Invacare Wheelchair Arrow Users Manual

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2015-02-02

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Service Manual

STORM SERIES®

WHEELCHAIRS

(RWD/MWD/FWD)

Arrow®

Torque SP

Ranger X

DEALER: KEEP THIS MANUAL. THE PROCEDURES

IN THIS MANUAL MUST BE PERFORMED BY AN

AUTHORIZED DEALER ONLY

WARNING

SAVE THESE INSTRUCTIONS

WARNING

THE PROCEDURES IN THIS MANUAL SHOULD ONLY BE PERFORMED BY

QUALIFIED TECHNICIAN.

DO NOT SERVICE OR OPERATE THIS EQUIPMENT WITHOUT FIRST

READING AND UNDERSTANDING THIS MANUAL AND THE OWNERS

MANUAL SUPPLIED WITH THE WHEELCHAIR. IF YOU ARE UNABLE TO

UNDERSTAND THE WARNINGS, CAUTIONS, AND INSTRUCTIONS,

CONTACT INVACARE TECHNICAL SUPPORT BEFORE ATTEMPTING TO

SERVICE OR OPERATE THIS EQUIPMENT - OTHERWISE INJURY OR

DAMAGE MAY RESULT.

SPECIAL NOTES

WARNING/CAUTION notices as used in this manual apply to hazards or unsafe practices

which could result in personal injury or property damage.

NOTICE

THE INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT

NOTICE.

WHEELCHAIR USER

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

Action wheelchairs to meet many needs of the end user. However, final selection of

the type of wheelchair to be used by an individual rests solely with the user and his/her

healthcare professional capable of making such a selection.

WHEELCHAIR TIE-DOWN RESTRAINTS AND SEAT POSITIONING STRAPS

Invacare recommends that wheelchair users NOT be transported in vehicles of any

kind while in wheelchairs. As of this date, the Department of Transportation has not

approved any tie-down systems for transportation of a user while in a wheelchair, in a

moving vehicle of any type.

It is Invacare’s position that users of wheelchairs should be transferred into appropri-

ate 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 wheel-

chair transportation systems.

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

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

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

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

CHAIR.

TABLE OF CONTENTS

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

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

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

where specified.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

TABLE OF CONTENTS

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

TABLE OF CONTENTS

TABLE OF CONTENTS (Continued)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS

SPECIFICATIONS

* in 1-inch increments

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

available on Storm Torque ONLY.

✪With MKIV RII Controller. ● With MKIV Rx or A Controller. u Non-Recliners ONLY.

vArrow specifications refer to RWD, MWD and FWD wheelchairs except where specified.

vARROW ** TORQUE **TORQUE SP X JUNIOR

Seat Width Range:

250 lbs Rating ✪ 16 to 20-in. *12 to 16-in.

MWD/RWD

300 lbs. Rating *16 to 22-in. 16 and 18-in. ● 16 to 20-in *16 to 22-in.

MWD/RWD FWD

400 lbs. Rating *19 to 24-in. *16 to 24-in.

Seat Depth Range: *16 to 22-in. 16 and 18-in. *16 to 18-in. *16 to 22-in. *12 to 15-in. w/CJ Back

Expandable to - *16 to 17-in.

Back Height Range: *16 to 24-in. 16, 18, 20,22-in. *16 to 22-in. *16 to 24-in. *12 to 18-in.

Seat-to-Floor

(approximate) MWD/RWD FWD Storm Base X Base

Standard: 17-1/2-in. 18-1/4-in. 17-1/2-in. 17-1/2-in. 17-1/2-in. 17-1/2-in. 17-1/2-in.

Optional: 19-3/4-in. 20-1/2-in. 19-3/4-in. 19-3/4-in. 19-3/4-in. 19-3/4-in. 19-3/4-in.

21-in. 21-3/4-in. N/A N/A 21-in.

Overall Width

of Base: 24-5/8-in. 25-1/4-in. 24-5/8-in. 24-5/8-in. 24-5/8-in.

(w/o joystick)

Overall Height MWD/RWD FWD Storm Base X Base

Standard: 34-1/4-in. 35-1/2-in 34-1/4-in. 34-1/4-in. 34-1/4-in. 34-1/4-in. 34-1/4-in.

Minimum: 34-1/4-in. 35-1/2-in N/A N/A 34-1/4-in. 32-1/4-in. 32-1/4-in.

Maximum: 44-1/4-in. 45-1/2-in N/A N/A 44-1/4-in. 40-1/2-in. 40-1/2-in.

Recliner - (Std.)

Low Seat Frame: 51-1/2-in. 52-3/4-in. N/A N/A 51-1/2-in. N/A

Med. Seat Frame: 53-3/4-in. 55-in. N/A N/A 53-1/4-in. N/A

High Seat Frame: 55-1/2 in. 58-1/2-in. N/A N/A 55-1/2-in. N/A

Overall Length

(without front

riggings) MWD/RWD FWD

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

Long Frame: 35-1/4-in. N/A N/A N/A 35-1/4-in. 35-1/4-in.

Weight

Standard Motor MWD/RWD FWD Storm Base X Base

W/O Batteries: 146 lbs. 199 lbs. 149 lbs. 149 lbs. 149 lbs. 146 lbs. 149 lbs.

W/Batteries:

Standard 248 lbs. 310 lbs. 224 lbs. 224 lbs. 224 lbs. 246 lbs. 224 lbs.

Optional N/A N/A 249 lbs. N/A 249 lbs. N/A 249 lbs.

Shipping (approx.): 176 lbs. 229 lbs. 176 lbs. 176 lbs. 176 lbs. 176 lbs. 176 lbs.

Gearless/Brushless

Motor

W/O Batteries: 166 lbs. N/A 169 lbs. N/A 169 lbs. 166 lbs. 169 lbs.

W/ Batteries:

Standard 243 lbs. N/A 243 lbs. N/A 243 lbs. 266 lbs. 243 lbs.

Optional 268 lbs. N/A 268 lbs. N/A 268 lbs. N/A 268 lbs.

Shipping (approx.): 196 lbs. N/A 196 lbs. N/A 196 lbs. 196 lbs. 196 lbs.

Drive Axle: *◆Adjustable (MWD/RWD only) *◆Adjustable *◆Adjustable *◆Adjustable *Adjustable

Drive Wheels/Tires:

(Foam Filled or

Pneumatic)

Standard: 14 X 3-in. 14 X 3-in. 14 X 3-in. 14 X 3-in. 14 X 3-in. 14 X 3-in.

Optional: 14 X 4-in. 14 X 4-in. 14 X 4-in. 14 X 4-in. 14 X 4-in. 14 X 4-in.

PHYSICAL

DIMENSIONS

SPECIFICATIONS

PHYSICAL DIMENSIONS vARROW ** TORQUE **TORQUE SP X JUNIOR

Casters w/Precision Sealed Bearings

Semi-Pneumatic 300 lbs. Rating

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

Option: 6 X 2-in. 6 X 2-in. 6 X 2-in. 6 X 2-in. 6 X 2-in.

Pneumatic or Foam Filled

Standard: 8 X 2-in. 8 X 2-in. 8 X 2-in. 8 X 2-in. 8 X 2-in.

Option: 9 X 2-3/4-in. 9 X 2-3/4-in. 9 X 2-3/4-in.

Pneumatic or Foam Filled 400 lbs. Rating

(RWD,MWD only)

Standard: 9 X 2-3/4-in.

Option: 8 X 2-in.

SPECIFICATIONS (Continued)

PERFORMANCE ARROW **TORQUE **TORQUESP X JUNIOR

Speed 0 to 5-3/4 (300 lbs. rating) RWD,MWD 0 to 6-1/2 0 to 4-1/4 0 to 6-1/2 Arrow Base X Base

(M.P.H.): 0 to 4-1/4 (400 lbs. rating) RWD,MWD 0 to 6-1/2 0 to 6-1/2

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

0 to 4 (400 lbs. rating) FWD

***Range(miles): up to 19 - RWD,MWD up to 16 (Std) Up to 16 up to 16 (Std) up to 19 up to 23 (Std)

(uGel Batteries) *up to 29 (Std) - RWD,MWD up to 19 (Opt) up to 19 (Opt) *up to 29 (Std) up to 19 (Opt)

*up to 29 (Opt) - RWD,MWD *up to 29 (Std) *up to 29 (Std) *up to 35 (Opt) *up to 29 (Std)

up to 16 - FWD *up to 35 (Std) *up to 35 (Opt) up to 35 (Opt)

Weight 300 lbs. (Standard Unit); 400 lbs. (FWD) 300 lbs. ✪ 250 lbs. 300 lbs. 250 lbs. 250lbs.

Limitation: *300 lbs. (Standard Unit)RWD,MWD *300 lbs. ● 300 lbs.

400 lbs. (Heavy Duty Unit) RWD,MWD *300 lbs.

vARROW, ** TORQUE, **TORQUE SP, X and JUNIOR

Anti-Tippers (3-inch wheels): Standard (N/A on FWD)

Caster Forks: Standard, Shock Fork (Optional)

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

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

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

Seat Angle Adjustment: Adjustable (0o to 10o)

Back Angle Adjustment: Adjustable (80o to 100o in 5o increments)

Seat Cushion: Cushion (Optional)

Chair Upholstery Options: Naugahyde and Nylon

Battery/Size (Not Supplied): BASE FRAMES uSTD BATTERIES uOPT BATTERIES

Two (2) Required Arrow w/ Standard motor Group 24 N/A

(uGel Batteries) - w/ **Gearless/Brushless motor Group 22 Group 24

Torque w/ Standard Motor Group 22 Group 24

- w/ Gearless/Brushless motor Group 22 Group 24

**Torque SP w/ Standard Motor Group 22 N/A

Ranger X w/Standard Motor Group 22 Group 24

- w/ Gearless/Brushless motor Group 22 Group 24

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

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

14 to 24-in. 16 to 22-in. 18-1/2 to 26-in. Arrow Base -300 Std./400 Optional 90o to 170o

✪ Torque SP Base - 250

X, Torque,● Torque SP Base - 300

Arrow, X, Torque Base W/ Gearless/

Brushless Motor - 300 lbs.

