor cable and controller cable together.
6. Remove the two (2) locknuts that secure the existing MKIV controller and washer(s) to the wheelchair.
7. Remove existing MKIV controller from the wheelchair.
INSTALLING.
1. On models without shrouds, install washer onto rear mounting stud.
2. Install new/existing MKIV controller onto wheelchair frame.
3. Secure the new/existing MKIV controller to the wheel­chair with NEW locknuts. Torque to 156-in/lbs.
4. Connect the following connections: A. The right hand motor and controller connection. B. The left hand motor and controller connection. C. Battery wiring harness and controller connection.
E
L E C
T R O N
I C S
Washer -
MWD
Locknuts
FIGURE 2 - REMOVING/INSTALLING MKIV
CONTROLLER - 16,18, 20-INCH WIDE
MODELS
14-inch Wide Models (FIGURE 3) REMOVING.
1. Remove the front and rear shrouds. Refer to
MOVING/INSTALLING SHROUDS in PROCEDURE 10 of this manual.
2. Remove the battery boxes. Refer to INSTALLING THE BATTERY BOXES in PROCE­DURE 12 of this manual.
3. Cut the tie wrap that secure the following connections to the wire connector support:
A. The right hand motor and controller connection.
Only
RE-
REMOVING/
NOTE: See FIGURE 3 for proper positioning of the con­nections noted in STEP 4 on the wire connector support.
5. Secure the connections noted in STEP 4 to the wire connector support with a tie-wrap
NOTE: Make sure to thread tie-wrap around crossbrace and through slot in wire connector support.
6. Secure the left hand motor cable and the controller cable to the crossbrace with a tie-wrap .
7. Install the battery boxes. Refer to STALLING THE BATTERY BOXES in PROCE­DURE 12 of this manual.
8. Install the front and rear shroud. Refer to INSTALLING SHROUDS in PROCEDURE 10 of this manual.
REMOVING/IN-
REMOVING/
B. The left hand motor and controller connection. C. Battery wiring harness and controller connection.
(BLUE)
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E
L E C
T R O N
C S
PROCEDURE 7 ELECTRONICS
Mounting Stud on
Wheelchair Frame
Washer
MKIV
Controller
Locknuts
I
Slot
Tie-Wrap
Tie-Wrap
Battery Wiring Harness
and Controller Connection
(BLUE)
Motor Cable
Right Hand Motor/Controller
Connection
Left Hand Motor/Controller
Connection
Wire Connector Support
FIGURE 3 - REMOVING/INSTALLING MKIV CONTROLLER - 14-INCH WIDE MODELS
MKIV
Controller
Controller
Cable
Left Hand
26
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PROCEDURE 8LIMIT SWITCH
This Procedure Includes the Following: Disconnecting/Connecting Limit Switch Adjusting Limit Switch
WARNING
After ANY adjustments, repair or service and BEFORE use, make sure all attaching hardware is tightened securely - other­wise injury or damage may result.
DISCONNECTING/CONNECTING LIMIT SWITCH (FIGURE 1)
NOTE: The following procedure is for High Back Captain's seat model wheelchairs only.
CAUTION
Disconnect limit switch BEFORE removing seat or damage to switch may occur.
1. Perform one (1) of the following: DISCONNECTING - While holding the body of the
limit switch phono plug, lift up gently.
NOTE: When the limit switch is unplugged the wheel­chair will NOT operate.
CONNECTING - Plug limit switch plug into
the limit switch phono jack.
ADJUSTING LIMIT SWITCH (FIGURE 2)
NOTE: The following procedure is for High Back Captain's seat model wheelchairs only.
WARNING
NEVER operate the wheelchair while in any recline position over 114o RELATIVE TO THE SEAT FRAME. If the limit switch does not stop the wheelchair from operating in a recline position greater than 114 RELATIVE TO THE SEAT FRAME, DO NOT op­erate the wheelchair. Adjust the limit switch or have the wheelchair serviced by a dealer or qualified technician, oth­erwise injury or damage may occur.
1. Place the wheelchair on a level surface.
o
2. Recline the captain's seat back to a 24 the 114 JUSTING CAPTAIN'S SEAT in PROCEDURE 5 of the owner's manual, part number 1080722.
o
angle relative to the seat frame. Refer to AD-
to achieve
NOTE: The captain's seat frame is at a 5o angle relative to the ground. When the back angle is adjusted to 114 relative to the seat, it will measure 61o 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 3 and ad­just the back until the magnetic protractor reads 61o.
o
o
L
I
M
I
T
S
W
I
T C H
MWD
FWD
Limit Switch Phono Plug
Body
Limit Switch Phono Jack
FIGURE 1 - DISCONNECTING/CONNECTING
LIMIT SWITCH
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
CAPTAIN'S SEAT in PROCEDURE 5 of the owner's manual, part number 1080722.
ADJUSTING
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 wheel-
chair).
CAUTION
DO NOT over tighten the phillips screws that secure the actuator to the upper limit switch bracket. Damage to the actuator may occur.
27
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L
M
T
S
W
T C H
PROCEDURE 8 LIMIT SWITCH
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.
I
I
E. Repeat STEPS 1-3 until the wheelchair does not
operate when the captain's seat back is at a 24 angle.
24o Back
o
o
114
Recline Angle
I
5-3/4 inches
Magnetic Protractor - (Will
read 61o when back recline
angle is at 114o relative to the
seat frame)
Upper Limit
Switch
Bracket
Phillips
Screws,
Washers
and Lock-
nuts
Actuator
61
o
5o Seat Angle
FIGURE 2 - ADJUSTING LIMIT SWITCH
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Page 29
PROCEDURE 9WHEELS
This Procedure Includes the Following: Replacing Pneumatic Tires/Tubes -
Drive Wheels/Casters Removing/Installing Drive Wheels Removing/Installing Drive Wheel Hub Replacing Casters Replacing Forks
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 a qualified technician.
INSTALLING.
NOTE: The keystock in the wheel hub MUST lineup with the cutout in the gearbox drive shaft.
1. Install new/existing front wheel onto the motor drive shaft. Make sure the chamfered (angled in) side of the wheel hub is pointing away from the wheelchair.
2. Install washer onto motor drive shaft.
3. Install the NEW locking tab washer onto the motor drive shaft. Make sure the locking tab is in line with the keyway of the front wheel.
4. Apply Loctite 242 to the hex screw.
5. Install the hex screw. Use a torque wrench only and torque to 90-inch pounds.
Keystock
Chamfered
Side of Wheel
Hub
Locking Tab
Washer
Keyway
Motor
Driveshaft
W
H E E L S
NOTE: If drive wheels or casters are pneumatic, under­inflation causes excessive wear which results in poor per­formance of the tires.
REMOVING/INSTALLING DRIVE WHEELS
WARNING
NEVER use a locking tab washer more than once. ALWAYS use a NEW locking tab washer when installing the drive wheels.
12-inch Drive Wheel (FIGURE 1) REMOVING.
1. The tab of the locking washer that is bent 90 against the head of the mounting screw MUST be flattened before the mounting screw can be removed.
2. Remove the hex screw, locking tab washer and washer that secure the existing front wheel to the wheel hub.
3. Use a wheel puller to remove the existing front wheel from the motor drive shaft.
o
up
Washer
Hex Screw (Apply Loctite 242 and use a Torque
Wrench only to Torque to 90-inch pounds)
TIGHTEN Hex Screw if Locking Tab is not
Parallel with Flat on Head
Flat on Head
of Hex Screw
Locking
Tab
Bend Tab up tight against Flat on
Head of Hex Screw
FIGURE 1 - REMOVING/INSTALLING 12-
INCH DRIVE WHEELS
(STEP 9)
Locking Tab Parallel
with Flat on Head of
Hex Screw
(STEP 9)
(STEP 10)
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PROCEDURE 9 WHEELS
W
H E E L S
6. Examine the head of the hex screw and the locking tab washer. Make sure one (1) of the tabs on the locking tab washer is parallel with one (1) of the flats on the head of the hex screw.
7. If one (1) of the tabs on the locking tab washer is NOT parallel with one (1) of the flats on the head of the hex screw (FIGURE 1), TIGHTEN the hex screw until the closest flat and locking tab are parallel.
NOTE: Tighten hex screw only. DO NOT loosen hex screw to make one of the tabs on the locking washer parallel.
8. Bend the parallel tab of locking tab washer up tight against flat of the hex screw (FIGURE 1).
14-inch Drive Wheel (FIGURE 2) REMOVING.
1. Remove the battery boxes. Refer to I REMOVING BATTERY BOXES for one (1) of the following:
FWD WHEELCHAIRS - in PROCEDURE 13 of this manual.
MWD WHEELCHAIRS - in PROCEDURE 14 of this manual.
2. Remove the four (4) beveled locknuts that secure the drive wheel to the wheel hub.
NSTALLING/
INSTALLING.
1. Install drive wheel onto wheel hub
2. Secure the drive wheel onto the drive wheel hub with the existing four (4) beveled locknuts. Torque locknuts to 160­inch pounds.
3. Repeat STEPS 1-2 for opposite side if necessary.
4. Install the battery boxes. Refer to I ING BATTERY BOXES for one (1) of the following:
FWD WHEELCHAIRS - in PROCEDURE 13 of this manual.
MWD WHEELCHAIRS - in PROCEDURE 14 of this manual.
NSTALLING/REMOV-
REMOVING/INSTALLING DRIVE WHEEL HUB (FIGURE 3)
NOTE: Drive wheel hubs are only on 14-inch drive wheels.
WARNING
NEVER use a locking tab washer more than once. ALWAYS use a NEW locking tab washer when installing the drive wheels.
Removing
3. Remove the existing drive wheel from the wheel hub.
Wheel Hub
Drive Wheel Assembly
Four (4) Beveled
Hex Nuts
FIGURE 2 - REMOVING/INSTALLING 14-
INCH DRIVE WHEELS
Assembly
1. Remove the drive wheels. Refer to STALLING THE DRIVE WHEELS in this procedure of the manual.
NOTE: The tab of the locking washer that is bent 90o up against the head of the mounting screw MUST be flattened before the mounting screw can be removed.
2. Flatten the tab of the locking washer that is bent 90o up against the head of the mounting screw.
3. Remove the mounting screw, locking tab washer and washer that secure the existing drive wheel to the wheel hub.
4. Remove the wheel hub and keystock from drive shaft.
Installing
1. Position the keystock on the drive shaft
REMOVING/IN-
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.).
30
Page 31
2. Apply a thin film of anti-seize compound one (1) inch in length to the end of the drive shaft.
PROCEDURE 9WHEELS
Keystock
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. Install the washer and NEW locking tab washer onto the wheel hub. Make sure the locking tab is in line with the keyway of the wheel hub.
5. Apply Loctite 242 to the mounting screw.
6. Install the mounting screw. Use a torque wrench only and torque to 90-inch pounds.
7. Examine the head of the hex screw and the locking tab washer. Make sure one (1) of the tabs on the locking tab washer is parallel with one (1) of the flats on the head of the hex screw.
8. If one (1) of the tabs on the locking tab washer is NOT parallel with one (1) of the flats on the head of the hex screw (FIGURE 1), TIGHTEN the hex screw until the closest flat and locking tab are parallel.
NOTE: Tighten hex screw only. DO NOT loosen hex screw to make one of the tabs on the locking washer parallel.
9. Bend the parallel tab of locking tab washer up tight against flat of the hex screw (FIGURE 1).
10. Reinstall the drive wheel onto the wheel hub. Refer to REMOVING/INSTALLING DRIVE WHEELS in this pro- cedure of the manual.
11. Repeat procedure for the opposite side of the wheel­chair, if necessary.
Locking
Washer
Mounting
Screw
Keyway
Washer
Mounting Screw (Apply Loctite 242 and use a
Torque Wrench only to Torque to 90-inch pounds)
TIGHTEN Hex Screw if Locking Tab is not
Parallel with Flat on Head
Flat on Head
of Hex Screw
Locking
Tab
Bend Tab up tight against Flat on
Head of Hex Screw
FIGURE 3 - REMOVING/INSTALLING DRIVE
WHEEL HUB
(STEP 9)
Locking Tab Parallel
with Flat on Head of
Hex Screw
(STEP 10)
Drive Shaft
(STEP 9)
W
H E E L S
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PROCEDURE 9 WHEELS
W
H E E L S
REPLACING CASTERS (FIGURE 4)
1. Remove the hex screw, washers and locknut that secure the caster to the fork.
2. Remove the caster from the fork.
3. Install Loctite 242 onto the hex screw.
4. Replace caster and reverse STEPS 1-3.
5. Torque the locknut to 120-inch pounds.
6. Loosen the locknut 1/8 of a turn.
7. Move the caster side to side.
NOTE: If the caster moves side to side, tighten the locknut slightly. Repeat STEP 7 until there is no side to side movement of the caster.
Fork
Hex Screw
Locknut
NOTE: Check bearing assemblies and replace if nec­essary.
7. Ensure that new fork slides completely into the caster head tube.
8. Install nylon washer and secure with locknut.
WARNING
Improper positioning of the washer will prohibit the free movement of the forks.
9. Install Loctite 242 onto the hex screw.
10. Position the caster into the new fork.
11. Reinstall the hex screw, washers and locknut that secure the caster to the new fork.
12. Torque the locknut to 120-inch pounds.
13. Loosen the locknut 1/8 of a turn.
14. Move the caster side to side.
NOTE: If the caster moves side to side, tighten the locknut slightly. Repeat STEP 14 until there is no side to side movement of the caster.
Washer
Washer
FIGURE 4 - REPLACING CASTERS
Caster
REPLACING FORKS (FIGURE 5)
1. Remove the hex screw, washers and locknut that secure the caster to the existing fork.
2. Remove the caster from the existing fork.
3. Remove the dust cover.
4. Remove the locknut and nylon washer.
5. Drop the existing fork out of the caster head tube.
6. Slide the new fork into the caster head tube.
15. Adjust the fork. Refer to ADJUSTING FORKS in PROCEDURE 8 of the owner's manual, part num- ber 1080737.
Caster Headtube
Dust Cover
Locknut
Nylon Washer
Fork
Hex Screw
Washer
FIGURE 5 - REPLACINGFORKS
Locknut
Washer
Caster
32
Page 33
PROCEDURE 10SHROUDS
This Procedure Includes the Following: Removing/Installing Shrouds
WARNING
After ANY adjustments, repair or service and BEFORE use, make sure all attaching hardware is tightened securely - other­wise injury or damage may result.
REMOVING/INSTALLING SHROUDS
MWD Wheelchairs (FIGURE 1) REMOVING FRONT SHROUD.
1. Turn the two (2) 1/4-turn bolts that secure front shroud to the two (2) side shrouds COUNTERCLOCKWISE.
2. Remove the front shroud from the wheelchair.
INSTALLING FRONT SHROUD.
1. Position the two (2) 1/4-turn bolts with the two (2) mount­ing holes in the side shrouds.
2. Install the front shroud onto the two (2) side shrouds.
3. Turn the two (2) 1/4-turn bolts that secure the front shroud to the two (2) side shrouds CLOCKWISE.
REMOVING REAR SHROUD AND REAR STORAGE COMPARTMENT.
NOTE: The rear storage compartment is available on wheelchairs NOT equipped with weight shift basic tilt only.
1. Lift up on rear shroud and remove from wheelchair.
2. Turn the two (2) 1/4-turn bolts that secure the rear stor­age compartment to the wheelchair frame COUNTER­CLOCKWISE.
3. Remove rear storage compartment from wheelchair.
INSTALLING REAR SHROUD AND REAR STORAGE COMPARTMENT.
1. Position the two (2) 1/4-turn bolts with the two (2) mount­ing holes in the wheelchair frame.
2. Install rear storage compartment onto chair frame.
3. Turn two (2) 1/4-turn bolts that secure the rear storage compartment to the wheelchair frame CLOCKWISE.
4. Position rear shroud on the two (2) side shrouds and slide towards the front of the wheelchair until it stops.
5. Press down on the rear shroud until the two (2) clips secure the rear shroud to the two (2) side shrouds.
REMOVING SIDE SHROUDS.
1. Remove the front shroud from the wheelchair. Refer to REMOVING/INSTALLING FRONT SHROUD in this procedure of the manual.
2. Remove rear shroud and rear storage compartment (if equipped) from the wheelchair. Refer to INSTALLING REAR SHROUD AND REAR STORAGE COMPARTMENT in this procedure of the manual.
3. Perform one (1) of the following: A. INTEGRATED SLING SEAT MODELS - Fold the
wheelchair. Refer to II MWD - INTEGRATED SLING SEATS in PRO- CEDURE 12 of this manual.
B. CAPTAIN'S SEAT MODELS - Remove the
Captain's Seat from the wheelchair. Refer to MOVING/INSTALLING CAPTAIN'S SEAT in PRO- CEDURE 5 of this manual.
C. WEIGHT SHIFT BASIC TILT MODELS - Pro-
ceed to STEP 4.
4. Remove the phillips screws and washers that secure side shroud to wheelchair frame. Refer to FIGURE 1 for phillips screw and washer locations.
5. Remove the phillips bolt and locknut that secure the side shroud to the wheelchair frame. Refer to FIGURE 1 for phillips bolt and locknut location.
6. Repeat STEPS 4-5 for the opposite side of the wheel- chair, if necessary.
INSTALLING SIDE SHROUDS.
1. Position the side shroud on the wheelchair frame.
2. Line up the mounting holes in the side shroud with the mounting holes in the wheelchair frame.
TRANSPORTING RANGER
REMOVING/
RE-
CAUTION
DO NOT overtighten the phillips screws and phillips bolt that secure the side shroud to the wheelchair frame - otherwise damage to the side shroud can occur.
3. Install the phillips bolt and locknut that secure the side shroud to the wheelchair frame and tighten securely. DO NOT OVERTIGHTEN. Refer to FIGURE 1 for phillips bolt and locknut location.
4. Install the phillips screws and washers that secure the side shroud to the wheelchair frame and tighten se­curely. DO NOT OVERTIGHTEN. Refer to FIGURE 1 for phillips screw and washer locations.
