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

Service Manual

Ranger II Storm Series

Wheelchairs

MWD/FWD

Ranger II

BASIC

STANDARD

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.

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

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

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

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

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

C O N

T E

SPECIFICATIONS

S P E C

C A T

O N S

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

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

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

STANDARD

BASIC

STANDARD

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

(55

- 114o)

(98o)

(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.

BASIC

/ R2

250 series

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

- 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

/R2

- 22NF Gel Cell (Two (2) Required); R2

STANDARD

250 series

250-SERIES

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.

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.

BASIC

AND

has

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

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

STANDARD

BASIC

STANDARD

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)

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

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)

STANDARD

250 SERIES

(35o - 170o)

- Gray fabric

S P E C

I C A T

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

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

250-SERIES

250 SERIES

uses - U1 GEL CELL)

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.

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.

AND

has

S P E C

C A T

O N S

SPECIFICATIONS

NOTE: All specifications are approximate.

Seat Width Range: 14-inches

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

to 105o - in 5o increments

With 8-inch rear casters and no front riggings: 32-1/2-inches

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

PERFORMANCE

Speed (M.P.H.): 0 to 3.6 Turning Radius: 24-inches Range (variable)2: 14 miles

L Weight Limitation3: 200 lbs.

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.

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

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.

E N E R A L

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.

GENERAL GUIDELINESPROCEDURE 1

WARNING/CAUTION LABEL LOCATION - MWD MODELS

E R A

L G

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

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

E R A

L G

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.

GENERAL GUIDELINESPROCEDURE 1

WARNING/CAUTION LABEL LOCATION - FWD MODELS (R2JR)

E R A

L G

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

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 Owner’s 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

E R A

L G

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 Owner’s 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

TROUBLESHOOTINGPROCEDURE 2

This Procedure Includes the Following: Field Load Test

T R O U B

E S H O O

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.

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

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

U B L E S

H O O

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)

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

sent to Invacare Technical Services for inspection/repair.

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

1. Once the motor brush caps have been removed, pull the brushes out of the motor. The end of the brushes should be smooth and shiny and the spring should not be damaged or discolored. If one or both of the brushes are damaged, only the damaged or worn brushes need be replaced. It is very important that any time a brush is replaced, it must be “burned in”. This is accomplished by running the motor for one hour in each direction with a half hour break in-between. This should also be done with little or no load on the motor, i.e., put the wheelchair up on blocks so the drive (large) wheels do not contact the ground and run the wheelchair. A motor with only one brush replaced will only carry a small percentage of its rated load capacity until the NEW brush is burned in.

ELECTRO-MECHANICAL PARKING BRAKE TESTING (FIGURE 5)

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

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

3. Measure the resistance between the two (2) brake contacts. A normal reading is 100 ohms (Ω). A reading of 0 ohms (Ω) or a very high reading; i.e., MEG ohms or O.L. (out of limit) indicates a shorted brake or an open connection respectively. If either condition exists, send the motor to Invacare Technical Service for inspection/repair.

CAUTION

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

NOTE: A bad motor can damage the controller module but a bad controller 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

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.

Flip Up Footboard

PROCEDURE 3

FRONT RIGGINGS

F R O N

T R

G G

N G

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

FOOTBOARD

NOTE:This footboard assembly is available on models

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

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

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 Owner’s 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 Owner’s 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

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-

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

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

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

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.

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)

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

S E A

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

SEAT FRAMEPROCEDURE 6

S E A

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)

DETAIL "B"

100

Locknut

Washers

105

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

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.

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

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

PROCEDURE 7

ELECTRONICS

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)

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)

- CAPTAIN’S 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/

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.

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)

L E C

T R O N

C S

PROCEDURE 7 ELECTRONICS

Mounting Stud on

Wheelchair Frame

Washer

MKIV

Controller

Locknuts

Slot

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

Cable

Left Hand

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