* With gearless/brushless motor option.

** Storm Torque/Torque SP wheelchairs are available in rear

wheel drive ONLY. Gearless Brushless Motor Option is avail-

able on Storm Torque ONLY.

***Range will vary with battery conditions,

surface, terrain and operators weight.

✪ With MKIV RII Controller.

● With MKIV Rx or A Controller.

v Arrow specifications refer to RWD, MWD and FWD wheel-

chairs except where specified.

Arrow FWD has a 400 lb. rating.

GENERAL GUIDELINESPROCEDURE 1

REPAIR OR SERVICE INFORMATION

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

Invacare. The final tuning adjustments of the controller may affect other activities of

the wheelchair. Damage to the equipment could occur under these circumstances. If

non-certified individuals perform any work on these units, the warranty is void.

OPERATING INFORMATION GENERAL WARNINGS

Performance adjustments should only be made by professionals of the healthcare field

or persons fully conversant with this process and the driver's capabilities. Incorrect set-

tings 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 speci-

fications. Repeat this procedure until the wheelchair performs to specifications.

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

TIRE PRESSURE

DO NOT use your wheelchair unless it has the proper tire pressure (P.S.I.). DO NOT overin-

flate the tires. Failure to follow these suggestions may cause the tire to explode and

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

ELECTRICAL

Grounding Instructions:

DO NOT, under any circumstances, cut or remove the round grounding prong from any

plug used with or for Invacare products. Some devices are equipped with three-prong

(grounding) plugs for protection against possible shock hazards. Where a two-prong wall

receptacle is encountered, it is the personal responsibility and obligation of the customer

to contact a qualified electrician and have the two-prong receptacle replaced with a

properly grounded three-prong wall receptacle in accordance with the National Elec-

trical 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 re-

move these tags. Carefully read battery/battery charger information prior to installing,

servicing or operating your wheelchair.

BATTERIES

The warranty and performance specifications contained in this manual are based on

the use of deep cycle gel cell or sealed lead acid batteries. Invacare strongly

recommends their use as the power source for this unit.

Battery connecting cables are NOT interchangeable. Battery connecting cables with

single fuse setup MUST only be used on wheelchairs with conventional motor/gearbox

assembly. Otherwise, damage may result. Refer to INSTALLING/REMOVING BATTERIES

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

This Procedure Includes the Following:

Repair or Service Information

Operating Information

GENERAL GUIDELINES PROCEDURE 1

WARNING/CAUTION LABEL LOCATION - RWD MODELS

SUSPENSION ARM USED

WITH GEARLESS/BRUSHLESS

MOTOR

NOTE: WARNING LABEL also

found on side frame near the rear

of the chair.

SUSPENSION ARM

USED

WITH CONVENTIONAL

MOTOR/GEARBOX

ASSEMBLY

NOTE: These caution labels are only found on bat-

tery boxes used with the gearless/brushless motor

GROUP 24 BATTERIES GROUP 22 BATTERIES

NOTE: This caution label is only

found on wiring harnesses used

with the conventional motor/gear-

box application.

ONE (1) CONNECTOR BATTERY

BOX WIRING HARNESS

NOTE: For models with the gearless/brushless motor, read the

manufacturers CAUTION LABEL located on side of the motor.

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

NOTE: This wiring harness is found on wheel-

chair models built BEFORE 11/15/99.

NOTE: This wiring harness is found on

wheelchair models built AFTER 11/15/99.

1070497

MUST

MWD MODELS

Suspension Arm

(located on inside of

drive wheel)

NOTE: CAUTION LABEL also

found on side frame near the front

of the chair.

GENERAL GUIDELINESPROCEDURE 1

WARNING/CAUTION LABEL LOCATION

BATTERY BOX WIRING HARNESS

FWD MODELS

NOTE: Stablilizer springs

are found on models built

BEFORE 7/11/99 ONLY.

(+)

(-)

FIGURE 1 - FIELD LOAD TEST

Battery Charger

Connector

Digital Voltmeter

FIELD LOAD TEST (FIGURE 1)

NOTE: The following test can also be performed through

the controller of the wheelchair along with a remote pro-

grammer. 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 us-

ing the digital voltmeter.

NOTE: Invacare recommends that ONLY qualified ser-

vice personnel perform this test.

1. Ensure that power is OFF.

2. Make sure battery is fully charged. An extremely dis-

charged battery will exhibit the same symptoms as a

bad one.

3. Remove the footrests from the wheelchair and per-

form one (1) of the following:

A. RWD MODELS - place the CASTERS of the

wheelchair against a wall, workbench or other

stationary object.

B. MWD MODELS - place the STABILIZER

wheels of the wheelchair against a wall, work-

bench or other stationary object.

C. FWD MODELS -place the DRIVE wheels of

the wheelchair against a wall, workbench or

other stationary object.

USING HYDROMETER TO CHECK

BATTERY CELLS (LEAD ACID)

(FIGURE 2)

NOTE: Perform this procedure when a digital voltmeter is

not available.

WARNING

NEVER smoke or strike a match near the

batteries. If the caps of the battery cells

are removed, NEVER look directly into

them when charging the battery.

The use of rubber gloves and chemical

goggles or face shields is recommended

when working with batteries.

TROUBLESHOOTING PROCEDURE 2

This Procedure Includes the Following:

Field Load Test

Using Hydrometer To Check Battery Cells (Lead

Acid)

Motor Testing

Motor Brush Inspection

Electro-Mechanical Parking Brake Testing

4. Place the voltmeter leads into the charger plug on the

wheelchair. Most digital voltmeters are not affected by

polarity, however, analog meters (meters with swing-

ing needles) can be and should be used carefully. A

good meter reading should be 25.5 to 26 VDC.

5. Have two (2) individuals (one [1] on each arm) apply

as much downward pressure as possible on the arms

of the wheelchair.

6. Turn the wheelchair ON and push the joystick for-

ward, trying to drive the wheelchair through the sta-

tionary 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.

TROUBLESHOOTING

PROCEDURE 2

WARNING

When reading a hydrometer, DO NOT al-

low 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 wheel-

chair, clothing, and household items.

Therefore, take readings cautiously and

only in designated areas.

ONLY use distilled water when topping off

the battery cells.

Most batteries are not sold with instructions.

However, warnings are frequently noted

on the cell caps. Read them carefully.

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

REMOVING BATTERY BOXES - GROUP 24 BAT-

TERY BASE FRAMES or INSTALLING/REMOVING

BATTERY BOX - GROUP 22 BATTERY BASE

FRAMES in PROCEDURE 9 of this manual.

2. Remove the battery caps from the battery.

3. Squeeze the air from the hydrometer.

4. Place the hydrometer into a battery cell.

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

5. Draw up sufficient acid to cover float balls.

6. Tap lightly to remove air bubbles.

7. Number of floating balls indicates charge.

Number of Floating Balls

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 prop-

erly read. A shorted or dead cell can be detected when

it is the only cell that does not charge.

FIGURE 2 - USING HYDROMETER TO CHECK

BATTERY CELLS (LEAD ACID)

Number of Floating

Balls Will Vary

According to Charge

9. Flush hydrometer in cold running water by allowing

the water to rise into hydrometer as far as possible.

Do this several times to guard against burn damage.

10. Replace the battery caps.

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

MOVING BATTERY BOXES - GROUP 24 BATTERY

BASE FRAMES or INSTALLING/REMOVING BAT-

TERY BOX - GROUP 22 BATTERY BASE FRAMES

in PROCEDURE 9 of this manual.

MOTOR TESTING (FIGURE 3)

NOTE: This procedure should only be performed on

wheelchairs with the conventional motor/gearbox assem-

bly. For gearless/brushless motors, there are no service-

able parts. Return motor to manufacturer for testing.

1. On the 4-pin motor connector, locate the two (2) con-

tacts 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.

TROUBLESHOOTING

ELECTRO-MECHANICAL PARKING

BRAKE TESTING (FIGURE 5)

NOTE: This procedure should only be performed on

wheelchairs with conventional motor/gearbox assembly.

1. On the four-pin motor connector, locate the side by

side connectors in the black housings.

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

3. Measure the resistance between the two (2) brake con-

tacts. 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 connec-

tion 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 con-

troller. DO NOT connect a shorted electro-

mechanical brake to a good controller mod-

ule. A shorted brake MUST be replaced.

NOTE: A bad motor can damage the controller module

but a bad controller will NOT damage a motor.

4 Pin Motor Connector

Ohmmeter

Cap Motor

Cap

4 Pin Motor Connector

Motor

FIGURE 5 - ELECTRO-MECHANICAL

PARKING BRAKE TESTING

MOTOR BRUSH INSPECTION

(FIGURE 4)

NOTE: This procedure should only be performed on wheel-

chairs with conventional motor/gearbox assembly.

There are two (2) contact brushes on ACTION STORM mo-

tors 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-be-

tween. 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.

FIGURE 4 - MOTOR BRUSH INSPECTION

TROUBLESHOOTING PROCEDURE 2

FIGURE 3 - MOTOR TESTING

Motor Connector

Ohmmeter

Motor Connector

Ohmmeter

PROCEDURE 3 HARDWARE TORQUE SPECIFICATIONS

HARDWARE TORQUE SPECIFICATIONS

*Torque to

60 in/lbs

**Torque

156 in/lbs

Torque to

156 in/lbs

**Torque to

156 in/lbs

**Torque to

156 in/lbs

STANDARD SEAT FRAME

*Loctite® and

Torque to

75 in/lbs

*Loctite and

Torque to

75 in/lbs

**Torque to

156 in/lbs

NOTE:

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

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

PROCEDURE 3HARDWARE TORQUE SPECIFICATIONS

Torque to

75-in/lbs

HARDWARE TORQUE SPECIFICATIONS

*CAPTAINS VAN SEAT

Loctite and Torque to

75 in/lbs

Torque to

156 in/lbs

*ADJUSTABLE SEAT FRAME

Torque to

156 in/lbs

Torque to

156-in/lbs Torque to

156-in/lbs

Torque to

156-in/lbs

Torque to

156-in/lbs

* NOTE: For additional torque specifications, refer to the torque specifications drawing for the standard

seat frame assembly.