5. Repeat STEPS 1-4 for the opposite side of the wheel- chair, if necessary.
6. Perform one (1) of the following: A. INTEGRATED SLING SEAT MODELS - Unfold
the wheelchair. Refer to RANGER II MWD - INTEGRATED SLING SEATS in PROCEDURE 12 of this manual.
B. CAPTAIN'S SEAT MODELS - Reinstall the
Captain's Seat onto the wheelchair. Refer to MOVING/INSTALLING CAPTAIN'S SEAT in PRO- CEDURE 5 of this manual.
TRANSPORTING
RE-
S H R O U D
S
33
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SHROUDSPROCEDURE 10
S H R O U D S
C. WEIGHT SHIFT TILT MODELS - Proceed to
STEP 7.
7. Reinstall the rear shroud and rear storage compart­ment (if equipped) onto the wheelchair. Refer to MOVING/INSTALLING REAR SHROUD AND REAR STORAGE COMPARTMENT in this procedure of the manual.
WHEELCHAIRS NOT EQUIPPED WITH WEIGHT SHIFT BASIC TILT
Rear Shroud
Rear Storage Compartment
Wheelchair
Frame
RE-
8. Reinstall the front shroud onto the wheelchair. Refer to
REMOVING/INSTALLING FRONT SHROUD in this
procedure of the manual.
Side Shroud
Phillips Screws
Washers
Side Shroud
Phillips Bolts
Side Shroud
Locknut
WHEELCHAIRS EQUIPPED WITH WEIGHT SHIFT BASIC TILT
Rear Shroud
Wheelchair
Frame
Side Shroud
1/4-Turn Bolts
Front Shroud
Washers
Phillips Screws
1/4-Turn Bolts
Phillips Bolts
FIGURE 1 - REMOVING/INSTALLING SHROUDS - MWD WHEELCHAIRS
Locknut
34
Front Shroud
Page 35
PROCEDURE 10SHROUDS
FWD Wheelchairs (FIGURE 2) REMOVING FRONT SHROUD.
1. Unclip the retaining strap securing the front shroud and battery box to the wheelchair.
2. Feed the retaining strap through the front shroud.
3. Remove the front shroud from the wheelchair.
INSTALLING FRONT SHROUD.
1. Feed the retaining strap through the front shroud as shown in FIGURE 2.
2. Position the bottom of the front shroud between the battery box and the battery tray.
3. Clip the retaining strap together.
4. Pull end of retaining strap to secure front battery box and front shroud in place.
REMOVING REAR SHROUD.
1. Perform one (1) of the following: A. For 16,18, and 20-inch wide chairs:
l Unclip the retaining strap securing the rear
shroud and battery box to the wheelchair.
l Feed the retaining strap through the rear
shroud.
l Remove the rear shroud from the wheelchair.
B. For 14-inch wide chairs:
l Lift up on rear shroud and remove from wheel-
chair.
INSTALLING REAR SHROUD.
1. Perform one (1) of the following: A. For 16,18, and 20-inch wide chairs:
l Feed the retaining strap through the rear
shroud as shown in FIGURE 2.
l Clip the retaining strap together. l Press down on the rear shroud until the two
(2) clips secure the rear shroud to the two (2) side shrouds.
l Pull end of retaining strap to secure rear bat-
tery box and shroud in place.
B. For 14-inch wide chairs:
l Algin clips of rear shroud with tabs on side
shrouds.
l Press down on rear shroud until the two clips
and dual lock fastener secure the rear shroud in place.
REMOVING SIDE SHROUDS AND FILLERS.
1. Remove the front shroud from the wheelchair. Refer to
REMOVING/INSTALLING FRONT SHROUD in this
procedure of the manual.
2. Remove the rear shroud from the wheelchair. Refer to REMOVING/INSTALLING REAR SHROUD in this procedure of the manual.
3. Perform one (1) of the following: A. INTEGRATED SLING SEAT MODELS - Fold the
wheelchair. Refer to II FWD in PROCEDURE 12 of this manual.
B. CAPTAIN'S SEAT MODELS - Remove the
Captain's Seat from the wheelchair. Refer to MOVING/INSTALLING CAPTAIN'S SEAT in PRO- CEDURE 5 of the owner's manual, part number
1080722.
4. HIGH BACK CAPTAIN'S SEAT MODEL WHEEL­CHAIRS ONLY (DETAIL "A") - Remove the phono jack nut that secures the phono jack to the side shroud.
5. Remove the phillips screws, bolts, washers and lock­nuts that secure side shroud and filler to the wheel­chair frame. Refer to FIGURE 2 for phillips screw and washer locations.
6. Remove side shroud and filler from the wheelchair.
7. Repeat STEPS 5-6 for the opposite side of the wheel- chair, if necessary.
INSTALLING SIDE SHROUDS AND FILLERS.
1. Position side shroud and filler on the wheelchair frame.
2. Line up the mounting holes in the side shroud and filler with the mounting holes in the wheelchair frame.
TRANSPORTING RANGER
RE-
CAUTION
DO NOT overtighten the phillips screws and phillips bolt that secure the side shroud to the wheelchair frame - oth­erwise damage to the side shroud can occur.
3. Install the phillips screws, bolts, washers and lock­nuts that secure the side shroud and filler to the wheel­chair frame and tighten securely. DO NOT OVER­TIGHTEN. Refer to FIGURE 2 for phillips screw, bolt, washer and locknut locations.
4. Repeat STEPS 1-3 for the opposite side of the wheel- chair, if necessary.
5. HIGH BACK CAPTAIN'S SEAT MODEL WHEEL­CHAIRS ONLY - If necessary, perform the following:
A. Position the phono jack on the side shroud. B. Reinstall the phono jack nut onto the phono jack
and tighten securely.
S H R O U D
S
35
Page 36
SHROUDSPROCEDURE 10
S H R O U D S
6. Perform one (1) of the following: A. INTEGRATED SLING SEAT MODELS - Unfold
the wheelchair. Refer to RANGER II FWD in PROCEDURE 12 of this manual.
B. CAPTAIN'S SEAT MODELS - Reinstall the
Captain's Seat onto the wheelchair. Refer to MOVING/INSTALLING CAPTAIN'S SEAT in PRO- CEDURE 5 of the owner's manual, part number
1080722.
Rear Shroud
14-inch wide chairs.
Clip
TRANSPORTING
Clip
7. Reinstall the rear shroud onto the wheelchair. Refer to
REMOVING/INSTALLING REAR SHROUD in this
procedure of the manual.
8. Reinstall the front shroud onto the wheelchair. Refer to REMOVING/INSTALLING FRONT SHROUD in this procedure of the manual.
RE-
Pull this end of
retaining strap to
secure battery
box in place
Locknut
Phillips Screws
Phillips Screws
Rear Shroud
16,18,20-inch
wide chairs.
Wheelchair
Frame
Phillips Bolts
Phono Jack
Nut
Side
Shroud
Retaining
Strap
Filler
Battery Box
Side Shroud
Washers
Battery Charger
Cover
Retaining Strap
Pull this end of
retaining strap to
secure battery
box in place
Phono Jack
DETAIL "A"
Battery Tray
FIGURE 2 - REMOVING/INSTALLING SHROUDS - FWD WHEELCHAIRS
36
Front Shroud
Page 37
PROCEDURE 11CROSSBRACES
This Procedure Includes the Following: Adjusting Seat Width - Integrated Sling Seats Replacing Crossbraces - Captain's Seats
WARNING
After ANY adjustments, repair or service and BEFORE use, make sure all attaching hardware is tightened securely - other­wise injury or damage may result.
ADJUSTING SEAT WIDTH ­INTEGRATED SLING SEATS (FIGURE 1)
1. If necessary remove the shrouds. Refer to REMOV-
ING/INSTALLING SHROUDS in PROCEDURE 10 of this manual.
2. Perform one (1) of the following: FWD WHEELCHAIRS -
A. Remove the battery boxes from the wheelchair.
INSTALLING/REMOVING BATTERY BOXES in PROCEDURE 13 of this manual.
B. Fold the battery tray. Refer to
TRAY FOR TRANSPORT in PROCEDURE 13 of this manual.
MWD WHEELCHAIRS ­A. Remove the battery boxes from the wheelchair.
INSTALLING/REMOVING BATTERY BOXES in PROCEDURE 14 of this manual.
B. Remove the battery tray from the wheelchair.
Refer to TRAY in PROCEDURE 14 of this manual.
3. Remove the existing back and seat upholstery from the wheelchair. Refer to STERY in PROCEDURE 5 of this manual and RE­PLACING SEAT UPHOLSTERY in PROCEDURE 5 of the owner's manual, part number 1080722.
INSTALLING/REMOVING BATTERY
REPLACING BACK UPHOL-
NOTE: If adjusting the seat width of the wheelchair, the back and seat upholstery MUST be changed as well.
4. Remove the hex bolts and locknuts that secure the two (2) pivot links to the wheelchair frame and crossbraces. Refer to the following chart to determine if new pivot links will be needed:
PIVOT LINK SEAT WIDTH RANGE (in inches)
16-18 or 20
5. Remove the dust covers from the bottom of the cross­braces.
NOTE: Note position of the tie wraps that secure the wir­ing harness to the crossbraces.
FOLDING BATTERY
6. Cut the tie wraps that secure the wiring harness to the crossbrace.
7. Remove the hex bolts, washers and locknuts that se­cure the bottom of the two (2) crossbraces to the wheelchair frame.
8. Remove the hex bolt, coved spacers, washers and locknut that secure the two (2) existing crossbraces together.
NOTE: Note coved spacer, washer and locknut order for reinstallation.
9. Remove the four (4) pivot tube plug pins from the bot­tom of the two (2) existing crossbraces.
10. Install the four (4) pivot tube plug pins into the bottom of the two (2) new crossbraces.
11. Assemble the two (2) new crossbraces together. Re­fer to DETAIL "A" in FIGURE 1 for hardware orienta­tion.
NOTE: FWD wheelchairs only - There are right and left crossbraces. Refer to DETAIL "B" in FIGURE 1.
12. Reinstall the hex bolts, washers and locknuts that se­cure the bottom of the two (2) new crossbraces to the wheelchair frame and tighten securely.
13. Reinstall the hex bolts and locknuts that secure the new/existing pivot links to the wheelchair frame and crossbraces and tighten.
NOTE: Seat widths are stamped on the pivot links.
14. Secure wiring harness to the new crossbraces with new tie wraps.
15. Reinstall the black dust covers onto the bottom of the crossbraces.
16. Install the new back and seat upholstery onto the wheelchair. Refer to STERY in PROCEDURE 5 of this manual and RE­PLACING SEAT UPHOLSTERY in PROCEDURE 5 of the owner's manual, part number 1080722.
17. Change the width of the battery tray. Refer to one (1) of the following:
FWD WHEELCHAIRS ­BATTERY TRAY in PROCEDURE 13 of this manual.
MWD WHEELCHAIRS ­BATTERY TRAY in PROCEDURE 14 of this manual.
18. Perform one (1) of the following: FWD WHEELCHAIRS -
A. Unfold the battery tray. Refer to
TERY TRAY FOR USE in PROCEDURE 13 of this manual.
B. Reinstall the battery boxes onto the wheelchair.
INSTALLING/REMOVING BATTERY BOXES in PROCEDURE 13 of this manual.
REPLACING BACK UPHOL-
CHANGING WIDTH OF
CHANGING WIDTH OF
FOLDING BAT-
C R O S S B R A C E S
37
Page 38
PROCEDURE 11 CROSSBRACES
C R O S S B R A C E S
MWD WHEELCHAIRS ­A. Reinstall the battery tray onto the wheelchair. Re-
fer to
INSTALLING/REMOVING BATTERY TRAY
in PROCEDURE 14 of this manual.
B. Reinstall the battery boxes onto the wheelchair.
INSTALLING/REMOVING BATTERY BOXES in PROCEDURE 14 of this manual.
Hex Bolt
(STEPS
4, 13)
(STEPS 4, 13)
Locknut
Locknut
(STEPS
7, 12)
Locknut
Pivot Link
(STEPS 4, 13)
Crossbrace
Hex Bolts
(STEPS 4, 13)
19. If necessary, reinstall the shrouds. Refer to REMOV­ING/INSTALLING SHROUDS in PROCEDURE 10 of this manual.
Wheelchair Frame
Washer
Hex Bolts
Black Dust Cover
Pivot Tube Plug Pin
(STEPS 7, 12)
(STEPS 7, 12)
(STEPS 5, 15)
(STEPS 9, 10)
DETAIL "B" - FWD WHEELCHAIRS
RIGHT LEFT
Tie Wraps
MWD WHEELCHAIRS
Note orientation of hex bolt, washers, coved washers and locknut for installation of new crossbraces.
(STEPS 6, 14)
NOTE: Right and left is determined by sit­ting in the wheelchair.
DETAIL "A" - (STEPS 8, 11)
Front of
Wheelchair
ONLY
FWD WHEELCHAIRS
Front of Wheelchair
FIGURE 1 - ADJUSTING SEAT WIDTH - INTEGRATED SLING SEAT S
38
Page 39
PROCEDURE 11CROSSBRACES
REPLACING CROSSBRACES ­CAPTAIN'S SEATS (FIGURE 2)
1. Remove the captain's seat from the wheelchair. Refer to
REMOVING/INSTALLING CAPTAIN'S SEAT in PRO-
CEDURE 5 of the owner's manual, part number
1080722.
2. Remove the shrouds. Refer to ING SHROUDS in PROCEDURE 10 of this manual.
3. Perform one (1) of the following: FWD WHEELCHAIRS -
A. Remove the battery boxes from the wheelchair.
INSTALLING/REMOVING BATTERY BOXES in PROCEDURE 13 of this manual.
B. Fold the battery tray. Refer to
TRAY FOR TRANSPORT in PROCEDURE 13 of this manual.
MWD WHEELCHAIRS ­A. Remove the battery boxes from the wheelchair.
INSTALLING/REMOVING BATTERY BOXES in PROCEDURE 14 of this manual.
B. Remove the battery tray from the wheelchair. Refer
INSTALLING/REMOVING BATTERY TRAY in
to PROCEDURE 14 of this manual.
4. Remove the hex bolts and locknuts that secure the two (2) pivot links to the existing crossbraces.
5. Remove the hex bolts, spacers, washers and locknuts that secure the two (2) push brackets to the existing crossbraces.
6. Remove the dust covers from the bottom of the existing crossbraces.
NOTE: Note position of the tie wraps that secure the wiring harness to the existing crossbraces.
7. Cut the tie wraps that secure the wiring harness to the existing crossbrace.
8. Remove the hex bolts, washers and locknuts that se­cure the bottom of the two (2) existing crossbraces to the wheelchair frame.
9. Remove the hex bolt, coved spacers, washers and lock­nut that secure the two (2) existing crossbraces together.
REMOVING/INSTALL-
FOLDING BATTERY
11. Install the four (4) pivot tube plug pins into the bottom of the two (2) new crossbraces.
12. Assemble the two (2) new crossbraces together. Refer to DETAIL "C" in FIGURE 2 for hardware orientation.
13. Reinstall the hex bolts, washers and locknuts that se­cure the bottom of the two (2) new crossbraces to the wheelchair frame and tighten.
14. Secure the wiring harness to the new crossbraces with new tie wraps.
15. Reinstall the dust covers onto the bottom of the new crossbraces.
16. Reinstall the hex bolts, spacers, washers and locknuts that secure the (2) push brackets to the new crossbraces and tighten securely.
17. Reinstall the hex bolts, washers and locknuts that se­cure the pivot links to the crossbraces and tighten se­curely.
18. Perform one (1) of the following: FWD WHEELCHAIRS -
A. Unfold the battery tray. Refer to
TERY TRAY FOR USE in PROCEDURE 13 of this manual.
B. Reinstall the battery boxes onto the wheelchair.
INSTALLING/REMOVING BATTERY BOXES in PROCEDURE 13 of this manual.
MWD WHEELCHAIRS ­A. Reinstall the battery tray onto the wheelchair. Re-
INSTALLING/REMOVING BATTERY TRAY
fer to in PROCEDURE 14 of this manual.
B. Reinstall the battery boxes onto the wheelchair.
INSTALLING/REMOVING BATTERY BOXES in PROCEDURE 14 of this manual.
19. Reinstall shrouds. Refer to SHROUDS in PROCEDURE 10 of this manual.
20. Reinstall the Captain's seat. Refer to STALLING CAPTAIN'S SEAT in PROCEDURE 5 of the owner's manual, part number 1080722.
REMOVING/INSTALLING
FOLDING BAT-
REMOVING/IN-
C R O
S
S B R
A C
E
S
NOTE: Note coved spacer, washer and locknut order for reinstallation.
10. Remove the four (4) pivot tube plug pins from the bot­tom of the two (2) existing crossbraces.
39
Page 40
PROCEDURE 11 CROSSBRACES
C R O S S B R A C E S
Wheelchair Frame
Washer
(STEPS 5, 16)
Hex Bolts
(STEPS 5, 16)
Hex Bolts
(STEPS 5, 16)
Crossbrace
Locknut
(STEPS 4, 17)
Spacer
(STEPS 5, 16)
Hex Bolt
(STEPS 4, 17)
Pivot Link
Push Bracket
Locknut
(STEPS 5, 16)
Dust Cover
Pivot Tube Plug Pin
(STEPS 6, 15)
Locknut
(STEPS 8, 13)
Spacer
(STEPS 10, 11)
(STEPS 8, 13)
Hex Bolts
(STEPS 8, 13)
Tie Wraps
DETAIL "A" - (STEPS 9, 12)
MWD WHEELCHAIRS FWD WHEELCHAIRS
Front of
Wheelchair
Note orientation of hex bolt, washers, coved washers and locknut for installation of new crossbraces.
FIGURE 2 - REPLACING CROSSBRACES - CAPTAIN'S SEATS
(STEPS 7, 14)
Front of
Wheelchair
40
Page 41
PROCEDURE 12BATTERIES
This Procedure includes the following: Installing/Removing Batteries into/From Battery
Boxes Connecting Battery Cables
WARNING
Make sure power to the wheelchair is OFF be­fore performing this procedure.
The use of rubber gloves and safety glasses is rec­ommended when working with batteries.