Torque to

160 in/lbs

Loctite and torque to

160 in/lbs

Torque to

1020 in/lbs

8 - inch Wheels -

Torque to 120 in/lbs

9 - inch Wheels -

Torque to 160 in/lbs

Torque to

160 in/lbs

Loctite and

torque to

75 in/lbs

Tighten until snug

Pneumatic with Flat-Free

Wheel Halves - Torque to

160 in/lbs

Pneumatic Wheel Halves -

8 - inch - Torque to 18 in/lbs

9 - inch - Torque to 160 in/lbs

Loctite and

Torque to

75 in/lbs

Torque to

160 in/lbs

Torque to

160 in/lbs

Wheel Halves -

Torque to 75 in/lbs

FRONT OF

WHEELCHAIR

REAR OF

WHEELCHAIR

PROCEDURE 3 HARDWARE TORQUE SPECIFICATIONS

REAR WHEEL DRIVE BASE FRAME HARDWARE

TORQUE SPECIFICATIONS

GEARLESS/BRUSHLESS MOTOR

Torque to 13 ft/lbs.

Torque to 25 in/lbs.

Torque to 75 in/lbs.

CONVENTIONAL MOTOR/GEARBOX

NOTE: All torque specifications called out for the con-

ventional motor/gearbox assembly are applicable to

the gearless/brushless motor except for the following:

MID-WHEEL DRIVE BASE FRAME HARDWARE

TORQUE SPECIFICATIONS

Torque to

160 in/lbs

Torque to

1020 in/lbs

Loctite and

Torque to

75 in/lbs

Torque to

160 in/lbs

Torque to

160 in/lbs

Torque to

160 in/lbs

Loctite and

torque to

75 in/lbs

Tighten

until snug

Torque to

40 in/lbs

Loctite and torque to

160 in/lbs

FRONT OF

WHEELCHAIR

REAR OF

WHEELCHAIR

8 - inch Wheels -

Torque to 120 in/lbs

9 - inch Wheels -

Torque to 160 in/lbs

Pneumatic with Flat-Free

Wheel Halves - Torque to 160

in/lbs

Pneumatic Wheel Halves -

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

inch - Torque to 160 in/lbs

Wheel Halves -

Torque to 75 in/lbs

PROCEDURE 3HARDWARE TORQUE SPECIFICATIONS

FRONT-WHEEL DRIVE BASE FRAME HARDWARE

TORQUE SPECIFICATIONS

Torque to

1020 in/lbs

Torque to

156 in/lbs

Torque to

156 in/lbs

Torque to

156 in/lbs

Torque to

15 in/lbs

Torque to

360 in/lbs

Torque to

156 in/lbs

Torque to

360 in/lbs

Torque to

156 in/lbs

Loctite and

Torque to

75 in/lbs FRONT OF

WHEELCHAIR

REAR OF

WHEELCHAIR

Torque to

160 in/lbs

8 - inch Wheels -

Torque to 120 in/lbs

9 - inch Wheels -

Torque to 160 in/lbs

Pneumatic with Flat-Free

Wheel Halves - Torque to 160

in/lbs

Pneumatic Wheel Halves -

8 - inch - Torque to 18 in/lbs

9 - inch - Torque to 160 in/lbs

Wheel Halves -

Torque to 75 in/lbs

PROCEDURE 3 HARDWARE TORQUE SPECIFICATIONS

Torque to

160 in/lbs

ARMS PROCEDURE 4

REPLACING ARMREST PADS -

CAPTAINS VAN SEATS (FIGURE 1)

1. Remove the mounting screws that secures the front

of the armrest pad to the armrest plate.

2. Remove the mounting screw that secures the rear of

the armrest pad and armrest insert to the armrest

plate.

3. Remove the existing armrest pad and position the

NEW armrest pad on the armrest plate.

4. Line up the mounting holes in the armrest insert, arm-

rest plate and NEW armrest pad.

5. Reinstall the rear mounting screw through the arm-

rest 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.

Armrest

Insert

Mounting

Screw

Armrest

Pad

Armrest Plate

FIGURE 1 - REPLACING ARMREST PADS -

CAPTAINS VAN SEATS

Mounting

Screw

REPLACING CAPTAINS VAN SEAT

ARMREST PLATE (FIGURE 2)

1. If necessary, remove the three (3) mounting screws,

spacers and locknuts that secure the joystick mount-

ing bracket to the armrest plate.

2. Remove armrest pad. Refer to REPLACING ARM-

REST PADS - CAPTAINS VAN SEATS in this proce-

dure of the manual.

3. Remove the mounting screw, washers and locknut that

secure the existing armrest plate to the arm weldment.

4. Position the NEW armrest plate on the armrest weldment

and secure with the mounting screw, washers, and lock-

nut. Refer to FIGURE 2 for correct hardware orientation.

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

ING ARMREST PADS - CAPTAINS VAN SEATS in

this procedure of the manual.

6. If necessary, reinstall the three (3) mounting screws,

spacers and locknuts that secure the joystick mount-

ing bracket to the armrest plate.

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

necessary.

Mounting

Screw

Washer Locknut

Washer

FIGURE 2 - REPLACING CAPTAINS VAN SEAT

ARMREST PLATE

Arm Weldment

Armrest

Plate

FRONTREAR

This Procedure Includes the Following:

Replacing Armrest Pads - Captains Van Seats

Replacing Captains Van Seat Armrest Plate

WARNING

After ANY adjustments, repair or service

and BEFORE use, make sure that all attach-

ing hardware is tightened securely - oth-

erwise injury or damage may result.

UPHOLSTERY/POSITIONING STRAPPROCEDURE 5

This Procedure Includes the Following:

Replacing Seat Positioning Strap - Captains Van

Seats

Replacing Back Upholstery

WARNING

After ANY adjustments, repair or service and BE-

FORE use, make sure that all attaching hardware

is tightened securely - otherwise injury or damage

may result.

FIGURE 1 - REPLACING SEAT POSITIONING STRAP -

CAPTAINS VAN SEATS

REPLACING BACK UPHOLSTERY

(FIGURE 2)

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

INSTALLING/REMOVING FLIP BACK ARMRESTS in

PROCEDURE 4 of the owners manual, 1081227.

2. If applicable, remove the two (2) mounting screws

and locknuts that secure the spreader bar to the back

canes.

3. Remove the two (2) mounting screws and washers

that secure the existing back upholstery to the back

canes.

4. Cut the tie-wraps that secure the bottom of the exist-

ing back upholstery to the back canes.

NOTE: Note the back angle before disassembly for proper

reinstallation.

5. On the side of the wheelchair that the armrest was

removed, remove one (1) of the mounting screws,

washer, spacer, and locknut that secures the back

cane to the seat frame.

NOTE: To avoid losing the insert in each back cane, thread

the mounting screw just removed through the cane from

the inside of the wheelchair to hold the insert in place.

6. Remove the other mounting screw, washer, spacer,

and locknut that secures the back cane to the seat

frame.

7. Slide the back cane out of the spreader bar (If appli-

cable) and the existing back upholstery.

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

STALLING/REMOVING FLIP BACK ARMRESTS in

PROCEDURE 4 of the owners manual, 1081227.

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

chair.

10. Slide the other back cane out of the spreader bar (if

applicable) and the existing back upholstery.

11. Slide one(1) back cane into NEW back upholstery

and through spreader bar (if applicable).

12. Secure back cane to the seat frame from the outside

of the wheelchair with the existing two (2) mounting

screws, washers, spacers, and locknuts. Use Loctite

242 and torque to 75-in/lbs.

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

14. Secure the top of the NEW back upholstery to the

back canes with the two (2) existing mounting screws.

Van Seat Frame

Seat Positioning

Strap

Locknuts

Washer FRONT OF SEAT

FRAME

REAR OF SEAT

FRAME Mounting

Screw

REPLACING SEAT POSITIONING

STRAP - CAPTAINS VAN SEATS

(FIGURE 1)

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

Refer to INSTALLING/REMOVING CAPTAINS VAN

SEAT ASSEMBLY in PROCEDURE 6 of this manual.

2. Remove the two (2) rear mounting screws, washers,

and locknuts that secure the seat positioning straps

to the van seat frame.

NOTE: The washer is positioned between the seat posi-

tioning strap and the mounting screw.

3. Secure the NEW seat positioning strap halves with

the mounting screws, washers and locknuts to the

van seat frame and torque to 75-inch pounds.

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

Refer to INSTALLING/REMOVING CAPTAINS VAN

SEAT ASSEMBLY in PROCEDURE 6 of this manual.

FIGURE 2 - REPLACING BACK UPHOLSTERY

Locknut

(STEP 2)

Mounting

Screw

(STEP 2)

Locknut

(STEP 2)

Mounting Screw

Torque to 60 in/lbs

(STEP 2)

Spreader Bar

(STEPS 2, 7, 16)

Mounting

Screw

(STEPS 3, 14)

Washer

(STEPS 3, 14)

Back

Upholstery

(STEPS 3, 7)

Back Cane

(STEPS 3, 12)

Insert

Seat Frame

Mounting Screws

Torque to 75 in/lbs

(STEPS 5, 6)

Washers

(STEPS 5, 6)

Mounting

Screws

(STEPS 5, 6)

Washers

(STEPS 5, 6)

Spacers

(STEPS 5, 6)

Locknuts

(STEPS 5, 6)

HEAVY DUTY MODELS

NOTE: Spreader bar required on all back heights.

BACK HEIGHT u SPREADER BAR

HEIGHT

16-17-inches 5-inches

18-24-inches 7-inches

uHeight of Spreader Bar from Bottom of Back

Canes to Top of Spreader Bar Clamp.

15. If applicable, reposition the spreader bar at the correct

height for the corresponding back height and torque

the mounting hardware to 60-in/lbs.

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

STALLING/REMOVING FLIP BACK ARMRESTS in

PROCEDURE 4 of the owners manual, 1081227.

NOTE: When replacing the back upholstery, back as-

sembly or changing back height, follow these guidelines

for spreader bar height:

STANDARD MODELS

BACK HEIGHT u SPREADER BAR

HEIGHT

16-inches* 5-inches

17-inches* 5-inches

18-19-inches* 7-inches

20-24-inches 7-inches

NOTE: Spreader Bar required on ALL back heights be-

tween 20-24-inches. *Spreader bar required on back

heights 16,17,18, or 19 ONLY if the width or depth of the

chair exceeds 19-inches.

uHeight of Spreader Bar from Bottom of Back

Canes to Top of Spreader Bar Clamp.

UPHOLSTERY/POSITIONING STRAP PROCEDURE 5

PROCEDURE 6 SEAT FRAME

This Procedure includes the following:

Preparation for Removing/Installing Seat Frame

(Standard Frame, Adjustable Frame,

and Captains Van Seat) ............................Page 21

Replacing Exact Same Size Standard

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

Removing/Installing Standard Seat Frame

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

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

Changing Seat Width (Standard and Adjustable

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

Installing/Removing Adjustable Seat Frame

Sub-Assembly and/or Component

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

Installing/Removing Captains Van Seat

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

Replacing Captains Van Seat and/or Captains

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

Converting From Standard Seat Frame to

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

Converting From Adjustable Seat Frame to

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

Converting From Standard Seat Frame to

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

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

Mounting Plate - Seat Angle Adjustment and

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

PREPARATIONS FOR REMOVING/

INSTALLING SEAT FRAME

(STANDARD FRAME, ADJUSTABLE

FRAME, AND CAPTAINS VAN SEAT)

(FIGURE 1)

NOTE: When installing/replacing components of the wheel-

chair, refer to the individual procedure for correct use of

LOCTITE 242 and torque specifications or PROCEDURE

3 of this manual.

NOTE: To reinstall these components, reverse the follow-

ing steps.

FIGURE 1 - PREPARATIONS FOR REMOVING/

INSTALLING SEAT FRAME (STANDARD FRAME,

ADJUSTABLE FRAME, AND CAPTAINS VAN SEAT)

Footrest

Location

(STEP 1)

Battery

Box(es)

(STEP 2)

Adjustment Lock

Lever for Joystick

(STEP 4)

Joystick

(STEPS

3,5)

Flip Back

Armrests

(STEP 6A)

Seat Pan

(STEP 7)

Controller, Left/Right Motor

Connectors (STEPS 8,9)

Back Upholstery

(STEP 10)

Seat Positioning

Strap (STEP 7)

NOTE: Illustration depicts tubular seat frame only. Prepa-

ration steps for the captains van seat apply in the same

manner.

Socket

Screw

Captains

Van Seat

Base

Height

Adjustment

Holes

STEP 6B

1. Remove footrest assemblies. Refer to PROCEDURE

4 in of the owners manual, 1081227.

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

MOVING GROUP 24 BATTERY BOXES or INSTALL-

ING/REMOVING GROUP 22 BATTERY BOX in PRO-

CEDURE 9 of this manual.

WARNING

After ANY adjustments, repair or service

and BEFORE use, make sure that all at-

taching hardware is tightened securely -

otherwise injury or damage may result.

NOTE: The procedures in this section of the manual refer

to NON-RECLINER seat frames only, EXCEPT Seat

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

CEDURE 14 of this manual.

3. Cut tie wraps and disconnect joystick from controller.

4. Turn the lever on the adjustment lock to release the

adjustment lock from the joystick mounting tube.

5. Remove the joystick from the wheelchair.

6. Perform one (1) of the following:

A. STANDARD OR ADJUSTABLE SEAT

FRAMES - Remove the flip-back armrests from

the wheelchair. Refer to INSTALLING/REMOVING

FLIP BACK ARMRESTS in PROCEDURE 4 of

the owners manual, 1081227.

B. CAPTAINS VAN SEAT - Remove the mounting

screw that secures the armrest to the van seat

frame. Repeat for opposite side.

7. For standard and adjustable seat frames, remove the

seat pan (including seat positioning straps). Refer to

REMOVING/INSTALLING SEAT PAN in this procedure

of the manual.

8. Disconnect battery and left/right motor connectors from

the controller. Refer to REPLACING WIRING HAR-

NESS in PROCEDURE 10 of this manual.

9. Remove tie-wraps that secures the wiring harness to

the seat frame and the charger cable from its mount-

ing bracket. Refer to REPLACING WIRING HARNESS

in PROCEDURE 10 of this manual.

10. For standard and adjustable seat frames, remove the

back upholstery (including back canes and spreader

bar, if applicable). Refer to REPLACING BACK UP-

HOLSTERY in PROCEDURE 5 of the manual.

11. Refer back to the starting procedure to complete the

desired change.

REPLACING EXACT SAME SIZE

STANDARD SEAT FRAME

1. Perform the instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND CAP-

TAINS VAN SEAT) in this procedure of the manual.

2. Remove the existing standard seat frame subassem-

bly and install the NEW standard frame. Refer to RE-

MOVING/INSTALLING STANDARD SEAT FRAME

SUBASSEMBLY in this procedure of the manual.

3. FOR 12-15-INCH SEAT DEPTHS ONLY: Remove

the CJ back brackets from the existing standard seat

frame and install onto the NEW standard seat frame.

Refer to REMOVING/INSTALLING CJ BACK BRACK-

ETS FROM SEAT FRAME in this procedure of the

manual.

4. Reinstall the components previously removed in STEP

1. Perform the instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND CAP-

TAINS VAN SEAT) in this procedure of the manual.

REMOVING/INSTALLING

STANDARD SEAT FRAME

SUBASSEMBLY (FIGURE 2)

NOTE: Perform steps required from starting procedure.

Removing

1. Remove the four (4) mounting screws, locknuts and

spacers, if applicable, that secure the standard seat

frame subassembly to the seat mounting plates.

2. Remove the existing standard seat frame.

FIGURE 2 - REMOVING/INSTALLING STANDARD

SEAT FRAME SUB-ASSEMBLY

Mounting Screws

(Torque to 156-

inch pounds)

Standard

Seat

Assembly

Locknuts Base Frame

Spacer

(16-inch

Wide Only)

Seat

Mounting

Plate

Spacer

(16-inch Wide

Only)

Mounting Screws

(Torque to 156-

inch pounds)

NOTE: For 16-inch wide seat frames, there will be spac-

ers positioned between the seat frame and the seat mount-

ing plates.

PROCEDURE 6SEAT FRAME

3. Refer back to the starting procedure to complete the

desired change.

Installing

1. Position NEW standard seat frame subassembly on

seat mount plates.

2. Secure NEW standard seat frame subassembly onto

seat mounting plates with the existing four (4) mount-

ing screws, locknuts and spacers, if applicable. Torque

to 156-inch pounds.

3. Refer back to the starting procedure to complete the

desired change.

CHANGING SEAT DEPTH

Standard Seat Frame

NOTE: Review the chart below. This will determine the

components needed to obtain the desired seat depth.

B. If the desired change only requires a NEW seat

pan, refer to

REMOVING/INSTALLING SEAT PAN

in this procedure of the manual.

C. For all other seat depth changes, perform the fol-

lowing:

lPREPARATIONS FOR REMOVING/IN-

STALLING SEAT FRAME (STANDARD

FRAME, ADJUSTABLE FRAME, AND CAP-

TAINS VAN SEAT) in this procedure of the

manual.

Perform one (1), two (2), or all three (3) of the pro-

cedures listed below depending on the compo-

nents required for the desired seat depth deter-

mined from STEPS 1-5:

lREMOVING/INSTALLING CJ BACK BRACK-

ETS in this procedure of the manual.

lREMOVING/INSTALLING STANDARD SEAT

SUBASSEMBLY in this procedure of the

manual.

lREMOVING/INSTALLING SEAT PAN in this

procedure of the manual.

After completing the procedure(s) listed above, per-

form the steps outlined in PREPARATIONS FOR

REMOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND

CAPTAINS VAN SEAT) to complete the desired

seat depth change.

Adjustable Seat Frame (FIGURE 3)

NOTE: Review the chart below. This will determine the com-

ponents needed to obtain your desired seat depth.

SEAT FRAME COMPONENTS

CJ BACK SEAT

SEAT BRACKETS SEAT FRAME

DEPTH REQUIRED PAN DEPTH

12-inches

to YES 17-inch 16-inch deep

15-inches

16-inches NO 16-inch 16-inch deep

17-inches NO 17-inch 16-inch deep

18-inches NO 18-inch 18-inch deep

19-inches NO 19-inch 18-inch deep

20-inches NO 20-inch 20-inch deep

21-inches NO 21-inch 20-inch deep

22-inches NO 22-inch 22-inch deep

COMPONENT IDENTIFICATION TABLE

FOR STANDARD SEAT FRAME

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

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

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

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

5. Compare existing components of the current seat depth

and the required components for the desired seat depth.

6. Perform one (1) of the following:

A. If the current seat depth and the desired seat depth

is within the 12-15-inch seat depth range, this change

can be accomplished by repositioning the back

canes on the CJ back brackets. Refer to CHANG-

ING SEAT DEPTH BETWEEN 12-15-INCHES in

this procedure of the manual.

NOTE: Note the four (4) different lengths of side frames

short, medium, long, and X-long, as well as the two differ-

ent center frames, short and long. These components are

interchanged to obtain the various different seat depths.

SEAT FRAME COMPONENTS

CJ BACK

SEAT BRACKETS SEAT SIDE CENTER

DEPTH REQUIRED PAN FRAME FRAME

12-inches

to YES 17-inch Short Short

15-inches

16-inches NO 16-inch Short Short

17-inches NO 17-inch Short Short

18-inches NO 18-inch Medium Short

19-inches NO 19-inch Medium Short

20-inches NO 20-inch Long Long

21-inches NO 21-inch Long Long

22-inches NO 22-inch X-Long Long

COMPONENT IDENTIFICATION TABLE

FOR STANDARD SEAT FRAME

PROCEDURE 6 SEAT FRAME

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

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

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

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

5. Compare existing components of the current seat depth

and the required components for the desired seat depth.