Invacare strongly recommends that battery in­stallation and battery replacement ALWAYS be done by a qualified technician.
After ANY adjustments, repair or service and BE­FORE use, make sure all attaching hardware is tightened securely - otherwise injury or damage may result.
NOTE: For changing or removing/installing the bat­tery boxes, refer to PROCEDURE 13 - FWD wheel­chairs or PROCEDURE 14 - MWD wheelchairs.
INSTALLING/REMOVING BATTERIES INTO/FROM BATTERY BOXES (FIGURE 1)
NOTE: When securing battery lifting strap to battery, observe polarity markings located on the ends of the battery lifting strap, (+) side to POSITIVE (+) battery terminal/post and (-) side to NEGATIVE (-) battery ter­minal/post.
1. If necessary, remove the battery boxes from the wheelchair. Refer to TERY BOXES in PROCEDURE 13 - FWD or PRO- CEDURE 14 - MWD of this manual.
2. Secure the battery lifting strap to battery terminal(s)/ post(s) (FIGURE 1).
INSTALLING/REMOVING BAT-
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 Strap
Or Hold Down Flanges
B
A T T E
R
I E S
NOTE: To remove the battery(ies) from the battery box(es), reverse the following procedure.
NOTE: Have the following tools available:
TOOL QTY COMMENTS Battery Lifting Strap 1 See Note
1/2-inch (6 pt) Box Wrench 1 Not Supplied 7/16-inch (6pt) Box Wrench 1 Not Supplied 3/8-inch (6pt) Box Wrench 1 Not Supplied Diagonal Cutters 1 Not Supplied
*NOTE: The Battery Lifting strap supplied is for Group 22 Batteries ONLY. Refer to the battery manufacturer for the proper lifting strap and/or battery tools for U1 battery removal/installation.
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.
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).
Battery
Group 22 ONLY
Battery Terminal(s)/Post(s)
U1 Battery Box
Bottom
22 NF Battery
Box Bottom
FIGURE 1 - INST ALLING/REMOVING BA TTERIES INTO/
FROM BA TTERY BOXES
41
Page 42
PROCEDURE 12 BATTERIES
B A T T E R
E S
CONNECTING BATTERY CABLES
WARNING
NEVER allow any of your tools and/or battery cable(s) to contact BOTH battery terminal(s)/post(s) at the same time. An electrical short may occur and serious personal injury or damage may occur.
The use of rubber gloves and safety glasses is rec­ommended when working with batteries.
Dual U1 or Dual Group 22 Battery Boxes
Perform one (1) of the following methods for connecting
I
the battery cable(s):
A. FOR DUAL U1 BA TTERIES - Use direct mount
method. Refer to FIGURES 2, and 3.
B. FOR DUAL GROUP 22 NF BA TTERIES THA T
HA VE MOUNTING HOLES IN THE BA TTERY TERMINAL(S)/POST(S) - Use direct mount
method. Refer to FIGURES 2, 3 AND 4.
C. FOR DUAL GROUP 22 NF BATTERIES THAT
DO NOT HAVE MOUNTING HOLES IN THE BA TTERY TERMINAL(S)/POST(S) - Use battery
clamp method. Refer to FIGURES 4, 5 AND 6.
CAUTION
When connecting the battery cables to the battery(ies), the battery cable(s) MUST be con­nected to the battery terminal(s)/post(s) as shown in DETAIL “A or DETAIL “B” of FIGURE 3 (depending on battery type), otherwise dam­age to the battery cable may result when in­stalling battery terminal caps.
2. Connect battery cable(s) to battery(ies) terminal(s)/ post(s) as follows (DETAIL “A” or DETAIL “B”of FIG- URE 3, depending on battery type):
A. NEGATIVE (-) BLACK battery cable to NEGA-
TIVE (-) battery terminal/post.
B. POSITIVE (+) RED battery cable to POSITIVE
(+) battery terminal/post.
3. Secure the battery cable(s)/ring terminal(s) to the battery terminal(s)/post(s), BLACK to NEGATIVE (-) and RED to POSITIVE (+), with the provided 1/4-20 x 7/8-inch hex flange screw and hex flange locknut. Securely tighten. (DETAIL “A” or DETAIL Bof FIGURE 3, depending on battery type).
4. Verify all battery cable(s)/ring terminal(s) are correctly installed and securely tightened.
DIRECT MOUNT METHOD (FIGURE 2 AND 3).
1. Install battery terminal cap(s) onto battery cable(s) as follows (FIGURE 2):
DUAL U1 BA TTERIES: A. ORANGE battery terminal cap onto RED bat-
tery cable.
B. GRAY battery terminal cap onto BLACK battery
cable.
DUAL GROUP 22 NF BA TTERIES: A. RED battery terminal cap onto RED battery cable.
B. BLACK battery terminal cap onto BLACK bat-
tery cable.
INST ALLING BA TTERY TERMINAL CAPS
Battery Cable
Battery Terminal
Cap
5. Slide terminal cap(s) down battery cable(s) and onto battery clamps (FIGURE 3).
6. Secure each terminal cap in place with a tie-wrap (Use tie-wraps 11-1/2-inches long) (FIGURE 3).
NOTE: It will be necessary to trim excess tie-wrap in order to install the battery box top(s).
7. Install the battery box top(s).
8. Install the battery box(es) into the wheelchair. Refer to
INSTALLING/REMOVING BATTERY BOX(ES) in
the PROCEDURE 13 - FWD MODELS or PROCE­DURE 14 - MWD MODELS of this manual.
NOTE: New Battery(ies) MUST be fully charged BE­FORE using, otherwise the life of the battery(ies) will be reduced.
9. If necessary, charge the battery(ies). Refer to CHARGING BATTERIES in the PROCEDURE 13 ­FWD MODELS or PROCEDURE 14 - MWD MOD­ELS of this manual.
NOTE: Only one (1) battery cable and terminal cap shown for clarity. Both caps install in the same manner.
FIGURE 2 - CONNECTING BA TTERY CABLES -
DIRECT MOUNT METHOD
42
Page 43
PROCEDURE 12BATTERIES
DUAL U1 BA TTERIES
1/4-20 x 7/8-Inch
Hex Flange Screw
U1
Battery
Positive (+) Battery
Terminal/Post
CONNECT
BA TTERY
CABLE(S) RING
TERMINAL(S) TO
THIS SIDE OF
BA TTERY
TERMINAL(S)/
POST(S)
DET AIL “A
Negative (-)
Battery Terminal/
Post
1/4-20
Hex
Flange
Locknut
DET AIL “B
DUAL GROUP 22 NF BA TTERIES
POSITIVE (+) Battery Terminal/Post
POSITIVE (+) Red
Battery Cable
1/4-20
Hex
Flange
Locknut
Group 22NF
Battery
NEGATIVE (-) Battery
Terminal/Post
NEGATIVE (-)
Black Battery
CONNECT BA TTER Y
CABLE TO BATTERY
TERMINAL AS SHOWN.
Hex Flange Screw
Cable
1/4-20 x 7/8-Inch
B
A T T E
R
I E S
POSITIVE
(+) Battery
Terminal/
Tie-
Wrap
U-1
Battery
Post
DUAL U1 BA TTERIES
Gray
Battery
Terminal
Cap
Orange Battery
Terminal Cap
FIGURE 3 - CONNECTING BA TTERY CABLES - DIRECT MOUNT METHOD
NEGATIVE
(-) Battery
Terminal/
Post
Wrap
Tie-
Wrap
Group 22 NF
Battery
43
DUAL GROUP 22 NF BA TTERIES
NEGATIVE
(-) Battery
Terminal/
Post
Tie-
BLACK BatteryTerminal
RED
Battery
Terminal
Cap
Cap
POSITIVE (+) Battery
Terminal/
Post
Tie-
Wrap
Page 44
PROCEDURE 12 BATTERIES
B A T T E R
E S
BATTERY CLAMP METHOD (FIGURES 4, 5 AND 6).
WARNING
The battery clamp of the POSITIVE (+) battery terminal/post MUST be mounted in the posi­tion shown in FIGURE 5, otherwise the battery box top cannot be installed properly.
1. Perform one (1) of the following: A. If the battery clamp of the POSITIVE (+) battery
I
POSITIVE (+) Battery Terminal/Post
terminal/post is NOT mounted in the orientation shown in FIGURE 5, perform the following:
Loosen the hex nut that secures the battery
clamp to the POSITIVE (+) battery terminal/post.
CAUTION
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.
Remove the battery clamp from the POSI-
TIVE (+) battery terminal/post.
Reposition the battery clamp on the POSI-
TIVE (+) battery terminal/post as shown in FIGURE 4.
Securely tighten the hex nut that secures
the battery clamp to the positive (+) battery terminal/post.
B. If the battery clamp on the POSITIVE (+) battery
terminal/post is positioned as shown in FIGURE 4, proceed to STEP 2.
CORRECT ORIENT ATION OF THE POSITIVE (+)
BA TTERY TERMINAL/POST BATTERY CLAMP
(Note position of battery clamp)
NEGATIVE (-) Battery
Hex
Terminal/Post and Battery Clamp
Nut
2. Install battery clamp covers onto battery cables as follows (FIGURE 5):
A. RED battery clamp cover onto RED battery cable. B. BLACK battery clamp cover onto BLACK bat-
tery cable.
NOTE: Only one (1) battery cable and battery clamp cover are shown for clarity. Both battery clamp covers install in the same manner.
INST ALLING BATTERY CLAMP COVERS
Battery Clamp
Cover
FIGURE 5 - CONNECTING BA TTERY CABLES -
BATTERY CLAMP METHOD
Battery Cable
CAUTION
When connecting the battery cable/ring terminal(s) to the battery(ies) clamp(s), the battery cable(s) MUST be connected in the position shown in DET AIL A”, otherwise damage may occur to the battery cable and/or battery clamp covers.
3. Connect battery cable(s) to battery(ies) terminal(s)/ post(s) as follows (DETAIL “A”):
A. NEGATIVE (-) BLACK battery cable/ring termi-
nal between the mounting plate and battery clamp of NEGATIVE (-) battery terminal/post.
B. POSITIVE (+) RED battery cable/ring terminal be-
tween the mounting plate and battery clamp bat­tery clamp of POSITIVE (+) battery terminal/post.
4. Secure the battery cable(s)/ring terminal(s) to the battery clamp(s), BLACK to NEGATIVE (-) and RED to POSI­TIVE (+), with exisitng hex screws. Securely Tighten. (DETAIL “A”)
5. Verify battery cable ring terminal(s) are correctly installed and securely tightened.
6. Slide battery clamp covers down battery cables and onto battery terminals. (DETAIL “B”)
Group 22NF
Battery
FIGURE 4 - CONNECTING BA TTERY CABLES -
BATTERY CLAMP METHOD
7. Secure each terminal cap in place with a tie-wrap (Use tie-wraps 11-1/2-inches long). (DETAIL “B”)
NOTE: It will be necessary to trim excess tie-wrap in order to install the battery box top(s).
8. Install the battery box top(s).
44
Page 45
PROCEDURE 12BATTERIES
9. Install the battery box(es) into the wheelchair. Refer to
INSTALLING/REMOVING BATTERY BOX(ES) in
the PROCEDURE 13 - FWD MODELS or PROCE­DURE 14 - MWD MODELS of this manual.
NOTE: New Battery(ies) MUST be fully charged BEFORE using, otherwise the life of the battery(ies) will be reduced.
CONNECTING BA TTERY CABLE(S) TO BA TTERY(IES) TERMINAL(S)/POST(S)
CONNECTING BA TTERY CABLE(S) TO BA TTERY(IES) TERMINAL(S)/POST(S)
POSITIVE (+) Battery Terminal/
Post and Battery Clamp
Fuse Box placement
when box top
is installed
Positive (+) RED
Battery Cable
Fuse
Box
NEGATIVE (-) Battery Terminal/
Post and Battery Clamp
10. If necessary, charge the battery(ies). Refer to
CHARGING BATTERIES in the PROCEDURE 13 - FWD MODELS or PROCEDURE 14 - MWD MOD­ELS of this manual.
Negative (-) BLACK
Battery Cable
TOP VIEW
Group 22NF Battery
B
A T T E
R
I E S
Positive (+) RED
Battery Cable
Negative (-) BLACK
Battery Cable
Group 22NF Battery
NEGATIVE (-) Battery Terminal/Post
Hex Screw
Mounting Plate
Mounting Plate
Battery Clamp
POSITIVE (+) Battery
NOTE: Battery clamps exploded away for clarification purposes only.
DET AIL “B
RED Battery Clamp Cover
NEGATIVE (-) Battery
Terminal/Post
DET AIL "A"
EXPLODED
VIEW
Terminal/Post
POSITIVE (+) Battery
Terminal/Post
Tie-Wrap
Group 22NF Battery
FIGURE 6 - CONNECTING BA TTER Y CABLES - BATTERY CLAMP METHOD
Tie-Wrap
BLACK Battery Clamp Cover
45
Page 46
PROCEDURE 13 FWD WHEELCHAIRS
F
W
D
W
H E E
L C H A
R S
This Procedure Includes the Following: Assembling Ranger II FWD When to Charge Batteries Charging Batteries Replacing Batteries Installing/Removing Battery Boxes Battery Tray Replacing Wiring Harness Repositioning Motors Replacing Clutch Handles - R2 Replacing Motor/Gearbox - R2
I
Replacing Motor/Gearbox - R2
BASIC
BASIC
STANDARD
WARNING
After ANY adjustments, repair or service and BE­FORE use, make sure all attaching hardware is tightened securely - otherwise injury or damage may result.
ASSEMBLING RANGER II FWD-
Integrated Sling Seats (FIGURE 1)
WARNING
The weight of the wheelchair without the user and batteries is still between 83 and 100 lbs. Use proper lifting techniques (lift with your legs) to avoid injury. Extreme caution is advised when it is necessary to move an UNOCCUPIED power wheelchair. Invac­are recommends using two (2) assistants and mak­ing thorough preparations. Make sure to use ONL Y secure, non-detachable parts for hand-hold sup­ports.
Keep hands and fingers clear of moving parts to avoid injury.
The overall performance of the wheelchair WILL be affected by the front wheel mounting posi­tion. Refer to REPOSITIONING MOTORS - FWD WHEELCHAIRS in this procedure of the manual BEFORE operating the wheelchair.
UNFOLDING THE WHEELCHAIR.
1. Push down on the seat rails until the seat rails are positioned in the seat guides.
Install the electronics. Refer to PREPARING MKIV JOYSTICK FOR USE in PROCEDURE 7 of this manual.
Determine the proper motor mounting position. Refer to RE­POSITIONING MOTORS ­FWD WHEELCHAIRS ONLY in this procedure of the manual.
2. Assemble the wheelchair. Refer to FIGURE 1.
FOLDING THE WHEELCHAIR.
1. Remove the batteries and footrests/legrests from the wheelchair. Refer to FIGURE 1.
2. Lift the battery tray UP and out of the way. Refer to FIGURE 1.
3. Lift up on the seat rails of the wheelchair.
Seat
Rails
Seat
Guides
Install the footrests/legrests. Refer to INSTALLING/REMOVING FOOT­RESTS or INSTALLING ELEVAT­ING LEGRESTS in PROCEDURE 3 of the owner's manual, part num- ber 1080722.
Position the battery tray for use. Re­fer to BATTERY TRAY in this pro­cedure of the manual.
Install the batteries. Refer to INSTALL­ING/REMOVING BATTERY BOXES in this procedure of the manual.
FIGURE 1 - ASSEMBLING RANGER II FWD- INTEGRATED SLING SEA TS
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PROCEDURE 13FWD WHEELCHAIRS
Unfolding/Folding - Captain's Seat (FIGURE 2) UNFOLDING.
1. Push down on the push brackets until they are flush with the pivot links on the crossbraces.
2. Assemble the wheelchair. Refer to FIGURE 2.
3. Install the shrouds. Refer to ING SHROUDS in PROCEDURE 9 of this manual.
4. Install the Captain's Seat. Refer to STALLING CAPTAIN'S SEAT in PROCEDURE 5 of this manual.
5. HIGH BACK CAPTAIN'S SEATS ONLY - Connect the limit switch. Refer to NECTING LIMIT SWITCH in PROCEDURE 6 of this manual.
Install the electronics. Refer to PREPARING MKIV JOYSTICK FOR USE in PROCEDURE 7 of this manual.
Determine the proper mo­tor mounting position. Re­fer to REPOSITIONING MOTORS - in this proce­dure of the manual.
REMOVING/INSTALL-
REMOVING/IN-
DISCONNECTING/CON-
FOLDING.
1. HIGH BACK CAPTAIN'S SEATS ONLY - Discon­nect the limit switch. Refer to CONNECTING LIMIT SWITCH in PROCEDURE 6 of this manual.
2. Remove the Captain's Seat. Refer to INSTALLING CAPTAIN'S SEAT in PROCEDURE 5 of this manual.
3. Remove the shrouds. Refer to ING SHROUDS in PROCEDURE 9 of this manual.
4. Remove the batteries, battery tray and footrests/leg­rests from the wheelchair. Refer to FIGURE 2.
5. Lift up on push brackets located on the crossbraces.
Install the footrests/legrests. Refer to INSTALLING/REMOVING FOOT­RESTS or INSTALLING ELEVAT­ING LEGRESTS in PROCEDURE 3 of the owner's manual, part num- ber 1080722.
DISCONNECTING/
REMOVING/
REMOVING/INSTALL-
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Push Brackets
Crossbraces
FIGURE 2 - TRANSPORTING RANGER II FWD - CAPTAIN'S SEA TS
Position the battery tray for use. Re­fer to BATTERY TRAY in this pro­cedure of the manual.
Install the batteries. Refer to ING/REMOVING BATTERY BOXES in PROCEDURE 10 of this manual.
INSTALL-
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PROCEDURE 13 FWD WHEELCHAIRS
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WHEN TO CHARGE BATTERIES (FIGURE 5)
NOTE: As a general rule, batteries should be recharged daily to assure longest possible life and minimize required charging time. In fact, a battery’s life is extended if the charge level is maintained well above a low condition. Plan to recharge batteries when it is anticipated wheel­chair will not be used for a long period of time.