To adjust the depth of the seat on the wheelchair, use

the following guidelines:

If the current seat depth is and the desired seat depth are

within the 12-15-inch seat depth range, this change can be

accomplished by repositioning the back canes on the CJ

back brackets. Refer to CHANGING SEAT DEPTH BE-

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

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

REMOVING/INSTALLING SEAT PAN in this procedure of

the manual.

If the desired change requires the removal/installation of CJ

back brackets, refer to REMOVING/INSTALLING CJ BACK

BRACKETS in PROCEDURE 8 of this manual.

If the desired change requires a new side frame, and/or new

center frame, perform the following steps:

A. Perform the instructions outlined in SEAT FRAME

REMOVING/INSTALLING PREPARATIONS FOR

STANDARD FRAME, ADJUSTABLE FRAME, AND

CAPTAINS VAN SEAT in this procedure of the

manual.

NOTE: Note the mounting hole position of the side

frame for proper installation of the NEW side frame.

B. Remove the two (2) mounting screws, coved wash-

ers, spacers, and locknuts that secure the side frame

to the center frame.

C. Remove the side frame from the center frame.

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

If the desired seat depth requires a new center

frame, determined in STEPS 1-5 perform STEPS

E - G, otherwise proceed to STEP H.

E. Remove the four (4) mounting screws that secure

the EXISTING center frame to support brackets.

F. Remove existing center frame from seat mount

plates.

G. Secure NEW center frame to support brackets with

the existing four (4) mounting screws and locknuts.

Torque to 156-inch pounds.

H. Secure NEW side frame to the center frame at the

position noted previously. Torque to 75-inch pounds.

NOTE: If seat width adjustment is also desired, re-

fer to CHANGING SEAT WIDTH in this procedure

of the manual for mounting hole locations and allow-

able seat width/seat depth combinations.

FIGURE 3- CHANGING SEAT DEPTH - ADJUSTABLE

SEAT FRAME

Side Frame

Side

Frame

Center

Frame

Mounting

Screws

(Torque to 75-

inch pounds)

Coved

Washers

Spacers

Locknuts

Mounting Screws

(Torque to 156-

inch pounds)

Support Brackets

Changing Seat Depth Between 12 and 15-

Inches (FIGURE 4)

NOTE: There are two (2) sizes of CJ back brackets. Refer

to the following chart to determine if the seat depth required

is obtainable by repositioning the back canes only, or if the

CJ back brackets must be replaced.

CJ BACK BRACKET (SEAT DEPTH) RANGES

12 and 13-inches OR 14 and 15-inches

If seat depth required is within seat depth range of

the original CJ back brackets, only the back canes

need to be repositioned. Refer to the following pro-

cedure.

If the seat depth required is NOT within the seat depth

range of the original CJ back brackets, the CJ back

brackets must be replaced before repositioning the

back canes. Refer to REMOVING/INSTALLING CJ

BACK BRACKETS in PROCEDURE 8 of this manual.

PROCEDURE 6SEAT FRAME

FIGURE 4 - ADJUSTING SEAT DEPTH - CHANGING

SEAT DEPTH BETWEEN 12 AND 15-INCHES

CJ Back

Bracket

Seat

Frame

Threaded

Insert

Washers

Back Cane

Coved

Washers

Mounting Screws (Torque to 75-inch pounds)

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

STALLING/REMOVING FLIP BACK ARMRESTS in

PROCEDURE 4 of the owners manual, 1081227.

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

CJ back brackets.

3. Pull the bottom of the back upholstery away from the

rear of the seat pan.

4. Remove mounting screw, washer and coved washer

from the top mounting hole of the CJ back bracket and

back cane.

NOTE: Before removing the back canes from the CJ back

brackets, note the BACK ANGLE for reinstallation.

NOTE: To avoid losing the insert in each back cane, line up

the holes in the insert with the holes in the back cane and

start one of the screws through the cane from the inside of

the wheelchair to hold the insert in place.

5. Remove the mounting screw, washer and coved

washer from the bottom mounting hole of the CJ back

bracket and the back cane.

6. Reposition the back cane to the desired seat depth

and angle. If changing the back angle as well, refer to

BACK ANGLE ADJUSTMENT in PROCEDURE 8 of

this manual.

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

8. Secure the bottom of the back upholstery to the CJ

back brackets with new tie wraps.

9. Use Loctite 242 and torque the mounting screws to

75-inch pounds.

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

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

STALLING/REMOVING FLIP BACK ARMRESTS in

PROCEDURE 4 of the owners manual, 1081227.

CHANGING SEAT WIDTH

(STANDARD AND ADJUSTABLE

SEAT FRAME)

Standard Seat Frame

NOTE: If changing seat width below 16-inches wide, you must

convert to an adjustable seat frame. Refer to CONVERT-

ING FROM STANDARD TO ADJUSTABLE SEAT

FRAME OR VICE VERSA in this procedure of the manual.

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

steps.

1. Perform the instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND CAP-

TAINS VAN SEAT) in this procedure of the manual.

2. Remove the existing standard seat frame subassem-

bly and install the NEW standard frame. Refer to RE-

MOVING/INSTALLING STANDARD SEAT FRAME

SUBASSEMBLY in this procedure of the manual.

3. FOR 12-15-INCH SEAT DEPTHS ONLY: Remove

the CJ back brackets from the existing standard seat

frame and install onto the NEW standard seat frame.

Refer to REMOVING/INSTALLING CJ BACK BRACK-

ETS in PROCEDURE 8 of this manual.

4. Reinstall the components previously removed in STEP

1. Perform the instructions outlined in

PREPARATIONS

FOR REMOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND CAP-

TAINS VAN SEAT) in this procedure of the manual.

Adjustable Seat Frame (FIGURE 5)

NOTE: If changing seat width above 16-inches wide, you

must convert to a standard seat frame. Refer to CONVERT-

ING FROM STANDARD TO ADJUSTABLE SEAT

FRAME OR VICE VERSA in this procedure of the manual.

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

steps.

1. Perform the instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND CAP-

TAINS VAN SEAT) in this procedure of the manual.

2. Review the following chart for the allowable seat width

and seat depth combinations for the adjustable seat

frame.

PROCEDURE 6 SEAT FRAME

ALLOWABLE SEAT WIDTH AND DEPTH

COMBINATIONS FOR ADJUSTABLE SEAT FRAME

NOTE: The seat widths and seat depths enclosed in the

outlined box will require the use of CJ back brackets and a

17-inch deep seat pan.

3. Remove the two (2) mounting screws, coved washers,

spacers, and locknuts that secure the side frame to the

center frame.

4. Adjust side frame to desired width determined from

STEP 2. See DETAIL A for proper mounting hole

position.

5. Secure side frame to center frame with existing mount-

ing screws, coved washers, spacers, and locknuts.

Torque mounting screws to 75-inch pounds.

WARNING

Both side frames MUST be adjusted to the

same mounting hole position to maintain

proper weight balance of user and seat

frame. If weight is not balanced, injury to

the assistant and/or user and damage to

the wheelchair may result.

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

7. Perform one (1) of the following:

A. For adjusting the seat width only, perform the in-

structions outlined in PREPARATIONS FOR RE-

MOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND

CAPTAINS VAN SEAT) in this procedure of the

manual.

NOTE: When performing the steps outlined in

PREPARATIONS FOR REMOVING/INSTALL-

ING SEAT FRAME (STANDARD FRAME, AD-

JUSTABLE FRAME, AND CAPTAINS VAN

SEAT) the seat pan, seat cushion, back uphol-

stery and spreader bar (if applicable), will need to

be replaced. Spreader bars are only required on

seat depths greater than 19-inches.

FIGURE 5 -CHANGING SEAT WIDTH - ADJUSTABLE

SEAT FRAME

Side

Frame

STEPS 3-6

Side Frame

Center

Frame

Mounting

Screws

Coved

Washers

Spacers

Locknut

INSTALLING/REMOVING

ADJUSTABLE SEAT FRAME

SUBASSEMBLY AND/OR

COMPONENT REPLACEMENT

(FIGURE 6)

Converting from Adjustable Seat Frame to

Standard Seat Frame or Captains Van Seat

NOTE: This section must be performed in conjunction with

a starting procedure.

1. Remove the four (4) mounting screws that secure the

two (2) support brackets of the adjustable seat frame

subassembly to the seat mounting plates.

2. To complete conversion, refer back to the starting pro-

cedure to complete the desired change.

Converting from Standard Seat Frame or

Captains Van Seat To Adjustable Seat Frame

NOTE: This section must be performed in conjunction with

a starting procedure.

NOTE: When converting the seat frame, you will need a

seat pan, seat cushion, back upholstery and spreader bar (if

applicable). Spreader bars are only required on seat depths

of greater than 19-inches.

PROCEDURE 6SEAT FRAME

12 13 14 15 16

12 ✓✓✓✓✓

13 ✓✓✓✓✓

14 ✓✓✓✓✓

15 ✓✓✓✓✓

16 ✓✓✓✓✓

17 N/A N/A ✓✓✓

18 N/A N/A ✓✓✓

19 N/A N/A ✓✓✓

20 N/A N/A ✓✓✓

21 N/A N/A ✓✓✓

22 N/A N/A ✓✓✓

SEAT WIDTH

B. For all other changes regarding seat frame changes,

refer back to the starting procedure to complete the

desired change.

DETAIL “A”

12-inches

13-inches

14-inches

15-inches

16-inches

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

REPLACEMENT

Mounting Screws

(Torque to 156-inch pounds)

Side Frame

Center Frame

Spacer

Locknuts

Support

Bracket

Base

Frame

Coved Washer

Locknuts

Support

Bracket

Mounting Screws

(Torque to 156-inch

pounds)

Mounting Screws

(Torque to 156-inch

pounds)

Mounting

Plate

Mounting Screws

(Torque to 75-inch

pounds)

1. Secure both support brackets to the seat mounting plates

with four (4) mounting screws and locknuts as shown in

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

2. Secure the center frame to the support brackets with

four (4) mounting screws, locknuts, and spacers. Torque

to 156-inch pounds.

3. Insert the side frame into the center frame and secure

with mounting screw, coved spacer, spacer, and lock-

nut. Torque to 75-inch pounds. Repeat for opposite side

frame.

4. To complete conversion, refer back to the starting proce-

dure to complete the desired change.

Component Replacement

1. Perform the instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND CAP-

TAINS VAN SEAT) in this procedure of the manual.

NOTE: Note the mounting hole position of the current side

frame(s) for proper installation of the NEW side frame(s).

2. Remove the two (2) mounting screws, coved spacers,

spacers, and locknuts that secure the side frame to the

center frame.

Mounting Screws

(Torque to 156-inch pounds)

PROCEDURE 6 SEAT FRAME

3. Perform one (1) of the following:

A. If center frame needs replaced, repeat STEP 2 for

opposite side frame and proceed to STEP 4.

B. If opposite side frame needs replaced, repeat STEP

2, then proceed to STEP 6. Otherwise proceed to

STEP 6.

4. Remove the four (4) mounting screws and locknuts that

secure the center frame to the support brackets.

5. Secure NEW center frame to support brackets with ex-

isting four (4) mounting screws and locknuts. Torque to

156-inch pounds.

WARNING

Both side frames MUST be adjusted to the

same mounting hole position to maintain

proper weight balance of user and seat

frame. If weight is not balanced, injury to

the assistant and/or user and damage to

the wheelchair may result.

6. Install new/existing side frame(s) into new/existing cen-

ter frame at the mounting position previously noted. Torque

to 75-inch pounds.

7. Perform the instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND CAP-

TAINS VAN SEAT) in this procedure of the manual.

INSTALLING/REMOVING CAPTAINS

VAN SEAT ASSEMBLY (FIGURE 7)

NOTE: This procedure is to be performed in conjunction with

a starting procedure. Proceed to the section that reflects the

desired change.

Installing Captains Van Seat

1. Position the captains van seat on the seat mounting plates

at the position shown in FIGURE 7.

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

and the mounting holes in the seat mounting plates.

3. Secure the captains van seat to the seat mounting plates

with four (4) mounting screws, and locknuts. Torque to

156-inch pounds.

4. Refer back to the starting procedure to complete the

desired change.

Removing Captains Van Seat

1. Remove the four (4) mounting screws and locknuts that

secure the captains van seat to the seat mounting plates.

2. Remove captains van seat from seat mounting plates.

3. Refer back to the starting procedure to complete the

desired change.

FIGURE 7 - REMOVING/INSTALLING CAPTAINS VAN

SEAT ASSEMBLY

Mounting

Screws

(Torque to 156-

inch pounds)

Locknuts

Seat

Mounting

Plate

Base Frame

Seat Mounting

Plate

Captains Van

Seat

REPLACING CAPTAINS VAN SEAT

AND/OR CAPTAINS VAN SEAT

FRAME (FIGURE 8)

1. Perform the instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND CAP-

TAINS VAN SEAT) in this procedure of the manual.

2. Remove the captains van seat assembly from the wheel-

chair. Refer to INSTALLING /REMOVING CAPTAINS

VAN SEAT ASSEMBLY in this procedure of the manual.

Mounting Screw

(Torque to 75-inch

pounds)

FIGURE 8 - REPLACING CAPTAINS VAN SEAT AND/

OR CAPTAINS VAN SEAT FRAME

Captains

Van Seat

Frame

Captains

Van Seat

Washer

Spacer

PROCEDURE 6SEAT FRAME

6. Perform the instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND CAP-

TAINS VAN SEAT) in this procedure of the manual.

CONVERTING FROM ADJUSTABLE

SEAT FRAME TO CAPTAINS VAN

SEAT OR VICE VERSA

1. Perform the instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND CAP-

TAINS VAN SEAT) in this procedure of the manual.

2. Perform one (1) of the following:

A. Remove the adjustable seat frame subassembly.

Refer to REMOVING/INSTALLING STANDARD

SEAT FRAME SUBASSEMBLY in this procedure

of the manual.

B. Remove the captains van seat Assembly. Refer to

INSTALLING/REMOVING CAPTAINS VAN SEAT

ASSEMBLY in this procedure of the manual.

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

Adjustable Frames

A. Install the adjustable seat frame subassembly. Re-

fer to INSTALLING/REMOVING ADJUSTABLE

SEAT FRAME SUBASSEMBLY AND/OR COM-

PONENT REPLACEMENT in this procedure of

the manual.

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

CHANGING SEAT WIDTH in this procedure of the

manual for mounting hole locations and allowable

seat width/seat depth combinations.

C. 12-15-INCH SEAT DEPTHS ONLY: Install the CJ

back brackets, seat positioning strap, and quick re-

lease pin from the onto the adjustable seat frame.

Refer to REMOVING/INSTALLING CJ BACK

BRACKETS in PROCEDURE 8 of this manual.

D. Perform the instructions outlined in PREPARA-

TIONS FOR REMOVING/INSTALLING SEAT

FRAME (STANDARD FRAME, ADJUSTABLE

FRAME, AND CAPTAINS VAN SEAT) in this proce-

dure of the manual.

Captains Van Seat

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

REMOVING CAPTAINS VAN SEAT ASSEMBLY in

this procedure of the manual.

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

Refer to ADJUSTING CAPTAINS VAN SEAT in this

procedure of the manual.

3. Remove the four (4) mounting screws, two (2) wash-

ers, and two (2) spacers that secure the captains van

seat to the seat frame.

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

5. Secure new/existing captains van seat to the new/exist-

ing captains van seat frame with existing four (4) mount-

ing screws and spacers. Torque to 75- inch pounds.

6. Install new captains van seat assembly onto the wheel-

chair. Refer to INSTALLING/REMOVING CAPTAINS VAN

SEAT ASSEMBLY in this procedure of the manual.

7. Perform the instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND CAP-

TAINS VAN SEAT) in this procedure of the manual.

CONVERTING FROM STANDARD

SEAT FRAME TO ADJUSTABLE

SEAT FRAME OR VICE VERSA

1. Perform the instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND CAP-

TAINS VAN SEAT) in this procedure of the manual.

2. Perform one (1) of the following:

A. Remove the existing standard seat frame subas-

sembly. Refer to REMOVING/INSTALLING STAN-

DARD SEAT FRAME SUBASSEMBLY in this pro-

cedure of the manual.

B. Remove the adjustable seat frame subassembly.

Refer to REMOVING/INSTALLING ADJUSTABLE

SEAT FRAME SUBASSEMBLY AND/OR COM-

PONENT REPLACEMENT in this procedure of the

manual.

3. Perform one (1) of the following:

A. Install the standard frame subassembly. Refer to

INSTALLING/REMOVING STANDARD SEAT

FRAME SUBASSEMBLY in this procedure of the

manual.

B. Install the adjustable seat frame subassembly. Re-

fer to INSTALLING/REMOVING ADJUSTABLE

SEAT FRAME SUBASSEMBLY AND/OR COM-

PONENT REPLACEMENT in this procedure of

the manual.

4. ADJUSTABLE FRAMES ONLY: Adjust side frame to

desired seat width. Refer to CHANGING SEAT WIDTH

in this procedure of the manual for mounting hole loca-

tions and allowable seat width/seat depth combinations.

5. STANDARD AND ADJUSTABLE FRAME WITH 12-

15-INCH SEAT DEPTHS ONLY: Remove the CJ back

brackets from the existing standard seat frame and in-

stall onto the NEW standard seat frame. Refer to RE-

MOVING/INSTALLING CJ BACK BRACKETS in PRO-

CEDURE 8 of this manual.

PROCEDURE 6 SEAT FRAME

3. Remove the six (6) mounting screws, locknuts, and spac-

ers that secure the seat pan, seat positioning strap, and

quick release pin to the seat frame.

NOTE: When removing seat pan, note tab position of quick

release pin to the seat positioning strap.

Installing

1. Position the NEW seat pan on the seat frame, aligning

the mounting holes of the seat pan and the mounting

holes of the seat frame.

2. Position the seat positioning strap and quick release pin

tab onto the seat frame and secure with mounting screw

and locknut. See FIGURE 9 for proper orientation. Re-

peat for other seat positioning strap.

NOTE: Check seat positioning strap for proper length. The

width range for the four (4) seat positioning straps are: 12-16-

inches wide (Junior), 16-19-inches wide, 20-22-inches wide,

and 23-24-inches wide.

3. Reinstall the remaining mounting screws, locknuts, and

spacers. Torque all mounting screws to 75-inch pounds.

4. Remove the protective strips from new seat pan and

reinstall the seat cushion onto the seat pan.

5. Perform one (1) of the following:

A. When changing the seat width or depth, refer back

to that procedure to complete the desired change.

FIGURE 9 - REMOVING/INSTALLING SEAT PAN

Seat

Pan

Seat Frame

Seat

Positioning

Strap

Locknut Quick Release Pin

NOTE: Illustration shows standard frame only for clarity.

The seat pan removes/installs onto the adjustable seat

frame the way.

Mounting

Screws

Tab Locknut

Spacer

C. Perform the instructions outlined in PREPARA-

TIONS FOR REMOVING/INSTALLING SEAT

FRAME (STANDARD FRAME, ADJUSTABLE

FRAME, AND CAPTAINS VAN SEAT) in this proce-

dure of the manual.

CONVERTING FROM STANDARD

SEAT FRAME TO CAPTAINS VAN

SEAT OR VICE VERSA

1. Perform the instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND CAP-

TAINS VAN SEAT) in this procedure of the manual.

2. Perform one (1) of the following:

A. Remove the standard seat frame subassembly.

Refer to REMOVING/INSTALLING STANDARD

SEAT FRAME SUBASSEMBLY in this procedure

of the manual.

B. Remove the captains van seat Assembly. Refer to

INSTALLING/REMOVING CAPTAINS VAN SEAT

ASSEMBLY in this procedure of the manual.

3. Perform one (1) of the following:

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

REMOVING CAPTAINS VAN SEAT ASSEMBLY in

this procedure of the manual.