MCC-MKIV X, A or A+ Joystick
BATTERY GAUGE DISPLAY (BGD) is the bar graph display located on the MKIV X, A or A+ 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
I
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.
MKIV RII Joystick
BATTERY DISCHARGE INDICATOR (BDI) is located at the rear of the joystick housing and provides informa­tion on the remaining charge in the batteries. At FULL charge the BDI will be GREEN. As the battery becomes discharged, the BDI indicator will turn AMBER (YEL­LOW), then RED and finally FLASHING RED. If the BDI is FLASHING RED, the user should charge the batteries as soon as possible.
NOTE: Accurate readings are displayed when in neu­tral.
Battery Discharge
Indicator
MKIV- RII
JOYSTICK
FIGURE 5 - WHEN TO CHARGE BA TTERIES
Battery Gauge
Display
MKIV X, A OR A+
JOYSTICK
NOTE: MKIV X Shown.
CHARGING BATTERIES (FIGURE 6)
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 fully BEFORE initial use or battery life will be reduced.
NOTE: As a general rule, batteries should be recharged daily to assure longest possible life and minimize required charging time. In fact, a battery’s life is extended if the charge level is maintained well above a low condition. Plan to recharge batteries when it is anticipated 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:
The amount of electrical current drawn within a given time to charge a battery is called 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.
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.
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PROCEDURE 13FWD WHEELCHAIRS
Required Items:
TOOL QUANTITY COMMENTS
Battery Charger 1 Supplied
✪✪
Extension Cord 1 Not Supplied
✪✪
3-prong plug, 15 ampere current rating; industrial type
1. Attach the battery charger connector to the charger cable/battery harness.
2. Plug the chargers AC power cord, or extension, into the grounded 120 VAC wall outlet.
3. Wait until charging is complete.
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 the 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.
NOTE: If the batteries need to be charged more often or take longer to charge than normal, they may need to be replaced. Contact an authorized dealer for service.
Battery Charger
Connector (on side
of Wheelchair)
Recommended Battery Types
WARNING
Only deep cycle, sealed case construction batteries should be used in this device.
CAUTION
Failure to use the correct battery size and/or volt­age may cause damage to your wheelchair and give you unsatisfactory performance.
CHAIR SEAT QTY VOLTS BATTERY REMARKS
WIDTH SIZE
14-inch 2 12 U1 Deep Cycle
16,18, 20-inches 2 12 22NF Deep Cycle
1. Remove the battery boxes from the wheelchair. Re­fer to
REMOVING/INSTALLING BATTERY BOXES
in this procedure of the manual.
2. Remove existing batteries from the battery boxes. Refer
INSTALLING/REMOVING BATTERIES INTO/FROM
to BATTERY BOXES in this procedure of the manual.
3. Clean the new battery terminals.
4. Install the new batteries into the battery boxes. Refer to
INSTALLING/REMOVING BATTERIES INTO/
FROM BATTERY BOXES in this procedure of the manual.
Cleaning Battery Terminals
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From Battery Charger
NOTE: Position of Battery Charger Connector may vary depending on wheelchair options.
FIGURE 6 - CHARGING BA TTERIES
REPLACING BATTERIES
WARNING
Most batteries are not sold with instructions. How­ever, warnings are frequently noted on the cell caps. Read them carefully, otherwise injury or damage can occur.
NOTE: Invacare recommends that both batteries be re­placed if one (1) battery is defective.
WARNING
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 immediately and thoroughly with cool water. In serious cases or if eye contact is made, seek medical attention IMMEDIA TELY.
The use of safety glasses is recommended when cleaning the battery terminals.
NEVER smoke or strike a match near batteries. If the caps of the battery cells are removed, NEVER look directly into them while charging batteries.
1. Examine battery clamps and terminals for corrosion.
2. Verify that the 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: When done, these areas should be shiny, not dull.
4. Carefully dust off all metal particles.
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PROCEDURE 13 FWD WHEELCHAIRS
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INSTALLING/REMOVING BATTERY BOXES
W ARNING
NEVER unplug the battery cables by pullling on the wires. Unplug the battery cables by pulling on the connector ONL Y. Otherwise, injury or dam­age may occur.
NOTE: To remove the battery boxes, reverse the follow­ing procedure.
NOTE: Motors should be in the engaged position when removing/installing batteries. Refer to ENGAGING MOTORS in PROCEDURE 8 of this manual.
I
Installing R2
1. Verify that the ON/OFF switch on the joystick is in the
2. If necessary, remove the captain's seat. Refer to
3. If necessary, remove the front and rear shrouds. Re-
4. Position the battery boxes onto the battery tray.
AND R2
BASIC
OFF position.
REMOVING/INSTALLING THE CAPTAIN'S SEAT in PROCEDURE 5 of this manual.
REMOVING/INSTALLING THE SHROUDS in
fer to PROCEDURE 9 of this manual.
STANDARD
(FIGURE 7).
NOTE: Make sure the battery cable on the battery boxes are on the same side as the battery connectors on the wheelchair frame.
5. Feed the retaining strap through the slot located on the top of the front shroud.
6. Position the bottom of the front shroud in-between the battery box and the battery tray.
7. Clip the retaining strap together and pull strap tight to secure the front shroud and battery box in place.
8. Feed the retaining strap through the slot located on the top of the rear shroud.
9. Bundle excess joystick cable and tie wrap together. See DET AIL "A".
10. Position bundled joystick cable between retaining strap and rear battery box. See DET AIL "A".
11. Clip the retaining strap together to secure the rear shroud and battery box in place.
12. Press down on the rear shroud until the two (2) clips secure the rear shroud to the two side shrouds.
13. Connect the battery cables from the battery boxes to the battery connectors on the wheelchair frame.
ENGAGING/DIS-
14. If necessary, install the Captain's Seat. Refer to
MOVING/INSTALLING CAPTAIN'S SEAT in PRO­CEDURE 5 of this manual.
Joystick Cable
DET AIL "A"
RE-
Rear Battery
Box
Tie-Wrap
Retaining
Strap
Rear
Battery
Retaining
Strap
Retaining
Strap Clip
Front
Battery Box
Box
Front of the
Battery
Wheelchair
Tray
Battery Connections on
Side of Wheelchair Frame
NOTE: Wheelchair Frame not shown for clarity.
FIGURE 7 - INST ALLING/REMOVING BA TTERY BOXES
ALL MODELS EXCEPT R2
R2JR (FIGURE 8).
1. Verify that the ON/OFF switch on the joystick is in the OFF position.
2. If necessary, remove the front and rear shrouds. Re­fer to
REMOVING/INSTALLING SHROUDS in PRO-
CEDURE 9 of this manual.
JR
NOTE: Make sure the battery cables on the battery boxes are on the same side as the battery connectors on the wheelchair frame.
NOTE: The battery cables of the front battery box must be connected to the battery connectors on the wheelchair before placing battery on battery tray.
3. Connect the battery cables from the front battery box to the battery connectors on the wheelchair frame.
4. Position the front battery box onto the battery tray as shown in FIGURE 8.
5. Feed the front retaining strap through the slot located on the top of the front shroud.
6. Position the bottom of the front shroud in-between the front battery box and edge of battery tray.
7. Clip the front retaining strap together.
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PROCEDURE 13FWD WHEELCHAIRS
8. Pull end of retaining strap to secure front battery box and front shroud in place.
9. Position the rear battery box onto the battery tray as shown in FIGURE 8.
10. Connect the battery cable from the rear battery box to the rear battery connectors on the wheelchair frame.
11. Bundle excess joystick cable and tie wrap together. See DETAIL "A".
12. Position excess joystick cable between retaining strap and rear battery box. See DETAIL "A".
13. Clip the rear retaining strap together.
14. Pull end of retaining strap to secure battery box and joystick in place.
15. Install the rear shroud. Refer to
REMOVING/INSTALL-
ING SHROUDS in PROCEDURE 9 of this manual.
DET AIL "A"
Joystick
Cable
Rear Battery
Box
BATTERY TRAY
W ARNING
Pinch point exists between battery tray and bat­tery bracket.
Folding Battery Tray for Transport (FIGURE 9)
1. If necessary, remove the front and rear shroud. Refer REMOVING/INSTALLING SHROUDS - FWD
to WHEELCHAIRS in PROCEDURE 9 of this manual.
2. Remove the battery boxes from the wheelchair. Refer
INSTALLING/REMOVING BATTERY BOXES in this
to procedure of the manual.
3. Perform one (1) of the following:
A. FOR R2
side of the battery tray and rotate UP towards the battery tray pivot.
B. FOR R2
tery tray and rotate UP towards the battery tray pivot.
4. Fold the wheelchair. Refer to
RANGER II FWD in this procedure of the manual.
and R2
BASIC
- Lift up on the notched side of the bat-
JR
STANDARD
- Lift up on the pin
TRANSPORTING
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Tie-Wrap
Retaining
Strap
Rear Shroud
Retaining
Strap
Pull this end of
retaining strap to
secure battery
box in place
Slot
Rear
Battery
Box
Retaining
Battery
Connections
on Side of
Wheelchair
Frame
Battery
Tray
Front
Battery
Box
Shroud
Strap
Front
FIGURE 8 - INST ALLING/REMOVING BA TTERY BOXES
R2
JR
Unfolding Battery Tray for Use (FIGURE 10)
1. Unfold the wheelchair. Refer to
TRANSPORTING
RANGER II FWD in this procedure of the manual.
2. Perform one (1) of the following:
A. FOR R2
BASIC
and R2
STANDARD
-
WARNING
Make sure pins of battery tray are secure in the mounting slots of the hanger bracket, otherwise injury or damage may result.
Rotate the pin side of the battery tray DOWN against the mounting slots on the hanger bracket.
B. FOR R2
tray and DOWN against the battery tray stop.
3. Install the battery boxes. Refer to
MOVING BATTERY BOXES in this procedure of the manual.
4. If necessary install the front shroud. Refer to ING/INSTALLING SHROUDS - FWD WHEEL­CHAIRS in PROCEDURE 9 of this manual.
- Rotate the notched side of the battery
JR
INSTALLING/RE-
REMOV-
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PROCEDURE 13 FWD WHEELCHAIRS
R2
BASIC
AND R2
STANDARD
R2
BASIC
AND R2
STANDARD
Pins
Hanger Bracket
Mounting
Slots
Pivot
Battery Tray
Battery Tray
I
R2
JR
R2
JR
Pins
Battery
Bracket
Notch
Battery Tray
Pivot
FIGURE 9 - BA TTERY TRAY - FOLDING BATTER Y TRAY
FOR TRANSPORT
Battery
Tray
Stop
l
Notch
Battery Tray
FIGURE 10 - BA TTERY TRAY - UNFOLDING BATTER Y
TRAY FOR USE
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PROCEDURE 13FWD WHEELCHAIRS
Changing Width of Battery Tray (FIGURE 11)
NOTE: This procedure applies to
R2
BASIC
AND R2
STANDARD
only.
NOTE: This procedure is only necessary when changing the width of the wheelchair.
1. Fold the battery tray. Refer to FOLDING BATTERY
TRAY FOR TRANSPORT in this procedure of the manual.
2. Remove the hex bolt and locknut that secure one (1) of the battery tray pins to the battery tray.
3. Refer to FIGURE 11 to determine mounting hole in the battery tray that corresponds to width of the wheelchair.
4. Reposition the battery tray pin to the mounting hole determined in STEP 3.
5. Secure the battery tray pin to the battery tray with the hex bolt and locknut.
6. Repeat STEPS 2-5 for remaining battery tray pin and two battery tray pivots.
Battery Tray Pin
Battery Tray
INSTALLING (FIGURE 12).
1. Line up mounting holes in the new/existing battery tray with the mounting holes in the battery tray hanger bracket.
2. Position one (1) of the washers between the battery hanger bracket and the new/existing battery tray.
3. Reinstall one (1) of the hex bolts and washers through the new/existing battery tray, washer and battery tray hanger bracket and loosely tighten with a locknut.
4. Repeat STEPS 2-3 for the remaining washers, hex bolt, and locknut.
5. Tighten the two (2) hex bolts and locknuts.
NOTE: Tighten the Two (2) hex bolts and locknuts until the tray stays up by itself. Over tightening the hex bolts and locknuts will make the battery tray difficult to flip up.
6. Reinstall the battery boxes. Refer to INSTALLING/RE­MOVING BATTERY BOXES in this procedure of the manual.
Battery Tray Hanger Bracket
Washers
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Hex Bolts
Locknuts
Battery Tray
Pivot
16-inch Wheelchair
18-inch Wheelchair 20-inch Wheelchair
FIGURE 11 - BA TTERY TRAY - CHANGING WIDTH OF
BA TTERY TRAY
Removing/Installing Battery Tray for R2 and R2
STANDARD
.
BASIC
REMOVING (FIGURE 12).
1. Remove the battery boxes from the wheelchair. Refer to
INSTALLING/REMOVING BATTERY BOXES in this
procedure of the manual.
2. Remove the two (2) hex bolts, four (4) washers and two (2) locknuts that secure the existing battery tray and washers to the battery tray hanger bracket.
3. Remove the existing battery tray from the wheelchair.
Hex Bolts
Locknuts
Battery Tray
FIGURE 12 - REMOVING/INST ALLING BA TTER Y TRAY
FOR R2
BASIC
AND R2
Removing/Installing Battery Tray R2
STANDARD
.
.
JR
(FIGURE 13) REMOVING.
1. Remove the battery boxes from the wheelchair. Refer to
INSTALLING/REMOVING BATTERY BOXES in this
procedure of the manual.
2. Remove the two (2) mounting screws, four (4) wash­ers, and two (2) locknuts that secure the battery tray to the battery tray bracket.
3. Remove the battery tray from the wheelchair.
INSTALLING.
1. Position battery tray inside tab of battery tray bracket.
2. Secure battery tray to battery bracket with the exist­ing two (2) mounting screws, four (4) washers, and two (2) locknuts. Torque mounting screws to 72-inch pounds. See Figure 12 for hardware orientation.
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PROCEDURE 13 FWD WHEELCHAIRS
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FOR MODEL R2
(FIGURE 15).
JR
NOTE: Right and left is determined by sitting in wheel­chair.
1. Remove the footrests. Refer to INSTALLING /RE­MOVING FOOTRESTS in PROCEDURE 3 of the Owner's Manual, part number 1080722.
2. Remove the battery boxes from the wheelchair. Refer
INSTALLING/REMOVING BATTERY BOXES in this
to procedure of the manual.
3. Remove the battery tray. Refer to TERY TRAY in this procedure of the manual.
4. Remove the two (2) mounting screws that secures the existing right battery tray hanger bracket to
I
wheelchair frame.
5. Secure NEW battery tray hanger bracket to wheel­chair frame with the existing two (2) mounting screws. Securely tighten.
6. Reinstall battery tray, battery boxes, and footrests by reversing STEPS 1-3.
REMOVING BAT-
Mounting Screws
B. WHEELCHAIR NOT EQUIPPED WITH FLIP-UP
REMOVABLE FOOTBOARD - Remove the front hex screw that secures the existing left battery tray bracket to the wheelchair frame.
4. Remove the locknut that secures existing left battery tray hanger bracket and MKIV controller from the wheelchair.
5. Remove the existing left battery tray hanger bracket from the wheelchair.
6. Line up the mounting holes in the new battery tray hanger bracket with the front mounting hole and rear stud on the wheelchair frame.
7. Perform one (1) of the following: A. WHEELCHAIR EQUIPPED WITH FLIP-UP RE-
MOVABLE FOOTBOARD - Reinstall the hex screw and spacer that secures the new left bat­tery tray hanger bracket and footboard mounting bracket to the wheelchair frame. Use Loctite 242 and torque to 156-in/lbs.
B. WHEELCHAIR NOT EQUIPPED WITH FLIP-
UP REMOVABLE FOOTBOARD - Reinstall the front hex screw that secures the new left battery tray hanger bracket to the wheelchair frame. Use Loctite 242 and torque to 156-in/lbs.
8. Reinstall locknut. Use Loctite 242 and torque to 156­in/lbs.
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Battery Tray
Hanger Bracket
Wheelchair
Frame
FIGURE 15 - REPLACING RIGHT BA TTERY TRAY
HANGER BRACKET FOR MODEL R2
Replacing Left Battery Tray Hanger Bracket FOR MODELS R2
(FIGURE 16).
BASIC
AND R2
STANDARD
JR
NOTE: Right and left is determined by sitting in wheel­chair.
1. Remove the battery boxes from the wheelchair. Re­fer to
INSTALLING/REMOVING BATTERY BOXES
in this procedure of the manual.
2. Loosen, but do not remove the rear locknut that se­cures MKIV controller to the wheelchair.
3. Perform one (1) of the following: A. WHEELCHAIR EQUIPPED WITH FLIP-UP RE-
MOVABLE FOOTBOARD - Remove the hex screw and spacer that secures the existing left battery tray hanger bracket and footboard mount­ing bracket to the wheelchair frame.
9. Torque the rear locknut that secures MKIV controller to the wheelchair to 156-in/lbs.
Wheelchair
Battery Tray Hanger Bracket
Frame
MKIV
Controller
Spacer
Hex Screw
Locknut
Rear Locknut - Loosen,
but Do Not Remove
FIGURE 16 - REPLACING LEFT BA TTERY TRAY
HANGER BRACKET FOR MODELS R2
R2
STANDARD
Footboard
Mounting
Bracket
BASIC
AND
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PROCEDURE 13FWD WHEELCHAIRS
FOR MODEL R2
(FIGURE 17).
JR
NOTE: Right and left is determined by sitting in wheel­chair.
1. Remove the footrests. Refer to INSTALLING /RE­MOVING FOOTRESTS in PROCEDURE 3 of the Owner's Manual, part number 1080722.
2. Remove the front and rear shrouds. Refer to RE­MOVING/INSTALLING SHROUDS in PROCE­DURE 10 in this manual.
3. Remove the battery boxes from the wheelchair. Re-
INSTALLING/REMOVING BATTERY BOXES
fer to in this procedure of the manual.