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

ING/INSTALLING STANDARD SEAT FRAME SUB-

ASSEMBLY in this procedure of the manual.

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

DEPTHS ONLY: Install the CJ back brackets from the

onto the adjustable seat frame. Refer to REMOVING/

INSTALLING CJ BACK BRACKETS in PROCEDURE

8 of this manual.

5. Perform the instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND CAP-

TAINS VAN SEAT) in this procedure of the manual.

6. Adjust the captains van seat to the desired position. Re-

fer to ADJUSTING CAPTAINS VAN SEAT in this proce-

dure of the manual.

REMOVING/INSTALLING SEAT PAN

(FIGURE 9)

Removing

1. Remove the seat cushion from the seat pan.

2. Remove the flip-back armrests from the wheelchair. Refer

to INSTALLING/REMOVING FLIP BACK ARMRESTS

in PROCEDURE 4 of the owners manual, 1081227.

PROCEDURE 6SEAT FRAME

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

Refer to INSTALLING/REMOVING FLIP BACK ARM-

RESTS in PROCEDURE 4 of the owners manual,

1081227.

MOUNTING PLATE - SEAT ANGLE

ADJUSTMENT AND INSTALLATION

ORIENTATION (FIGURE 10)

Seat Angle Adjustment

NOTE: The angle of the seat is factory set providing the user

with a 5o seat dump. This angle can changed by adjusting

either the front or back of the seat mount plate to obtain any

angle between 0o or 10o seat dump.

NOTE: There are three (3) heights of seat mounting plates;

low, medium, and high. See chart below for proper settings.

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

A. Loosen the two (2) mounting screws that secure

the rear of the seat frame to the seat mount plate.

B. Position the mounting screws at the bottom of the

rear slot.

C. Securely tighten both mounting screws. Torque to

15-in/lbs.

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

A. Loosen the two (2) mounting screws that secure

the front of the seat frame to the seat mount plate.

B. Position the mounting screws at the bottom of the

front slot.

C. Securely tighten both mounting screws. Torque to

15-in/lbs.

Installation Orientation

1. Medium and High Seat Mounting Plates: Install with

the angled end toward the front of the wheelchair.

2. Low Seat Mounting Plates: Install with the thicker

end toward the front of the wheelchair.

Mounting Screw

Mounting

Screw

Rear of Seat Frame

Medium Height

Seat Mount Plate

Angled End of Seat

Mounting Plate

LOW MEDIUM AND HIGH

Thicker End

DETAIL A

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

MEDIUM

HEIGHT

HIGH

HEIGHT

LOW

HEIGHT

0o5o10o

SEAT DUMP

SEAT

MOUNT

PLATE

FRONT OF

CHAIR

REAR OF

CHAIR

FRONT OF

CHAIR

REAR OF

CHAIR

FRONT OF

CHAIR

REAR OF

CHAIR

FRONT OF

CHAIR

REAR OF

CHAIR

FRONT OF

CHAIR

REAR OF

CHAIR

FRONT OF

CHAIR

REAR OF

CHAIR

FRONT

OF CHAIR

REAR OF

CHAIR

FRONT OF

CHAIR

REAR OF

CHAIR

FRONT OF

CHAIR

REAR OF

CHAIR

PROCEDURE 6 SEAT FRAME

Front of Seat

Frame

This Procedure Includes the Following:

Replacing Seat Mounting Plates

Replacing Seat Support Brackets

Replacing Seat Support Bracket T-Nuts

Replacing Battery Charger Bracket and T-Nut

Removing/Installing Seat Stop Screws

WARNING

After ANY adjustments, repair or service and BE-

FORE use, make sure that all attaching hardware

is tightened securely - otherwise injury or dam-

age may result.

REPLACING SEAT MOUNTING

PLATES (FIGURE 1)

NOTE: When replacing components of the wheelchair, refer

to the individual procedure for correct use of LOCTITE 242

and torque specifications or PROCEDURE 3 of this Manual.

1. Perform the instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND CAP-

TAINS VAN SEAT) in PROCEDURE 6 of this manual.

2. Perform one (1) of the following:

A. Remove standard seat frame subassembly. Refer

to REMOVING/INSTALLING STANDARD SEAT

FRAME SUBASSEMBLY in PROCEDURE 6 of

this manual.

B. Remove adjustable seat frame subassembly. Re-

fer to INSTALLING/REMOVING ADJUSTABLE

SEAT FRAME ASSEMBLY AND OR COMPO-

NENT REPLACEMENT in PROCEDURE 6 of

this manual.

C. Remove captains van seat. Refer to INSTALLING/

REMOVING CAPTAINS VAN SEAT ASSEMBLY in

PROCEDURE 6 of this manual.

NOTE: Before removing seat mounting plates, note the po-

sition of the washers.

3. Remove the two (2) mounting screws, washers and

bolt strap bracket that secure the seat mounting plate to

the seat support bracket.

4. Secure NEW seat mounting plate with existing two (2)

mounting screws, washers, and bolt straps to seat sup-

port bracket using Loctite 242 and torque to 156-inch

pounds.

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

NOTE: For illustrations of the three (3) different seat mount-

ing plates, refer to MOUNTING PLATE - SEAT ANGLE

ADJUSTMENT AND INSTALLATION ORIENTATION in

PROCEDURE 6 of this manual.

Washer

Mounting

Screws

Seat

Mounting

Plate

Bolt Strap

FIGURE 1 - REPLACING SEAT MOUNTING PLATES

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

MOUNTING PLATE - SEAT ANGLE ADJUSTMENT

AND INSTALLATION ORIENTATION in PROCEDURE

6 of this manual.

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

8. Perform the instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND CAP-

TAINS VAN SEAT) in PROCEDURE 6 of this manual.

Seat

Support

Bracket

Mounting

Screws

REPLACING SEAT SUPPORT

BRACKETS (FIGURE 2)

1. Perform the instructions outlined in PREPARATIONS FOR

REMOVING/INSTALLING SEAT FRAME (STANDARD

FRAME, ADJUSTABLE FRAME, AND CAPTAINS VAN

SEAT) in PROCEDURE 6 of this manual.

2. Perform one (1) of the following:

A. Remove standard seat frame subassembly. Refer

to REMOVING/INSTALLING STANDARD SEAT

FRAME SUBASSEMBLY in PROCEDURE 6 of this

manual.

B. Remove adjustable seat frame subassembly. Re-

fer to INSTALLING/REMOVING ADJUSTABLE

SEAT FRAME ASSEMBLY AND OR COMPO-

NENT REPLACEMENT in PROCEDURE 6 of

this manual.

C. Remove captains van seat. Refer to INSTALLING/

REMOVING CAPTAINS VAN SEAT ASSEMBLY in

PROCEDURE 6 of this manual.

3. Remove seat mount plates. Refer to REPLACING SEAT

MOUNTING PLATES in this procedure of the manual.

NOTE: Note the position of the seat support brackets before

removing to ensure proper reinstallation.

BASE FRAME PROCEDURE 7

BASE FRAMEPROCEDURE 7

B. Remove adjustable seat frame subassembly. Re-

fer to INSTALLING/REMOVING ADJUSTABLE

SEAT FRAME ASSEMBLY AND OR COMPO-

NENT REPLACEMENT in PROCEDURE 6 of

this manual.

C. Remove captains van seat. Refer to INSTALLING/

REMOVING CAPTAINS VAN SEAT ASSEMBLY in

PROCEDURE 6 of this manual.

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

MOUNTING PLATES in this procedure of the manual.

NOTE: Before removing seat mounting plates, note the po-

sition of the washers.

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

ING SEAT SUPPORT BRACKETS in this procedure of

the manual.

5. Remove the seat stop screw that is closest to the end

cap. Refer to REMOVING/INSTALLING SEAT STOP

SCREWS in this procedure of the manual.

6. Remove the end cap and channel cover.

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

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

9. Replace channel cover and end cap.

WARNING

The seat stop screws must be in place be-

fore operation of your power wheelchair.

Ensure the T-Nut(s) are positioned between

both seat stop screws.

10. Use Loctite 242 and reinstall seat stop screw into base

frame.

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

PLACING SEAT SUPPORT BRACKETS in this pro-

cedure of the manual.

FIGURE 2 - REPLACING SEAT SUPPORT BRACKETS

Washer

Seat Support

Bracket

Base

Frame

Mounting Screws

T-Nut

WARNING

Do not adjust the position of the seat sup-

port bracket in this procedure. If an ad-

justment is desired, refer to ADJUSTING

WEIGHT DISTRIBUTION in PROCEDURE 15 -

MWD WHEELCHAIRS, PROCEDURE 16 - RWD

WHEELCHAIRS, or PROCEDURE 17 - FWD

WHEELCHAIRS of this manual.

4. Remove the two (2) mounting screws and washers that

secure the seat support bracket to the base frame.

WARNING

When installing seat support bracket, en-

sure the mounting screws are threaded

into the T-Nuts located inside the channel

of the base frame.

5. Secure the NEW seat support bracket to base frame

with the existing two (2) mounting screws and washers.

Torque to 156-inch pounds.

6. Reinstall seat mount plates. Refer to REPLACING SEAT

MOUNTING PLATES in this procedure of the manual.

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

MOUNTING PLATE - SEAT ANGLE ADJUSTMENT

AND INSTALLATION ORIENTATION in PROCEDURE

6 of this manual.

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

9. Perform the instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND CAP-

TAINS VAN SEAT) in PROCEDURE 6 of this manual.

REPLACING SEAT SUPPORT

BRACKET T-NUTS (FIGURE 3)

1. Perform the instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND CAP-

TAINS VAN SEAT) in PROCEDURE 6 of this manual.

2. Perform one (1) of the following:

A. Remove standard seat frame subassembly. Refer

to REMOVING/INSTALLING STANDARD SEAT

FRAME SUBASSEMBLY in PROCEDURE 6 of

this manual.

FIGURE 3 - REPLACING SEAT SUPPORT BRACKET

T-NUTS

Channel Cover

Mounting Screw

T-Nut

End Cap

Seat Support

Bracket

Base

Frame

Channel

Stop

Screw

Washer

8. Secure the battery charger connector to the mount

bracket with the EXISTING two (2) mounting screws.