4. Fold battery tray. Refer to ING BATTERY TRAY in this procedure of the manual.
5. Loosen, but do not remove the rear locknut that se­cures MKIV controller to the wheelchair.
6. Remove the front hex screw that secures the ex­isting left battery tray bracket to the wheelchair frame.
7. Remove the locknut that secures existing left battery tray hanger bracket and MKIV controller from the wheelchair.
8. Remove the existing left battery tray hanger bracket from the wheelchair.
9. Line up the mounting holes in the new battery tray hanger bracket with the front mounting hole and rear stud on the wheelchair frame.
10. Reinstall the front hex screw that secures the new left battery tray hanger bracket to the wheelchair frame. Use Loctite 242 and torque to 156-in/lbs.
Wheelchair
Frame
FOLDING/UNFOLD-
Battery Tray
Hanger Bracket
MKIV
Controller
Locknut
Rear Locknut - Loosen,
Front Hex
Screw
but Do Not Remove
FIGURE 17 - REPLACING LEFT BA TTERY TRAY
HANGER BRACKET FOR MODEL R2
JR
11. Reinstall locknut that secures the front of the MKIV controller and rear of the left battery tray hanger bracket to the wheelchair frame. Use Loctite 242 and torque to 156-in/lbs.
12. Tighten the rear locknut that secures MKIV controller to the wheelchair and torque to 156-in/lbs.
REPLACING WIRING HARNESS (FIGURE 18)
16, 18, and 20-inch Wide Models
1. If necessary, remove the front and rear shrouds. Re­fer to
REMOVING/INSTALLING SHROUDS in PRO-
CEDURE 10 of this manual.
2. Remove the battery boxes. Refer to REMOVING BATTERY BOXES in this procedure of the manual.
3. HIGH BACK CAPTAIN'S SEAT MODEL WHEEL­CHAIRS ONLY (DETAIL "A") - Perform the following:
A. Disconnect the limit switch. Refer to
NECTING/CONNECTING LIMIT SWITCH in PROCEDURE 8 of this manual.
B. Remove the phono jack nut that secures the
phono jack to the side shroud.
4. Disconnect the wiring harness (BLUE) from the con­troller connector (BLUE).
5. Remove the two (2) phillips screws and spacers that secure the rear battery connector to the wheelchair frame.
6. Remove the two (2) phillips bolts and locknuts that secure the front battery connector to wheelchair frame.
7. Remove the two (2) phillips screws that secure the wiring harness to the charger cable mounting bracket.
8. Note the position of the tie wraps that secure the ex­isting wiring harness and motor cables to the crossbraces.
9. Cut the tie wraps that secure the existing wiring har­ness and motor cables to the crossbraces.
10. Remove the existing wiring harness from wheelchair.
11. Position the rear battery connector of the new wiring harness on the wheelchair frame as shown in FIG­URE 18 and secure with the two (2) phillips screws and spacers.
12. Position the front battery connector on the wheelchair frame as shown in FIGURE 18 and secure with the two (2) phillips bolts and locknuts.
13. Secure the wiring harness to existing charger cable mounting bracket on the seat frame with the two (2) phillips screws.
55
INSTALLING/
DISCON-
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PROCEDURE 13 FWD WHEELCHAIRS
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14. Resecure the wiring harness and motor cables to the crossbraces with new tie wraps at the positions noted in STEP 8.
15. Connect the wiring harness (BLUE) to the controller connector (BLUE).
16. HIGH BACK CAPTAIN'S SEAT MODEL WHEEL­CHAIRS ONLY - Perform the following:
A. Position the new phono jack on the side shroud. B. Reinstall the phono jack nut onto the new phono
jack and tighten securely.
Phono Jack
I
Nut
Side
Shroud
Phono Jack
17. Reinstall the battery boxes. Refer to
18. If necessary, install the front and rear shrouds. Refer
Spacers
(STEPS 5, 11)
C. Connect the limit switch. Refer to DISCONNECT-
ING/CONNECTING LIMIT SWITCH in this PRO- CEDURE 8 of this manual.
INSTALLING/ REMOVING BATTERY BOXES in this procedure of the manual.
to
REMOVING/INSTALLING SHROUDS in PROCE-
DURE 10 of this manual.
Phillips Screws
(STEPS 5, 11)
Wiring
Harness
Tie Wraps
(STEPS 8, 16)
Charger Cable Mounting Bracket
Locknuts
FIGURE 18 - REPLACING WIRING HARNESS - 16, 18, AND 20-INCH WIDE MODELS
(STEPS 6, 12)
Phillips Bolts
(STEPS 6, 12)
Phillips Screws
To Controller
(STEPS 4, 15)
(STEPS 7, 13)
56
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PROCEDURE 13FWD WHEELCHAIRS
14-inch Wide Models (FIGURE 19)
1. Remove the shrouds. Refer to
ING SHROUDS in PROCEDURE 10 of this manual.
2. Remove the battery boxes. Refer to STALLING THE BATTERY BOXES in PROCEDURE 12 of this manual.
3. Cut the tie wrap that secure the following connections to the wire connector support:
A. The right hand motor and controller connection. B. The left hand motor and controller connection. C. Battery wiring harness and controller connection.
(BLUE)
4. Disconnect the battery wiring harness (BLUE) and controller connector (BLUE).
5. Remove the two (2) phillips screws and spacers that secure the rear battery connector to the wheelchair frame.
6. Remove the two (2) phillips bolts and locknuts that secure the front battery connector to wheelchair frame.
7. Remove the two (2) phillips screws that secure the wiring harness to the charger cable mounting bracket.
REMOVING/INSTALL-
REMOVING/IN-
11. Secure the wiring harness to existing charger cable mounting bracket on the seat frame with the two (2) phillips screws.
12. Connect the wiring harness (BLUE) to the controller connector (BLUE).
NOTE: See FIGURE 19 for proper positioning of con­nections on wire connector support.
13. Postion the right hand motor/controller connection and the left hand motor/controller connection side by side on the wire connector support.
14. Postion the battery wiring harness/controller con­nection on top of the right/left hand motor/con­troller connections.
NOTE: When securing the above connections to wire connector support, make sure to wrap tie-wrap around crossbrace and thread through slot in wire connector support.
15. Secure the connections stated in STEPS 13 and 14 to the wire connector support with a tie-wrap.
16. Install the battery boxes. Refer to INSTALLING THE BATTERY BOXES in PRO­CEDURE 12 of this manual.
REMOVING/
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8. Remove the existing wiring harness from wheelchair.
9. Position the rear battery connector of the new wiring harness on the wheelchair frame as shown in FIG­URE 19 and secure with the two (2) phillips screws and spacers.
10. Position the front battery connector on the wheelchair frame as shown in FIGURE 19 and secure with the two (2) phillips bolts and locknuts.
17. Install the shrouds. Refer to
ING SHROUDS in PROCEDURE 10 of this manual.
REMOVING/INSTALL-
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PROCEDURE 13 FWD WHEELCHAIRS
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MKIV
Controller
Right Hand Motor and
Controller Connection
I
Left Hand Motor and
Controller Connection
Wire Connector Support
Slot
Rear Battery
Connector
Tie-Wrap
Phillips Screws
Battery Wiring Harness
and Controller Connection
(BLUE)
Wiring
Harness
To Controller
Phillips Screws
Charger Cable
Mounting Bracket
FIGURE 19 - REPLACING WIRING HARNESS - 14-INCH WIDE MODELS
Spacer
Phillips Bolts
Spacer
Front Battery
Connector
Locknuts
58
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PROCEDURE 13FWD WHEELCHAIRS
REPOSITIONING MOTORS (FIGURE
20)
WARNING
The overall performance of the wheelchair WILL be affected by the front wheel mounting posi­tion. The following charts show the mounting po­sition of the motors for each seat width and depth depending on the factory setting or user's weight.
If the mounting position that corresponds to the user's weight is different than the factory setting, the motors MUST BE repositioned to maintain proper stability and controllability BEFORE using the wheelchair. Otherwise injury or damage can occur.
Periodically review the following charts to make sure the motor mounting position still corresponds to the user's weight to maintain the proper stabil­ity and controllability.
R2
ONL Y - NEVER reposition the motors. Reposi-
JR
tioning the motors forward WILL reduce the con­trollability of the wheelchair. This procedure MUST be performed by an Invacare Dealer.
NOTE: If motors are repositioned, the front riggings may need to be repositioned. Refer to ADJUSTING/REPLAC­ING TELESCOPING FRONT RIGGING SUPPORT in PROCEDURE 9 of the owner's manual, 1080722.
F ACTORY SETTINGS - MOTOR MOUNTING POSITIONS
(R2
STANDARD
SEA T
WIDTH
*14
16 18 20
16
N/A FRONT FRONT FRONT
F ACTORY SETTINGS - MOTOR MOUNTING POSITIONS
(R2
BASIC
SEA T
WIDTH
*14
16 18 20
16
REAR MIDDLE MIDDLE MIDDLE
USERS' WEIGHT 200 LBS AND UNDER -
MOTOR MOUNTING POSITIONS
SEA T
WIDTH
*14
16 18 20
16
REAR REAR REAR REAR
)
SEAT DEPTH
17
N/A FRONT FRONT FRONT
AND R2JR)
SEAT DEPTH
17
REAR MIDDLE MIDDLE MIDDLE
SEA T DEPTH
17
REAR
REAR
REAR
REAR
18
N/A FRONT FRONT FRONT
18
REAR MIDDLE MIDDLE MIDDLE
18
REAR
REAR
REAR
REAR
USERS' WEIGHT 201 TO 250 LBS ­MOTOR MOUNTING POSITIONS
SEA T
WIDTH
*14
16 18 20
16
N/A MIDDLE MIDDLE MIDDLE
SEA T DEPTH
17
N/A MIDDLE MIDDLE MIDDLE
18
N/A MIDDLE MIDDLE MIDDLE
USERS' WEIGHT 251 TO 300 LBS
(FWD MOTORS WITH MOTOR LOCKS ONLY)-
MOTOR MOUNTING POSITIONS
SEA T
WIDTH
*14
16 18 20
16
N/A FRONT FRONT FRONT
SEAT DEPTH
17
N/A FRONT FRONT FRONT
18
N/A FRONT FRONT FRONT
*NOTE: 14 wide is only for R2JR.
1. Remove the battery boxes. Refer to INSTALLING/ REMOVING BATTERY BOXES in this procedure of the manual.
2. Perform one (1) of the following: A. WHEELCHAIR EQUIPPED WITH FLIP-UP RE-
MOVABLE FOOTBOARD - Remove the hex screws and spacers that secure the battery tray hanger bracket and footboard mounting bracket to the wheelchair frame.
B. WHEELCHAIR NOT EQUIPPED WITH FLIP-UP
REMOVABLE FOOTBOARD - Remove the front hex screw that secures the battery tray hanger bracket to the wheelchair frame.
3. Rotate battery tray hanger bracket up.
4. Left side of wheelchair only - Remove the front dust cover from the end of the crossbrace.
NOTE: Left is determined by sitting in the wheelchair.
5. Refer to the charts in this procedure to determine proper mounting position that corresponds to the user's weight.
6. Remove the six (6) socket screws that secure the mo­tor to the wheelchair frame.
7. Position the motor on the wheelchair frame at the po­sition noted in STEP 5 as shown in FIGURE 20.
CAUTION
The longer socket screws must be positioned in the mounting holes on the OUTSIDE of the wheel­chair frame and the short socket screws must be in the mounting holes on the INSIDE of the wheel­chair frame. Otherwise damage to the gearbox may result.
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PROCEDURE 13 FWD WHEELCHAIRS
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STEPS 2, 4, 10, 11, 12
Dust Cover (Not Shown) Battery Tray
Hanger
Bracket
Hex Screws
Footboard
Mounting
Bracket
LONG Socket Screws (Apply Loctite 242 and
torque to 60-inch pounds)
(STEPS 6, 8)
I
Wheelchair
Frame
SHORT Socket
Screws (Apply
Loctite 242 and
torque to 60-
inch pounds)
(STEPS 6, 8)
Motor/
Gearbox
NOTE: Basic motor/gearbox shown only for clarity. Stan­dard motor gearbox reposition the same way.
NOTE: Basic motor/gearbox - It is not necessary to dis-
connect clutch handle from the motor/gearbox.
FRONT MOTOR
MOUNTING POSITION
MIDDLE MOTOR
MOUNTING POSITION
REAR MOTOR
MOUNTING POSITION
FIGURE 20 - REPOSITIONING MOTORS
Spacers
8. Use Loctite 242 and tighten the motor to the wheel­chair frame securely with the six (6) socket screws. Torque to 60-inch pounds.
9. Repeat STEPS 2-8 for the opposite side of the wheel­chair, if necessary.
10. Line up the mounting hole in the battery tray hanger bracket with the mounting hole in the wheelchair frame.
11. Left side of wheelchair only - Reinstall the front dust cover onto the end of the crossbrace.
12. Perform one (1) of the following: A. WHEELCHAIR EQUIPPED WITH FLIP-UP RE-
MOVABLE FOOTBOARD - Reinstall the hex screws and spacers that secure the battery tray hanger bracket and footboard mounting bracket to the wheelchair frame. Use Loctite 242 and torque to 156-in/lbs.
B. WHEELCHAIR NOT EQUIPPED WITH FLIP-UP
REMOVABLE FOOTBOARD - Reinstall the front hex screw that secures the battery tray hanger bracket to the wheelchair frame. Use Loctite 242 and torque to 156-in/lbs.
13. Reinstall the battery boxes. Refer to MOVING BATTERY BOXES in this procedure of the manual.
INSTALLING/RE-
REPLACING CLUTCH HANDLES ­R2
1. Remove the battery boxes. Refer to INSTALLING/
2. Remove the tip from the existing clutch handle.
3. Remove the pin that secures the existing clutch
4. Disconnect the existing clutch handle from the mo-
5. Feed existing clutch handle through wheelchair
6. Remove the rubber tip from the new clutch handle.
7. Install the new clutch handle onto the wheelchair.
NOTE: Make sure the new clutch handle is pointing to­wards the outside of the wheelchair.
8. Install the rubber tip onto the new clutch handle.
9. Connect the clutch handle to the motor/gearbox and
10. Insert the pin through the clutch handle and motor/
NOTE: Make sure the detent ball on the pin is fully vis­ible.
AND R2JR (FIGURE 21)
BASIC
REMOVING BATTERY BOXES in this procedure of the manual.
handle to the motor/gearbox.
tor/gearbox.
frame.
line up the mounting holes in the clutch handle and motor/gearbox.
gearbox as shown in DETAIL "A" in FIGURE 21.
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PROCEDURE 13FWD WHEELCHAIRS
11. Repeat STEPS 2-10 for the opposite side of the wheelchair, if necessary.
12. Reinstall the battery boxes. Refer to REMOVING BATTERY BOXES in this procedure of the manual.
Tip
Clutch Handle
(STEPS 4, 7)
(STEPS 2, 6, 8)
INSTALLING/
Outside of
Wheelchair
Motor/
Gearbox
Pin
DETAIL "A"
(STEPS 3, 10)
Motor/Gearbox
5. Perform one (1) of the following: A. WHEELCHAIR EQUIPPED WITH FLIP-UP RE-
MOVABLE FOOTBOARD - Remove the hex screws and spacers that secure the battery tray hanger bracket and footboard mounting bracket to the wheelchair frame.
B. WHEELCHAIR NOT EQUIPPED WITH FLIP-UP
REMOVABLE FOOTBOARD - Remove the front hex screw that secures the battery tray hanger bracket to the wheelchair frame.
5. Rotate battery tray hanger bracket up.
6. Left side of wheelchair only - Remove the front dust cover from the end of the crossbrace.
NOTE: Left is determined by sitting in the wheelchair.
7. Remove the pin that secures the clutch handle to the existing motor/gearbox.
8. Disconnect clutch handle from existing motor/gear­box.
9. Note mounting position of motor/gearbox on the wheel­chair frame for installation of the new motor/gearbox.
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Clutch Handle
FIGURE 21 - REPLACING CLUTCH HANDLES -
(STEP 9)
RANGER II FWD BASIC
Detent Ball
REPLACING MOTOR/GEARBOX ­R2
1. Remove the battery boxes. Refer to INSTALLING/
2. Perform one (1) of the following:
3. Disconnect the right and left motor connector from
4. Remove the drive wheels from the wheelchair. Re-
AND R2
BASIC
REMOVING BATTERY BOXES in this procedure of the manual.
A. For R2 B. FOR R2
Cut the tie wrap that secures the following con­nections to the wire connector support:
l The right hand motor and controller con-
l The left hand motor and controller con-
l Battery wiring harness (BLUE)and control-
the controller.
fer to in PROCEDURE 9 of this manual.
BASIC
JR
nection.
nection.
ler connector (BLUE).
REMOVING/INSTALLING DRIVE WHEELS
(FIGURE 22)
JR
- Proceed to STEP 3
10. Remove the six (6) socket screws that secure the ex­isting motor/gearbox to the wheelchair frame.
11. Position the new motor/gearbox on the wheelchair frame at the position noted in STEP 9 as shown in FIGURE 22.
CAUTION
The longer socket screws must be positioned in the mounting holes on the OUTSIDE of the wheel­chair frame and the short socket screws must be in the mounting holes on the INSIDE of the wheel­chair frame. Otherwise damage to the gearbox may result.
12. Use Loctite 242 and tighten the motor/gearbox to the wheelchair frame securely with the six (6) socket screws. Torque to 60-inch pounds.
13. Connect the clutch handle to the new motor/gearbox and line up the mounting holes.
14. Insert the pin through clutch handle and new motor/ gearbox as shown in DETAIL "B" in FIGURE 22.
NOTE: Make sure the detent ball on the pin is fully visible.
15. Repeat STEPS 6-13 for the opposite side of the wheel­chair, if necessary.
16. Reinstall the drive wheels onto the wheelchair. Refer
REMOVING/INSTALLING DRIVE WHEELS in
to PROCEDURE 9 of this manual.
17. Left side of wheelchair only - Reinstall the front dust cover onto the end of the crossbrace.
18. Line up the mounting hole in the battery tray hanger bracket with the mounting hole in the wheelchair frame.
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PROCEDURE 13 FWD WHEELCHAIRS
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19. Perform one (1) of the following: A. WHEELCHAIR EQUIPPED WITH FLIP-UP RE-
MOVABLE FOOTBOARD - Reinstall the hex screws and spacers that secure the battery tray hanger bracket and footboard mounting bracket to the wheelchair frame. Use Loctite 242 and torque to 156-in/lbs.
B. WHEELCHAIR NOT EQUIPPED WITH FLIP-UP
REMOVABLE FOOTBOARD - Reinstall the front hex screw that secures the battery tray hanger bracket to the wheelchair frame. Use Loctite 242 and torque to 156-in/lbs.
20. Reconnect the right and left motor connector to the controller.
I
21. FOR R2 A. Position the right hand motor/controller con-
B. Position the battery wiring harness/controller
ONL Y -
JR
nection and the left hand motor/controller con­nection side by side on the wire connector support.
connection on top of the right/left hand mo­tor/controller connections.
NOTE: When securing the above connections to wire connector support, make sure to wrap tie­wrap around crossbrace and thread through slot in wire connector support.
C. Secure the above connections to the wire con-
nector support with a tie-wrap.
22. Reinstall the battery boxes. Refer to INSTALLING/ REMOVING BATTERY BOXES in this procedure of the manual.
REPLACING MOTOR/GEARBOX ­R2
STANDARD
1. Remove the battery boxes. Refer to INSTALLING/ REMOVING BATTERY BOXES in this procedure of the manual.
2. Disconnect the right and/or left motor connector from the controller.
3. Remove the drive wheels from the wheelchair. Re­fer to in PROCEDURE 9 of this manual.
4. Perform one (1) of the following: A. WHEELCHAIR EQUIPPED WITH FLIP-UP RE-
B. WHEELCHAIR NOT EQUIPPED WITH FLIP-
(FIGURE 23)
REMOVING/INSTALLING DRIVE WHEELS
MOVABLE FOOTBOARD - Remove the hex screw and washer that secure the battery tray hanger bracket to the wheelchair frame.
UP REMOVABLE FOOTBOARD - Proceed to STEP 6.
5. Rotate battery tray hanger bracket up.
6. Left side of wheelchair only - Remove the front dust cover from the end of the crossbrace.
NOTE: left is determined by sitting in the wheelchair.
7. Note the mounting position of the motor/gearbox on the wheelchair frame for installation of new motor/ gearbox.
8. Remove the six (6) socket screws that secure the existing motor/gearbox to the wheelchair frame.
9. Position the new motor/gearbox on the wheelchair frame at the position noted in STEP 6 as shown in FIGURE 23.
CAUTION
The longer socket screws must be positioned in the mounting holes on the OUTSIDE of the wheel­chair frame and the short socket screws must be in the mounting holes on the INSIDE of the wheel­chair frame. Otherwise damage to the gearbox casting can result.
10. Use Loctite 242 and tighten battery tray mounting bracket and motor/gearbox to the wheelchair frame securely with the six (6) socket screws. Torque to 60-inch pounds.
11. Repeat STEPS 2-10 for the opposite side of the wheel­chair, if necessary.
12. Reinstall the drive wheels onto the wheelchair. Refer
REMOVING/INSTALLING DRIVE WHEELS in
to PROCEDURE 9 of this manual.
13. Line up the mounting hole in the battery tray hanger bracket with the mounting hole in the wheelchair frame.
14. Left side of wheelchair only - Reinstall the front dust cover onto the end of the crossbrace.
15. Perform one (1) of the following: A. WHEELCHAIR EQUIPPED WITH FLIP-UP RE-
MOVABLE FOOTBOARD - Reinstall the hex screws and spacers that secure the battery tray hanger bracket and footboard mounting bracket to the wheelchair frame. Use Loctite 242 and torque to 156-in/lbs.
B. WHEELCHAIR NOT EQUIPPED WITH FLIP-
UP REMOVABLE FOOTBOARD - Reinstall the front hex screw that secures the battery tray hanger bracket to the wheelchair frame. Use Loctite 242 and torque to 156-in/lbs.
16. Reconnect the right and/or left motor connector to the controller.
17. Reinstall the battery boxes. Refer to REMOVING BATTERY BOXES in this procedure of the manual.
62
INSTALLING/
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PROCEDURE 13FWD WHEELCHAIRS
STEPS 4, 6,
13,14,15
Battery Tray
Hanger Bracket
Hex Screws
Footboard
Mounting
Bracket
Battery Motor Connectors
(STEPS 2, 16)
Dust Cover (Not Shown)
Spacers
SHORT Socket
Screws (Apply
Loctite 242 and
torque to 60-
inch pounds)
(STEPS 8, 10)
LONG Socket Screws (Apply Loctite 242 and torque to 60-
inch pounds)
(STEPS
8, 10)
Wheelchair
Frame
Motor/
Gearbox
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FIGURE 23 - REPLACING MOTOR/GEARBOX - RANGER II FWD - ST ANDARD
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PROCEDURE 14 MWD WHEELCHAIRS
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This Procedure Includes the Following: Assembling Ranger II MWD When to Charge Batteries Charging Batteries Replacing Batteries Installing/Removing Battery Boxes Battery Tray Replacing Wiring Harness
Stabilizer Identification Adjusting Stabilizer Springs Adjusting Stabilizer for User Preference
I
Replacing Stabilizer Cylinders Replacing Stabilizer Wheels Replacing Stabilizer Cylinder Springs Repositioning Motors Replacing Clutch Handles - R2 Replacing Motor/Gearbox - R2 Replacing Motor/Gearbox - R2
Install the electronics. Refer to REPOSITIONING MKIV JOYSTICK in PROCEDURE 7 of this manual.
AND R2
BASIC
AND R2
BASIC
STANDARD
250 SERIES
250 SERIES
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.
ASSEMBLING RANGER II MWD
WARNING
The weight of the wheelchair without the user and batteries is still between 100 and 116 lbs. Use proper lifting techniques (lift with your legs) to avoid injury. Extreme caution is advised when it is necessary to move an UNOCCUPIED power wheelchair. Invacare recommends using two (2) assistants and making thorough preparations. Make sure to use ONL Y secure, non-detachable parts for hand-hold supports.
Keep hands and fingers clear of moving parts to avoid injury.
Unfolding/Folding Integrated Sling Seats (FIGURE 1)
UNFOLDING.
1. Push down on the seat rails until the seat rails are positioned in the seat guides.
2. Assemble the wheelchair. Refer to FIGURE 1.
3. If necessary, install the shrouds. Refer to ING/INSTALLING SHROUDS in PROCEDURE 10 of this manual.
REMOV-
Seat Rails
Seat Guides
Install the footrests/legrests. Refer to MOVING FOOTRESTS or INSTALLING ELEVATING LEGRESTS in PROCEDURE 3 of the owner's manual, part number 1080722.
Adjust the stabilizers. Refer to ERS in this procedure of the manual.
Install the battery tray and batteries. Refer to INSTALL­ING/REMOVING BATTERY TRAY and INSTALLING/ REMOVING BATTERY BOXES in this procedure of the manual.
FIGURE 1 - ASSEMBLING RANGER II MWD - INTEGRA TED SLING SEATS
64
ADJUSTING STABILIZ-
INSTALLING/RE-
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MWD WHEELCHAIRS
PROCEDURE 14
FOLDING.
1. If necessary, remove the shrouds. Refer to
ING/INSTALLING SHROUDS in PROCEDURE 10 of this manual.
2. Remove the batteries, battery tray and footrests/ legrests from the wheelchair. Refer to FIGURE 1.
3. Lift up on the seat rails of the wheelchair.
Unfolding/Folding Captain's Seats (FIGURE 2) UNFOLDING.
1. Push down on the push brackets until they are flush with the pivot links on the crossbraces.
2. Assemble the wheelchair. Refer to FIGURE 2.
3. Install the shrouds. Refer to ING SHROUDS in PROCEDURE 10 of this manual.
4. Install the captain's seat. Refer to STALLING CAPTAIN'S SEAT in PROCEDURE 5 of the owner's manual, part number 1080722.
5. HIGH BACK CAPTAIN'S SEATS ONLY - Connect the limit switch. Refer to NECTING LIMIT SWITCH in PROCEDURE 8 of this manual.
REMOVING/INSTALL-
REMOVING/IN-
DISCONNECTING/CON-
REMOV-
FOLDING.
1. HIGH BACK CAPTAIN'S SEA TS ONLY - Disconnect
the limit switch. Refer to NECTING LIMIT SWITCH in PROCEDURE 8 of this manual.
2. Remove captain's seat. Refer to
STALLING CAPTAIN'S SEAT in PROCEDURE 5 of the owner's manual, part number 1080722.
3. Remove the shrouds. Refer to
ING SHROUDS in PROCEDURE 10 of this manual.
4. Remove the batteries, battery tray and footrests/
legrests from the wheelchair. Refer to FIGURE 2.
5. Lift up on push brackets located on the crossbraces.
DISCONNECTING/CON-
REMOVING/IN-
REMOVING/INSTALL-
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Install the electronics. Refer to REPOSITIONING MKIV JOY­STICK in PROCEDURE 7 of this manual.
Install the battery tray and batteries. Refer to INSTALLING/REMOVING BATTERY TRAY and INSTALLING/ REMOVING BATTERY BOXES in this procedure of the manual.
Push Brackets
Crossbraces
Adjust the stabilizers. Refer to
ADJUSTING STABILIZ-
ERS in this procedure of the manual.
Install the footrests/legrests. Refer to STALLING/REMOVING FOOTRESTS or INSTALLING/REMOVING ELEVATING LEGRESTS in PROCEDURE 3 of the owner's manual, part number 1080722.
IN-
FIGURE 2 - ASSEMBLING RANGER II MWD - CAPT AIN'S SEATS
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PROCEDURE 14 MWD WHEELCHAIRS
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WHEN TO CHARGE BATTERIES (FIGURE 5)
It is advantageous to recharge daily rather than only when necessary. In fact, a battery’s life is extended if the charge level is maintained well above a low condition.
NOTE: As a general rule, batteries should be recharged daily to assure longest possible life and minimize required charging time. Plan to recharge batteries when it is antici­pated wheelchair will not be used for a long period of time.
MKIV RII Joystick
BATTERY DISCHARGE INDICATOR (BDI) is located at the rear of the joystick housing and provides information on the remaining charge in the batteries. At FULL charge the BDI will be GREEN. As the battery becomes discharged,
I
the BDI indicator will turn AMBER (YELLOW), then RED and finally FLASHING RED. If the BDI is FLASHING RED, the user should charge the batteries as soon as possible.
NOTE: Accurate readings are displayed when in neutral.
MCC-MKIV X, A or A+ Joystick
BATTERY GAUGE DISPLA Y (BGD) is the bar graph display located on the MKIV X, A or A+ 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)
Battery Gauge
Display
CHARGING BATTERIES (FIGURE 6)
W ARNING
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/rear 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 fully 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.
SHUTOFF PROCEDURE.
A. For Models R2
tended, the charger should automatically shut-off when full charge is obtained.
B. For R2
250 SERIES
light will stay ON until the power switch on the bat­tery charger is moved to the OFF position.
BASIC
and R2
STANDARD
-If left unat-
-The Charger output and green
MKIV X, A OR A+ JOYSTICK
NOTE: MKIV X Shown.
MKIV- RII JOYSTICK
FIGURE 5 - WHEN TO CHARGE BA TTERIES
There are some basic concepts which will help you understand this automatic process:
The amount of electrical current drawn within a given time to charge a battery is called “charge rate. If, due to usage, the charge stored in the battery is low, the charge rate is high. (FOR MODELS R2
BASIC
and R2
STANDARD
- this is 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 following will occur:
A. For Models R2
BASIC
and R2
STANDARD
- the green light will stay illuminated for a longer period of time fol­lowed by a shorter off time.
B. For Model R2
250 SERIES
- the battery charger rate
decreases to a "trickle charge".
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MWD WHEELCHAIRS
PROCEDURE 14
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 QUANTITY COMMENTS
Battery Charger 1 Supplied
✪✪
Extension Cord 1 Not Supplied
✪✪
3-prong plug, 15 ampere current rating; industrial type
Wheelchairs Equipped With MCC-Mark IV Joystick (Detail "A" of FIGURE 6)
1. If necessary, remove the rear shroud. Refer to RE­MOVING/INSTALLING SHROUDS - MWD WHEEL­CHAIRS in PROCEDURE 9 of this manual.
2. Attach the battery charger connector to the charger cable/battery harness.
3. Plug the chargers AC power cord, or extension, into the grounded 120 VAC wall outlet.
4. Wait until charging is complete.
5. If necessary, install the rear shroud. Refer to MOVING/INSTALLING SHROUDS - MWD WHEEL­CHAIRS in PROCEDURE 9 of this manual.
RE-
DET AIL "A"
Battery Charger Connector (on Side of Wheelchair)
WHEELCHAIRS
WITHOUT
SHROUDS
From Battery
Charger
Battery Charger
Connector (at
WHEELCHAIRS
WITH SHROUDS
Rear of
Wheelchair)
From Battery Charger
DETAIL "B"
Battery Charger
Three (3)
Pronged Plug
Front View of
Joystick
From Battery
Charger
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Wheelchairs Equipped With Mark IV RII Joystick (Detail "B" of FIGURE 6)
1. Attach the battery charger connector to the charger port on the FRONT of the joystick.
2. Plug the chargers AC power cord, or extension, into the grounded 120 VAC wall outlet.
3. Wait until charging is complete.
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.
NOTE: R2
BASIC
and R2
STANDARD
ONLY - If the 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.
NOTE: If the batteries need to be charged more often or take longer to charge than normal, they may need to be replaced. Contact an Invacare dealer for service.
Charger
Port
Joystick
Battery
Boxes
Charger Port
FIGURE 6 - CHARGING BA TTERIES
REPLACING BATTERIES
WARNING
The following procedure should be performed only by aqualified technician.
Most batteries are not sold with instructions. How­ever, warnings are frequently noted on the cell caps. Read them carefully, otherwise injury or damage can occur.
NOTE: Invacare recommends that both batteries be re­placed if one (1) battery is defective.
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Recommended Battery Types
CAUTION
Failure to use the correct battery size and/or volt­age may cause damage to your wheelchair and give you unsatisfactory performance.
CHAIR QTY VOLTS BATTER Y REMARKS
MODEL SIZE
R2
BASIC
R2
STANDARD
R2
250 SERIES
1. Remove the battery boxes from the wheelchair. Refer to
REMOVING/INSTALLING BATTERY BOXES in this
I
procedure of the manual.
2. Remove existing batteries from the battery boxes. Refer INSTALLING/REMOVING BATTERIES TO/FROM
to BATTERY BOXES in this procedure of the manual.
3. Clean the new battery terminals.
4. Install the new batteries into the battery boxes. Refer to
INSTALLING/REMOVING BATTERIES TO/FROM BATTERY BOXES in this procedure of the manual.
Cleaning Battery Terminals
2 12 22NF Deep Cycle 2 12 22NF Deep Cycle 2 12 U1 Deep Cycle
W ARNING
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 immediately and thoroughly with cool water. In se­rious cases or if eye contact is made, seek medical attention IMMEDIATELY.
NEVER smoke or strike a match near batteries. If the caps of the battery cells are removed, NEVER look directly into them while charging batteries.
1. If applicable, verify that the plastic caps are in place over
the battery cell holes.
2. Cut the tie wraps around the terminal caps/covers.
3. Slide the terminal cap/cover up the wire to expose the
battery terminal.
4. Examine battery clamps and terminals for corrosion.
5. Clean terminals and inside the battery clamps by using a
battery cleaning tool, wire brush, or medium grade sand paper.
NOTE: When done, these areas should be shiny, not dull.
6. Carefully dust off all metal particles.
7. Slide the terminal cap/cover back down the wire to cover
the battery terminal.
8. Secure the terminal cap/cover using NEW tie wraps.
INSTALLING/REMOVING BATTERY BOXES (FIGURE 7)
Installing
NOTE: To remove the battery boxes from the wheelchair, reverse the following procedure.
WARNING
If the wheelchair is equipped with the removable footboard AND it is installed in the heighest posi­tion, it is necessary to remove the footboard plate BEFORE removing the battery boxes. Otherwise, injury can occur.
To remove the removable footboard, refer to REMOV­ING THE REMOVABLE FOOTBOARD ASSEMBLY FROM THE WHEELCHAIR in PROCEDURE 3 of this Owner's Manual, part number 1080722.
NOTE: Motors should be in the engaged position when removing/installing batteries. Refer to ENGAGING MOTORS in PROCEDURE 8 of this manual.
1. Verify that the ON/OFF switch on the joystick is in the OFF position.
2. If necessary, remove the front and rear shrouds. Re-
REMOVING/INSTALLING SHROUDS in PRO-
fer to CEDURE 9 of this manual.
WARNING
Battery boxes MUST be installed/removed in the order stated below or the battery tray could rotate causing the rear battery box to fall possibly causing injury or damage.
Use extreme care when installing/removing the battery boxes.
NEVER unplug the battery cables by pulling on the wires. Unplug the battery cables by pull­ing on the connector ONLY. Otherwise injury or damage may result.
When removing the battery boxes from the wheelchair, remove the rear battery box first.
3. Position the battery boxes onto the battery tray in the following order: A. FRONT Battery Box. B. REAR Battery Box.
4. Position retaining straps around each battery box as shown in DETAIL "A" of FIGURE 7 and clip retaining strap together.
NOTE: Make sure battery box leads are on the same side as battery connectors on wheelchair frame.
5. Connect the battery box leads to the battery con­nectors on the wheelchair frame.
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MWD WHEELCHAIRS
PROCEDURE 14
6. If necessary, reinstall the removeable footboard. Refer to FOOTBOARD ASSEMBLY FROM THE WHEEL­CHAIR in PROCEDURE 3 of this Owner's Manual, part number 1080722.
Retaining
Strap
Rear
Battery
Box
Battery Connections on
Side of Wheelchair Frame
FIGURE 7 - INST ALLING/REMOVING BA TTERY BOXES
REMOVING THE REMOVABLE
Front Battery Box
Retaining
Strap Clip
Front of the Wheelchair
Battery Box
Leads
BATTERY TRAY (FIGURE 8)
Installing Battery Tray onto Wheelchair NOT Equipped Weight Shift Basic Tilt
1. If necessary, remove the shrouds. Refer to ING/INSTALLING SHROUDS - MWD WHEEL­CHAIRS in PROCEDURE 10 of this manual.
2. Turn the battery tray slightly to one (1) side.
NOTE: Make sure the end of the battery tray labeled "FRONT" is towards the front of the wheelchair.
REMOV-
2. Turn the battery tray slightly to one (1) side.
3. Position the battery tray pins over the mounting slots on the hanger brackets.
WARNING
Make sure pins of battery tray are secure in the mounting slots of the hanger bracket, otherwise injury or damage may result.
4. Push down on the battery tray to secure in place.
5. Install the battery boxes. Refer to INSTALLING/RE­MOVING BATTERY BOXES in this procedure of the manual.
6. If necessary, install the shrouds. Refer to ING/INSTALLING SHROUDS - MWD WHEEL­CHAIRS in PROCEDURE 10 of this manual.
Removing
1. If necessary, remove the shrouds. Refer to ING/INSTALLING SHROUDS - MWD WHEEL­CHAIRS in PROCEDURE 10 of this manual.
2. Remove the battery boxes from the wheelchair. Re-
INSTALLING/REMOVING BATTERY BOXES
fer to in this procedure of the manual.
3. Lift up on the battery tray to release the battery tray pins from the mounting slots on the hanger brack­ets.
4. Turn the battery tray slightly to one (1) side.
5. Remove the battery tray from the wheelchair.
REMOV-
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3. Position the battery tray pins over the mounting slots on the hanger brackets.
WARNING
Make sure pins of battery tray are secure in the mounting slots of the hanger bracket, otherwise injury or damage may result.
4. Push down on the battery tray to secure in place.
5. Install the battery boxes. Refer to MOVING BATTERY BOXES in this procedure of the manual.
6. If necessary, install the shrouds. Refer to ING/INSTALLING SHROUDS - MWD WHEEL­CHAIRS in PROCEDURE 10 of this manual.
Installing Battery Tray onto Wheelchair Equipped Weight Shift Basic Tilt
1. If necessary, remove the shrouds. Refer to ING/INSTALLING SHROUDS - MWD WHEEL­CHAIRS in PROCEDURE 10 of this manual.
INSTALLING/RE-
REMOV-
REMOV-
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BATTERY TRAY FOR WHEELCHAIRS
EQUIPPED WITH WEIGHT SHIFT BASIC TILT
NOT
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C
Hanger
Bracket
"FRONT"
Label
Battery Tray
H
A
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Mounting
Slots
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Battery Tray Pins
Hanger
Bracket
Mounting
Slots
Battery Tray
BATTERY TRAY FOR WHEELCHAIRS
EQUIPPED WITH WEIGHT SHIFT BASIC TILT
Battery Tray Pins
FIGURE 8 - BA TTERY TRAY
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PROCEDURE 14MWD WHEELCHAIRS
Changing Width of Battery Tray (FIGURE 9)
NOTE: This procedure is only necessary when changing the width of the wheelchair.
1. Remove the battery tray from the wheelchair. Refer to
INSTALLING/REMOVING BATTERY TRAY in this procedure of the manual.
2. Remove the hex bolt and locknut that secure one (1) of the battery tray pins to the battery tray.
3. Refer to FIGURE 9 to determine the mounting hole in the battery tray that corresponds to the width of the wheelchair.
4. Reposition the battery tray pin to the mounting hole determined in STEP 3.
5. Secure the battery tray pin to the battery tray with the hex bolt and locknut.
6. Repeat STEPS 2-5 for the other three (3) battery tray pins.
7. Reinstall the battery tray onto the wheelchair. Refer to INSTALLING/REMOVING BATTERY TRAY in this procedure of the manual.
Battery Tray Pins
Battery Tray
Hex Bolts
16-inch Wheelchair
18-inch Wheelchair
Locknuts
FIGURE 9 - BA TTERY TRAY - CHANGING WIDTH OF
BA TTERY TRAY
20-inch Wheelchair
REPLACING WIRING HARNESS (FIGURE 10)
1. If necessary, remove the front and rear shrouds. Re­fer to
REMOVING/INSTALLING SHROUDS in PRO-
CEDURE 10 of this manual.
2. Remove the battery boxes. Refer to REMOVING BATTERY BOXES in this procedure of manual.
3. Disconnect the wiring harness (BLUE) from the con­troller connector (BLUE).
4. Remove the two (2) phillips screws and spacers that secure the rear battery connector to the wheelchair frame.
5. Remove the two (2) phillips bolts and locknuts that secure the front battery connector to wheelchair frame.
6. Remove the two (2) phillips bolts and locknuts that secure the wiring harness to the charger cable mount­ing bracket.
7. HIGH BACK CAPTAIN'S SEAT MODEL WHEEL­CHAIRS ONLY (DETAIL "A") - Perform the following:
A. Disconnect the limit switch. Refer to
NECTING/CONNECTING LIMIT SWITCH in this procedure of the manual.
B. Remove the phono jack nut that secures the
phono jack to the limit switch bracket.
8. Note the position of the tie wraps that secure the ex­isting wiring harness and motor cables to the cross­braces.
9. Cut the tie wraps that secure the existing wiring har­ness and motor cables to the crossbraces.
10. Remove the existing wiring harness from wheelchair.
11. Position the rear battery connector of the new wiring harness on the wheelchair frame as shown in FIG­URE 10 and secure with the two (2) phillips screws and spacers.
12. Position the front battery connector on the wheelchair frame as shown in FIGURE 10 and secure with the two (2) phillips bolts and locknuts.
13. Secure the wiring harness to existing charger cable mounting bracket on the seat frame with the two (2) phillips bolts and locknuts.
14. HIGH BACK CAPTAIN'S SEAT MODEL WHEEL­CHAIRS ONLY - Perform the following:
A. Position the new phono jack on the limit switch
bracket.
B. Reinstall the phono jack nut onto the new phono
jack and tighten securely.
C. Connect the limit switch. Refer to DISCONNECT-
ING/CONNECTING LIMIT SWITCH in this pro­cedure of the manual.
INSTALLING/
DISCON-
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15. Connect the wiring harness (BLUE) to the con­troller connector (BLUE).
16. Resecure the wiring harness and motor cables to the crossbraces with new tie wraps at the posi­tions noted in STEP 8.
NOTE: Position of Charger Cable Mounting Bracket may vary depending on wheel­chair model and options.
I
Charger
Cable
Mounting
Bracket
(STEPS 6, 13)
Spacers
(STEPS 4, 11)
Locknuts
MKIV Joystick
Phillips Screws
(STEPS 4, 11)
Wiring
Harness
17. Reinstall the battery boxes. Refer to
18. If necessary, install the front and rear shrouds. Refer
Phillips Bolts
(STEPS 5, 12)
INSTALLING/ REMOVING BATTERY BOXES in this procedure of manual.
to
REMOVING/INSTALLING SHROUDS in PRO-
CEDURE 10 of this manual.
(STEPS 7, 14)
Phono Jack Nut
Limit Switch Bracket
Controller
To Controller
(STEPS 3, 15)
DET AIL "A"
Phono Jack
Phillips Bolts
(STEPS 6, 13)
Locknuts
(STEPS 5, 12)
Tie Wraps
(STEPS 8, 16)
FIGURE 10 - REPLACING WIRING HARNESS
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MWD WHEELCHAIRS
PROCEDURE 14
STABILIZERS
STABILIZER IDENTIFICATION (FIGURE 11)
NOTE: Depending on the date of manufacture, the wheelchair will have one (1) of the following types of stabilizer assemblies. Refer to the chart below to determine the correct stabilizer assembly.
TYPE A TYPE B TYPE C
Wheelchairs built Whelchairs built Whelchairs built
before 7/1/1999 between 7/1/1999 and 3/1/2000 after 3/1/2000
FIGURE 11 -ST ABILIZER IDENTIFICATION
ADJUSTING SPRINGS FOR TYPE A STABILIZER ASSEMBLY (FIGURE 12)
NOTE: Refer to STABILIZER INDENTIFICATION above to determine correct stabilizer assembly.
W ARNING
Injury or damage can occur if the height of the stabilizer springs does not correspond to the ap­proximate weight of the user. If the height of the stabilizer springs does not correspond to the ap­proximate weight of the user, the wheelchair will feel less stable and possibly cause the footrests/ legrests to drag the ground.
If adjusting a new cylinder spring, it MUST be com­pressed to the 3-1/2-inch height (FIGURE 12) BEFORE adjusting the stabilizer spring to correspond to the approximate weight of the user. Otherwise the sta­bilizer will not work properly.
NOTE: If the height of the stabilizer springs is less than the height that corresponds to the approximate weight of the user, the wheelchair will not be able to clear 2-inch obstacles.
NOTE: The stabilizer springs are factory set for a user weigh­ing approximately 300-pounds. Use ing point when adjusting the stabilizer spring.
NOTE: The following adjustment should be made with an unoccupied wheelchair.
1. Determine the approximate weight of the user.
FIGURE 12
as a start-
2. NEW ST ABILIZER SPRINGS ONLY - Rotate adjust-
ment nut DOWN until the 3-1/2-inch height is obtained.
3. Refer to FIGURE 12 to determine the height of the
stabilizer spring.
4. Rotate the adjustment nut UP or DOWN to adjust the
stabilizer spring to the height determined in STEP 2.
5. Adjust the for user preference. Refer to ADJUSTING TYPE A STABILIZER ASSEMBLY FOR USER PREF­ERENCE in this procedure of the manual.
Stabilizer
Adjustment Nut
Measure This Height
USER'S WEIGHT (APPROXIMA TE
- IN POUNDS)
100 150 200 250 300
Spring
NOTE: If the user's approximate weight is not listed above, use the HIGHEST listed approximate weight closest to user's weight as a starting point to adjust the stabilizer spring.
FIGURE 12 - ADJUSTING ST ABILIZERS - SPRINGS
HEIGHT
MEASURED
(APPROXIMA TE
- IN INCHES) 4-3/16
4
3-7/8
3-11/16
3-1/2
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ADJUSTING STABILIZER FOR USER PREFERENCE
Adjusting Type A Stabilizer Assembly for User Preference (FIGURE 13)
NOTE: Refer to STABILIZER INDENTIFICATION in the beginning of this section to determine correct sta­bilizer assembly.
1. While the user is in the wheelchair, measure the dis­tance between the bottom of the stabilizer wheel and the ground/floor.
NOTE: Measurement MUST be between 7/8 and 1-inch.
2. If the measurement taken in STEP 1 IS NOT between
I
7/8 and 1-inch, perform the following procedure: A. Loosen the jam nut on the stabilizer cylinder rod
and back the jamnut down until it is touching the adjustment nut.
B. Remove bottom bolt and locknut that secure bot-
tom of the stabilizer cylinder to the stabilizer plates.
C. Perform one (1) of the following:
MEASUREMENT GREATER THAN 1-INCH -
Turn the bottom of the stabilizer cylinder COUN­TERCLOCKWISE.
MEASUREMENT LESS THAN 7/8-INCH - Turn the bottom of the stabilizer cylinder CLOCKWISE.
D. Line up mounting holes in stabilizer cylinder and
the stabilizer plates and reinstall the bottom bolt.
E. Perform one (1) of the following:
DISTANCE IS BETWEEN 7/8 AND 1-INCH -
Reinstall the locknut tighten securely.
DISTANCE IS NOT BETWEEN 7/8 AND 1-INCH
- Repeat STEPS B-E until the measurement is
between 7/8 and 1-inch.
F. Tighten the jamnut on the stabilizer cylinder.
Locknut
Jam Nut
Adjustment Nut
Stabilizer
Cylinder
Stabilizer
Plates
Adjusting Type B Stabilizer Assembly for User Preference (FIGURE 14)
NOTE: Refer to STABILIZER INDENTIFICATION in the beginning of this section to determine correct sta­bilizer assembly.
1. While the user is in the wheelchair, measure the dis­tance between the bottom of the stabilizer wheel and the ground/floor.
NOTE: The distance between the bottom of the stabilizer wheel and the ground/floor is factory set at one (1) inch.
2. To increase obstacle climbing ability or stability per­form the following:
A. Loosen the jam nut on the stabilizer cylinder rod
and back the jamnut down until it is touching the adjustment nut.
B. Remove bottom hex bolt and locknut that secure
bottom of the stabilizer cylinder to the stabilizer plates.
C. Perform one (1) of the following:
Increase obstacle climbing ability - Turn the bottom of the stabilizer cylinder
COUNTERCLOCKWISE. Increase stability - Turn the bottom of the stabi-
lizer cylinder CLOCKWISE.
D. Line up mounting holes in stabilizer cylinder and
the stabilizer plates and reinstall the bottom hex bolt.
E. Check performance of the wheelchair. Repeat
STEPS A-D if necessary.
F. Tighten the jamnut on the stabilizer cylinder.
Jam Nut
Adjustment Nut
Stabilizer
Cylinder
BOTTOM
Hex Bolt
Bottom of Stabilizer
Locknut
Stabilizer
Plates
Cylinder
BOTTOM
Hex Bolt
Bottom of Stabilizer
Cylinder
FIGURE 13 - ADJUSTING TYPE A ST ABILIZER
ASSEMBLY FOR USER PREFERENCE
FIGURE 14 - ADJUSTING TYPE B ST ABILIZER ASSEMBL Y
FOR USER PREFERENCE
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MWD WHEELCHAIRS
PROCEDURE 14
Adjusting Type C Stabilizer Assembly for User Preference (FIGURE 15)
NOTE: Refer to STABILIZER INDENTIFICATION in the beginning of this section to determine correct sta­bilizer assembly.
1. Rotating the locknut that is located on top of the lower spring provides one (1) of the following:
A. Rotating the locknut CLOCKWISE - provides
more resistance of the stabilizer when stopping and increases stability.
B. Rotating the locknut COUNTER-CLOCKWISE
- provides less resistance of the stabilizer when stopping and improves obstacle climbing ability.
Stabilizer
Locknut
Lower
Spring
5. Position the new stabilizer cylinder on the wheelchair as shown in FIGURE 16.
6. Secure the top of the new stabilizer cylinder to the wheelchair frame with the hex bolt and locknut.
W ARNING
DO NOT overtighten. Stabilizer cylinder will not operate properly.
7. Secure the bottom of the new stabilizer cylinder to the stabilizer plates with the hex bolt and locknut.
8. Repeat STEPS 2-7 for the opposite side of the wheel- chair, if necessary.
9. Tighten the jam nut on the stabilizer cylinder.
10. Adjust the front stabilizer(s). Refer to STABILIZERS in this procedure of the manual.
11. If necessary, install the front shroud. Refer to ING/INSTALLING SHROUDS in PROCEDURE 10 of this manual.
Wheelchair Frame
Jam Nut
Locknuts
ADJUSTING
REMOV-
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FIGURE 15 - ADJUSTING TYPE C ST ABILIZER
ASSEMBLY FOR USER PREFERENCE
REPLACING STABILIZER CYLINDERS
Replacing Stabilizer Cylinders for Type A and Type B Stabilizer Assemblies (FIGURE 16)
NOTE: Refer to STABILIZER INDENTIFICATION in the beginning of this section to determine correct sta­bilizer assembly.
1. If necessary, remove the front shroud. Refer to RE-
MOVING/INSTALLING SHROUDS in PROCEDURE 10 of this manual.
2. Remove the top hex bolt and locknut that secure the existing stabilizer cylinder to the wheelchair frame.
3. Remove the bottom bolt and locknut that secure the bottom of the existing stabilizer cylinder to the stabi­lizer plates.
TOP Hex
Bolt
BOTTOM
Hex Bolt
Stabilizer
Plates
NOTE: Only stabilizer cylinder for Type A stabilizer assemlby shown. Stabilizer cylinder for Type B stabi­lizer assembly removes/installs in the same manner.
FIGURE 16 - REPLACING ST ABILIZER CYLINDERS FOR
TYPE A AND TYPE B ST ABILIZER ASSEMBLIES
Stabilizer
Cylinder
4. Remove existing stabilizer cylinder from the wheel­chair.
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Replacing Stabilizer Cylinders for Type C Stabilizer Assemblies (FIGURE 17)
NOTE: Refer to STABILIZER INDENTIFICATION in the beginning of this section to determine correct stabilizer assembly.
1. Place a 1/2-inch block underneath drive wheel.
2. Remove the top mounting screw and locknut that se­cures the top of the stabilizer cylinder to the wheel­chair frame.
2. Note the mounting position of the existing stabilizer cylinder for proper installation of the new stabilizer cyl­inder.
3. Remove the bottom mounting screw, washers and
I
locknut that secures the bottom of the stabilizer cylin­der to the swing arm.
4. Remove the existing stabilizer cylinder.
Top
zRight Hand side of
Wheelchair Frame
Mounting
Screw
Stabilizer
Cylinder
Top of
5. Secure the bottom of the NEW stabilizer cylinder to the mounting hole on the swing arm noted in STEP 2 with the mounting screw, washers, and locknut. Loosely tighten.
6. Secure the top of the stabilizer cylinder to the wheel­chair frame with the top mounting screw and locknut. Loosely tighten.
7. Torque both mounting screws to 13 ft/lbs and then back off 1/8 to 1/4 turn.
NOTE: The length of the new stabilizer cylinder must be adjusted to match the length of the stabilizer cylinder just removed.
8. Measure the distance between the top mounting hole and the bottom mounting hole on the existing stabilizer cylinder. Note this distance as distance “A” . Refer to DETAIL “A
9. Place the wheelchair on a flat surface so that the stabi­lizer wheels can hang freely.
10. Loosen the jam nut, located underneath the hex nut adjuster, by turning CLOCKWISE as viewed from the top.
11. Rotate the hex nut adjuster in one (1) of the following directions:
Bottom of
Stabilizer
Cyliner
Locknut
Washer
There is no
need to remove
this mounting screw
and locknut
Bottom
Locknuts
Swing
Arm
NOTE: Stabilizer assembly exploded away for clarity. It is not necessary to remove the stabilizer assembly from the wheelchair frame.
FIGURE 17 - REPLACING ST ABILIZER CYLINDERS FOR
TYPE C ST ABILIZER ASSEMBLIES
Mounting
Screw
A. Rotating the hex nut adjuster CLOCKWISE, as
viewed from the top, will move the stabilizer wheel up.
B. Rotating the hex nut adjuster COUNTER - CLOCK-
WISE, as viewed from the top, will move the stabi­lizer wheel down.
12. When distance “A” is achieved, noted from STEP 8, retighten the jam nut by rotating COUNTER-CLOCK­WISE to lock the hex nut adjuster in position.
13. Place the wheelchair on a flat surface with all six wheels in contact with the surface.
REPLACING STABILIZER WHEEL
Replacing Stabilizer Wheel for Type A and Type B Stabilizer Assemblies (FIGURE 18)
NOTE: Refer to STABILIZER INDENTIFICATION in the beginning of this section to determine correct stabilizer as­sembly.
NOTE: Note the position of the stabilizer wheel for installa­tion of the new stabilizer wheel.
1. Remove the hex bolt and locknut that secure the exist­ing stabilizer wheel and spacers to the stabilizer plates.
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PROCEDURE 14MWD WHEELCHAIRS
2. Remove existing stabilizer wheel from the wheelchair.
3. Position the new stabilizer wheel and spacers between the stabilizer plates.
4. Reinstall the hex bolt through the stabilizer plates, spac­ers and new stabilizer wheel and tighten securely.
5. Repeat STEPS 1-4 for opposite side of wheelchair.
Mount Stabilizer Wheel in
TOP
Mounting
Hole
Stabilizer
Plates
Hex Bolt
Spacers
Stabilizer Wheel
FIGURE 18 - REPLACING ST ABILIZER WHEEL FOR
TYPE A AND TYPE B STABILIZER ASSEMBLIES
Replacing Stabilizer Wheel for Type C Stabilizer Assemblies (FIGURE 19)
NOTE: Refer to STABILIZER INDENTIFICATION in the beginning of this section to determine correct stabilizer assembly.
1. Secure the fork to the caster with one (1) 7/16-20 x 3­1/4-inch hex screw, washer, and locknut.
2. Torque the locknut to 120-in/lbs.
3. Loosen the locknut 1/8 of a turn by turning the locknut COUNTER-CLOCKWISE.
4. Move the caster side to side.
NOTE: If the caster moves side to side, tighten the locknut slightly. Repeat STEP 3 until there is no side to side move­ment.
5. Repeat STEP 1 for other caster and fork.
7/16-20x
3-1/4-inch
Hex Screw
Washer
Only
Locknut
Locknut
REPLACING STABILIZER CYLINDER SPRINGS (FIGURE 16)
Replacing Stabilizer Cylinder Springs for Type A Stabilizer Assemblies (FIGURE 14)
NOTE: Refer to STABILIZER INDENTIFICATION in the beginning of this section to determine correct sta­bilizer assembly.
1. If necessary, remove the front shroud. Refer to RE-
MOVING/INSTALLING SHROUDS in PROCEDURE 10 of this manual.
2. Loosen the jam nut on the stabilizer cylinder.
3. Remove the top hex bolt and locknut that secure the stabilizer cylinder to the wheelchair frame.
4. Remove the bottom bolt and locknut that secure the bottom of the stabilizer cylinder to the stabilizer plates.
5. Remove the stabilizer cylinder from the wheelchair.
6. Unscrew the stabilizer cylinder pivot and jam nut from the stabilizer cylinder.
WARNING
The stabilizer cylinder spring is under compression. SLOWL Y remove the adjustment nut while check­ing to make sure the cylinder spring is becoming uncompressed. If the spring is not becoming uncompressed, DO NOT remove the adjustment nut, otherwise injury or damage can occur. Con­tact Invacare Technical Service, 1-800-832-4707.
7. SLOWLY remove adjustment nut and plate from sta­bilizer cylinder while checking to make sure existing stabilizer cylinder spring is becoming uncompressed.
8. Remove the existing stabilizer cylinder spring from the stabilizer cylinder.
NOTE: Examine the stabilizer cylinder and replace if worn.
9. Install the new stabilizer cylinder spring onto the stabi­lizer cylinder.
10. Reinstall the plate and adjustment nut onto the stabi­lizer cylinder as shown in FIGURE 16.
11. Screw the jamnut and stabilizer cylinder pivot onto the stabilizer cylinder.
12. Position the new stabilizer cylinder on the wheelchair as shown in FIGURE 16.
13. Secure the top of the new stabilizer cylinder to the wheelchair frame with the hex bolt and locknut.
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Caster
Washer
FIGURE 19 - REPLACING ST ABILIZER WHEEL FOR
TYPE A AND TYPE B ST ABILIZER ASSEMBLIES
W ARNING
DO NOT overtighten. Stabilizer cylinder will not operate properly.
14. Secure the bottom of the new stabilizer cylinder to the stabilizer plates with the hex bolt and locknut.
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PROCEDURE 14
MWD WHEELCHAIRS
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15. Repeat STEPS 2-14 for the opposite side of the wheel-
chair, if necessary.
16. Tighten the jamnut on the stabilizer cylinder.
WARNING
Stabilizers MUST be adjusted BEFORE use, oth­erwise they will NOT operate properly.
17. Adjust the front stabilizer(s). Refer to
STABILIZERS in this procedure of the manual.
18. If necessary, install the front shroud. Refer to
ING/INSTALLING SHROUDS in PROCEDURE 10 of this manual.
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TOP Hex Bolt
(STEPS 3, 13)
Locknuts
Wheelchair
Frame
BOTTOM Hex
Bolt
(STEPS
4, 14)
Stabilizer Cylinder Pivot
(STEPS 3,
13)
Stabilizer Plates
(STEPS 6, 11)
Jam Nut
Adjustment Nut
Plate
Stabilizer Cylinder Spring
Inspect for Wear
(STEPS 2, 11, 16)
(STEPS 7, 9)
(STEPS 7, 10)
(STEPS 8, 9)
ADJUSTING
REMOV-
Stabilizer
Cylinder
2. Remove the battery boxes. Refer to INSTALLING/ REMOVING BATTERY BOXES in this procedure of the manual.
3. Remove the tip from the existing clutch handle.
4. Remove the pin that secures the existing clutch handle to the motor/gearbox.
5. Disconnect the existing clutch handle from the motor/ gearbox.
6. Feed the existing clutch handle through the wheel­chair frame.
7. Remove the rubber tip from the new clutch handle.
8. Install the new clutch handle onto the wheelchair.
NOTE: Make sure the new clutch handle is pointing to­wards the outside of the wheelchair.
9. Install the rubber tip onto the new clutch handle.
10. Connect the clutch handle to the motor/gearbox and line up the mounting holes in the clutch handle and motor/gearbox.
11. Insert the pin through the clutch handle and motor/ gearbox as shown in DETAIL "A" in FIGURE 21.
NOTE: Make sure the detent ball on the pin is fully visible.
12. Repeat STEPS 3-11 for the opposite side of the wheel­chair, if necessary.
13. Reinstall the battery boxes. Refer to REMOVING BATTERY BOXES in this procedure of the manual.
14. If necessary, install the shrouds. Refer to ING/INSTALLING SHROUDS in PROCEDURE 10 of this manual.
Tip
(STEPS 3, 7, 9)
Clutch Handle
(STEPS 5, 8)
INSTALLING/
REMOV-
Outside of
Wheelchair
Stabilizer Cylinder
FIGURE 16 - REPLACING ST ABILIZER CYLINDER
SPRINGS
REPOSITIONING MOTORS
W ARNING
Repositioning the motors MUST be performed by an authorized Invacare dealer or qualified technician.
REPLACING CLUTCH HANDLES ­R2
1. If necessary, remove the shrouds. Refer to REMOV-
AND R2
BASIC
ING/INSTALLING SHROUDS in PROCEDURE 10 of this manual.
250 SERIES
(FIGURE 21)
Motor/
Gearbox
Pin
DET AIL "A"
Clutch Handle
FIGURE 21 - REPLACING CLUTCH HANDLES -
78
(STEPS 4, 11)
(STEP 10)
RANGER II MWD BASIC
Motor/Gearbox
Detent Ball
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MWD WHEELCHAIRS
PROCEDURE 14
REPLACING MOTOR/GEARBOX ­R2
1. If necessary, remove the shrouds. Refer to REMOV-
2. Remove the battery boxes. Refer to
3. Cut the tie wrap that secures the motor wire to the
4. Disconnect the right and/or left motor connector from
5. Remove the drive wheels from the wheelchair. Refer
6. Remove the dust covers, hex bolt, washers and lock-
7. Remove the bottom of the crossbrace from the mount-
8. Remove the pin that secures the clutch handle to the
9. Disconnect clutch handle from existing motor/gear-
10. Note mounting position of motor/gearbox on the wheel-
11. Remove the six (6) socket screws that secure the ex-
12. Position the new motor/gearbox and existing battery
AND R2
BASIC
ING/INSTALLING SHROUDS in PROCEDURE 10 of this manual.
REMOVING BATTERY BOXES in this procedure of the manual.
battery tray mounting bracket.
the controller.
REMOVING/INSTALLING DRIVE WHEELS in
to PROCEDURE 9 of this manual.
nut that secure the bottom of the crossbrace to the wheelchair frame
ing bracket on the wheelchair frame.
existing motor/gearbox.
box.
chair frame for installation of the new motor/gearbox.
isting motor/gearbox and battery tray mounting bracket to the wheelchair frame.
tray mounting bracket on the wheelchair frame at the position noted in STEP 10 as shown in FIGURE 22.
250 SERIES
(FIGURE 22)
INSTALLING/
STEPS 5, 6 AND 17
Locknut
Crossbrace
Dust Cover
LONG Socket Screws (Apply
Loctite 242 and torque to 60-inch
pounds)
Wheelchair Frame
SHORT Socket
Screws (Apply
Loctite 242 and
torque to 60-inch
pounds)
(STEPS 11, 13)
(STEPS 11, 13)
Pin
(STEP 8)
Clutch Handle
(STEP 9)
Battery Motor
Connectors
(STEPS 4, 19)
Washer
Hex Bolt
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CAUTION
The longer socket screws must be positioned in the mounting holes on the OUTSIDE of the wheel­chair frame and the short socket screws must be in the mounting holes on the INSIDE of the wheel­chair frame. Otherwise damage to the gearbox may result.
13. Use Loctite 242 and tighten the battery tray mounting bracket and motor/gearbox to the wheelchair frame securely with the six (6) socket screws. Torque to 60­inch pounds.
14. Connect the clutch handle to the new motor/gearbox and line up the mounting holes.
15. Insert the pin through clutch handle and new motor/ gearbox as shown in DETAIL "B" in FIGURE 22.
Tie Wrap
(STEPS 3,
20)
Battery
Tray
Mounting
Bracket
Motor/
Gearbox
DET AIL "B"
Clutch Handle
(STEP 14)
FIGURE 22 - REPLACING MOTOR/GEARBOX -
79
Pin
(STEP 14)
RANGER II MWD BASIC
Motor/Gearbox
(STEP 14)
Detent Ball
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PROCEDURE 14 MWD WHEELCHAIRS
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NOTE: Make sure the detent ball on the pin is fully visible.
16. Repeat STEPS 3-15 for the opposite side of the wheel­chair, if necessary.
17. Reinstall the drive wheels onto the wheelchair. Refer
REMOVING/INSTALLING DRIVE WHEELS in
to PROCEDURE 9 of this manual.
18. Reinstall the hex bolt, washers, locknuts and covers that secure the bottom of the crossbrace to the wheel­chair frame.
19. Reconnect the right and/or left motor connector to the controller.
20. Secure motor wire to the battery tray mounting bracket with a new tie wrap.
21. Reinstall the battery boxes. Refer to
I
REMOVING BATTERY BOXES in this procedure of the manual.
22. If necessary, install the shrouds. Refer to ING/INSTALLING SHROUDS in PROCEDURE 10 of this manual.
INSTALLING/
REPLACING MOTOR/GEARBOX ­R2
STANDARD
1. If necessary, remove the shrouds. Refer to REMOV­ING/INSTALLING SHROUDS in PROCEDURE 10 of this manual.
2. Remove the battery boxes. Refer to MOVING BATTERY BOXES in this procedure of the manual.
3. Cut the tie wrap that secures the motor wire to the bat­tery tray mounting bracket.
4. Disconnect the right and/or left motor connector from the controller.
5. Remove the dust covers, hex bolt, washers and lock­nut that secure the bottom of the crossbrace to the wheelchair frame
(FIGURE 23)
INSTALLING/RE-
REMOV-
10. Position the new motor/gearbox and existing battery tray mounting bracket on the wheelchair frame at the position noted in STEP 8 as shown in FIGURE 19.
CAUTION
The longer socket screws must be positioned in the mounting holes on the OUTSIDE of the wheelchair frame and the short socket screws must be in the mounting holes on the INSIDE of the wheelchair frame. Otherwise damage to the gearbox casting may result.
11. Use Loctite 242 and tighten battery tray mounting bracket and motor/gearbox to the wheelchair frame securely with the six (6) socket screws. Torque to 60­inch pounds.
12. Repeat STEPS 3-11 for the opposite side of the wheel­chair, if necessary.
13. Reinstall the drive wheels onto the wheelchair. Refer to REMOVING/INSTALLING DRIVE WHEELS in PRO­CEDURE 9 of this manual.
14. Reinstall the hex bolt, washers, locknuts and dust cov­ers that secure the bottom of the crossbrace to the wheelchair frame.
15. Reconnect the right and/or left motor connector to the controller.
16. Secure the motor wire to the battery tray mounting bracket with a new tie wrap.
17. Reinstall the battery boxes. Refer to REMOVING BATTERY BOXES in this procedure of the manual.
18. If necessary, install the shrouds. Refer to ING/INSTALLING SHROUDS in PROCEDURE 10 of this manual.
INSTALLING/
REMOV-
6. Remove the bottom of the crossbrace from the mount­ing bracket on the wheelchair frame.
7. Remove the drive wheels from the wheelchair. Refer
REMOVING/INSTALLING DRIVE WHEELS in
to PROCEDURE 9 of this manual.
8. Note the mounting position of motor/gearbox on wheel­chair frame for installation of new motor/gearbox.
9. Remove the six (6) socket screws that secure the exist­ing motor/gearbox and battery tray mounting bracket to the wheelchair frame.
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MWD WHEELCHAIRS
PROCEDURE 14
Locknut
Crossbrace
Battery Motor Connectors
(STEPS 4, 15)
STEPS 5, 6 AND 14
Hex Bolt
Dust Cover
Washer
LONG Socket Screws (Apply Loctite 242 and
torque to 60-inch pounds)
(STEPS 9, 11)
Battery Tray
Mounting
Bracket
SHORT Socket Screws
(Apply Loctite 242 and
torque to 60-inch
pounds)
(STEPS 9, 11)
Wheelchair
Frame
Tie Wrap
(STEPS 3,
16)
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FIGURE 23 - REPLACING MOTOR/GEARBOX - RANGER II MWD STANDARD
Motor/Gearbox
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N
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NOTES
NOTES
T
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WARRANTY
LIMITED WARRANTY
PLEASE NOTE: THE W ARRANTY 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. With regards to the original purchaser/user only, Invacar e warrants the side frames and crossbraces to be
free from defects in materials and workmanship for a period of five (5) years from date of purchase; electronics for a period of one (1) year from the date of purchase; motors and gearboxes for a period of eighteen (18) months for Ranger II models with motors that have motor locks and a period of twelve (12) months for Ranger II models with motors that have clutches fr om the date of pur chase; all remain­ing components (including gas cylinders for recliners) for one (1) year from the date of pur chase except upholstered materials, padded materials and tires/wheels. If within such warranty period any 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.
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 on 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.
LIMIT ATIONS AND EXCLUSIONS: THE FOREGOING W ARRANTY SHALL NOT APPL Y TO SERIAL NUMBERED PROD­UCTS IF THE SERIAL NUMBER HAS BEEN REMOVED OR DEFACED, PRODUCTS SUBJECT 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 P ARTS OR ATT ACHMENTS; PRODUCTS DAMAGED BY REASON OF REP AIRS MADE TO ANY COMPONENT WITHOUT THE SPECIFIC CONSENT OF INVACARE, OR TO A PRODUCT DAMAGED BY CIRCUMSTANCES BEYOND INVACARE'S CONTROL, AND SUCH EVALUATION WILL BE SOLELY DETERMINED BY INVACARE. THE WARRANTY SHALL NOT APPLY TO PROBLEMS ARISING FROM NORMAL WEAR OR F AILURE TO ADHERE TO THESE INSTRUCTIONS. A CHANGE IN OPERA TING NOISE, PARTICULARLY RELATIVE TO MOTORS AND GEARBOXES DOES NOT CONSTITUTE A FAILURE. ALL SUCH DE­VICES WILL EXHIBIT A CHANGE IN OPERA TING NOISE DUE TO AGING.
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THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS WARRANTIES. IMPLIED WARRANTIES, IF ANY, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, SHALL NOT EXTEND BEYOND THE DURATION OF THE EXPRESSED WARRANTY PRO­VIDED HEREIN AND THE REMEDY FOR VIOLA TIONS OF ANY IMPLIED W ARRANTY SHALL BE LIMITED TO REP AIR OR REPLACEMENT OF THE DEFECTIVE PRODUCT PURSUANT TO THE TERMS CONT AINED HEREIN. INVACARE SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENT AL DAMAGES WHATSOEVER.
THIS WARRANTY SHALL BE EXTENDED TO COMPLY WITH STATE/PROVINCIAL LAWS AND REQUIREMENTS.
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Invacare Corporation www.invacare.com
USA Canada
One Invacare Way 5970 Chedworth Way Invacare and "Yes, you can" are trademarks of Invacare Elyria, Ohio USA Mississauga, Ontario Corporation. 44036-2125 L5R 3T9, Canada © 800-333-6900 905-890-8838 Form No. 98-273 Part No. 1085398 Rev B (1) 3/00
2000 Invacare Corporation
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