Tighten securely.

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

10. Perform the instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND CAP-

TAINS VAN SEAT) in PROCEDURE 6 of this manual.

12. Reinstall the seat mount plates. Refer to REPLACING

SEAT MOUNTING PLATES in this procedure of the

manual.

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

MOUNTING PLATE - SEAT ANGLE ADJUSTMENT

AND INSTALLATION ORIENTATION in PROCEDURE

6 of this manual.

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

15. Perform the instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND CAP-

TAINS VAN SEAT) in PROCEDURE 6 of this manual.

REPLACING BATTERY CHARGER

BRACKET AND T-NUT

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

RWD and MWD Models (FIGURE 4)

1. Perform the instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING THE SEAT FRAME

(STANDARD FRAME, ADJUSTABLE FRAME, AND

CAPTAINS VAN SEAT) in PROCEDURE 6 of this

manual.

2. Perform one (1) of the following:

A. Remove standard seat frame subassembly. Refer

to REMOVING/INSTALLING STANDARD SEAT

FRAME SUBASSEMBLY in PROCEDURE 6 of

this manual.

B. Remove adjustable seat frame subassembly. Re-

fer to INSTALLING/REMOVING ADJUSTABLE

SEAT FRAME ASSEMBLY AND OR COMPO-

NENT REPLACEMENT in PROCEDURE 6 of

this manual.

C. Remove captains van seat. Refer to INSTALLING/

REMOVING CAPTAINS VAN SEAT ASSEMBLY in

PROCEDURE 6 of this manual.

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

PLACING SEAT SUPPORT BRACKETS in this

procedure of this manual.

4. Remove the two (2) mounting screws that secure the

battery charger connector to the mount bracket.

5. Remove battery charger connector from mount bracket.

6. Remove the mounting screw which secures the battery

charger mount bracket to the T-nut located in the chan-

nel of the base frame.

7. Replace battery charger mount bracket and secure to

base frame with existing mounting screw.

NOTE: To replace the Battery Charger Bracket T-Nut, per-

form STEPS 3-13 in REPLACING SEAT SUPPORT

BRACKET T-NUTS in this procedure of the manual.

FIGURE 4 - RWD AND MWD MODELS

Battery

Charger

Connector

Battery

Charger

Mount

Bracket

Base

Frame

T-nut

Mounting Screw

BASE FRAME PROCEDURE 7

Arrow FWD Model (FIGURE 5)

1. Perform one (1) of the following:

A. For LOW MOUNT BRACKETS, perform

STEPS 1-11.

B. For MEDIUM/HIGH MOUNT BRACKETS per-

form STEPS 4-9 ONLY.

2. Perform the instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING THE SEAT FRAME

(STANDARD FRAME, ADJUSTABLE FRAME, AND

CAPTAINS VAN SEAT) in PROCEDURE 6 of this

manual.

3. Perform one (1) of the following:

A. Remove standard seat frame subassembly. Refer

to REMOVING/INSTALLING STANDARD SEAT

FRAME SUBASSEMBLY in PROCEDURE 6 of

this manual.

B. Remove adjustable seat frame subassembly. Re-

fer to INSTALLING/REMOVING ADJUSTABLE

SEAT FRAME ASSEMBLY AND OR COMPO-

NENT REPLACEMENT in PROCEDURE 6 of

this manual.

C. Remove captains van seat. Refer to INSTALLING/

REMOVING CAPTAINS VAN SEAT ASSEMBLY in

PROCEDURE 6 of this manual.

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

STALLING FRONT SHROUD in PROCEDURE 17

of the manual.

FIGURE 6 - REMOVING/INSTALLING SEAT

STOP SCREWS

Base

Frame

Front Seat Stop Screw

Rear Seat

Stop Screw

Seat Support Bracket

REMOVING/INSTALLING SEAT

STOP SCREWS (FIGURE 6)

NOTE: This procedure is for RWD and MWD wheel-

chairs ONLY.

NOTE: The front seat stop screw should only be removed

if replacing a T-nut for either the seat support bracket or

the battery charger mount bracket. The rear seat stop

screw should never be removed.

1. Unthread seat stop screw from base frame.

WARNING

The seat stop screws must be in place be-

fore operation of your power wheelchair.

Ensure the seat support bracket is posi

tioned between both seat stop screws.

2. When reinstalling the front seat stop screw, ensure

the seat support bracket is located in-between both

seat stop screws. Use loctite 242 and tighten securely.

5. Remove the two (2) mounting screws that secure the

battery charger connector to the mount bracket.

6. Remove battery charger connector from mount bracket.

7. Remove the mounting screw which secures the battery

charger mount bracket to the base frame.

8. Replace the battery charger mount bracket and se-

cure it to the base frame with the EXISTING mounting

screw. Securely tighten.

9. Secure the battery charger connector to the mount

bracket with the EXISTING two (2) mounting screws.

Tighten securely.

10. Reverse STEP 3A, 3B or 3C.

11. Perform the instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME, AND CAP-

TAINS VAN SEAT) in PROCEDURE 6 of this manual.

FIGURE 5 - ARROW FWD MODEL

Mounting

Screw

Mounting Screw

Base Frame

Battery

Charger

Mount

Bracket

Battery

Charger

Connector

BASE FRAMEPROCEDURE 7

PROCEDURE 8

This Procedure includes the following:

Removing/Installing CJ Back Brackets

Changing Back Height

Back Angle Adjustment

WARNING

After ANY adjustments, repair or service

and BEFORE use, make sure that all attach-

ing hardware is tightened securely - oth-

erwise injury or damage may result.

NOTE: The procedures in this section of the manual refer

to NON-RECLINER seat frames only. For recliner seat

frames, refer to PROCEDURE 14 of this manual.

REMOVING/INSTALLING CJ BACK

BRACKETS (FIGURE 1)

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

NOTE: This procedure is to be performed in conjunction with

a starting procedure except when replacement of CJ back

brackets is desired.

Removing CJ Back Brackets

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

RATIONS FOR REMOVING/INSTALLING SEAT

FRAME (STANDARD FRAME, ADJUSTABLE FRAME,

AND CAPTAINS VAN SEAT) in PROCEDURE 6 of this

manual.

2. Remove the locknuts and washers that secure the CJ

back bracket to the back angle plate.

3. Remove the mounting screw and locknut that secures

the quick release pin and CJ back bracket and seat po-

sitioning strap to the seat frame.

4. Remove the existing CJ back bracket.

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

6. Perform one (1) of the following:

A. For replacement of CJ back brackets, proceed to

REMOVING/INSTALLING CJ BACK BRACKETS

in this procedure of the manual.

B. For all other seat frame changes, refer back to the

starting procedure to complete the desired change.

Installing CJ Back Brackets

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

RATIONS FOR REMOVING/INSTALLING SEAT

FRAME (STANDARD FRAME, ADJUSTABLE FRAME,

AND CAPTAINS VAN SEAT) in PROCEDURE 6 of this

manual.

2. Install the threaded studs of the CJ back bracket through

the back angle plates as shown in FIGURE 1.

BACK FRAME

NOTE: Ensure the CJ back bracket is mounted in the front

holes of the back angle plates as shown in DETAIL A.

WARNING

Always wear your seat positioning strap.

3. Position the seat positioning strap and quick release pin

under the CJ back bracket.

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

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

pounds.

5. Install washers and locknuts onto the threaded studs of

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

6. Perform one (1) of the following:

A. For replacing CJ back brackets only, perform the

instructions outlined in PREPARATIONS FOR RE-

MOVING/INSTALLING SEAT FRAME (STANDARD

FRAME, ADJUSTABLE FRAME, AND CAPTAINS

VAN SEAT) in PROCEDURE 6 of this manual.

B. For all other seat frame changes, refer back to the

starting procedure to complete the desired change.

Mounting

Screw

Locknut

Quick

Release

Back

Angle

Plate

Seat Frame

Washers

Locknuts

CJ Back

Bracket

Seat

Positioning

Strap

FIGURE 1 - REMOVING/INSTALLING CJ BACK

BRACKETS

Toward Front of

Wheelchair

CJ Bracket

mounts in

Front Holes on

Back Angle

Plates.

DETAIL “A”

Threaded

Studs

Seat

Pan

NOTE: If needing a reference for proper mounting holes

for the back angle required, or if changing the original back

angle, refer to BACK ANGLE ADJUSTMENT in this pro-

cedure of the manual.

WARNING

The back canes MUST be fastened se-

curely to the seat frame BEFORE using the

wheelchair. Torque to 75-inch pounds.

13. Secure the two (2) NEW back canes to the seat frame

with the existing four (4) mounting screws, washers,

spacers, and locknuts. Use Loctite 242 and torque to

75-inch pounds.

14. Secure the top of the existing/new back upholstery to

the back canes with the two (2) existing mounting

screws and washers.

15. Secure bottom of the existing/NEW back upholstery

to rear of the seat pan.

16. Secure the bottom of the existing/NEW back uphol-

stery to the back canes with new tie-wraps.

NOTE: Clean upholstery with warm DAMP cloth and mild

detergent to remove superficial soil.

WARNING

Laundering or moisture will reduce flame

retardancy of the upholstery.

NOTE: When replacing the back upholstery, back as-

sembly or changing back height, follow these guidelines

for spreader bar height (where applicable):

BACK HEIGHT u SPREADER BAR

HEIGHT

16-inches* 5-inches

17-inches* 5-inches

18-19-inches* 7-inches

20-24inches 7-inches

NOTE: Spreader Bar required on back heights 20-24-

inches. *Spreader bar ONLY required on these back

heights if the width or depth of the chair exceeds 19-inches.

u Height of Spreader Bar from Bottom of Back Canes

to Top of Spreader Bar Clamp.

HEAVY DUTY MODELS

NOTE: Spreader bar required on all Heavy Duty models.

BACK HEIGHT u SPREADER BAR

HEIGHT

16-17-inches 5-inches

18-24-inches 7-inches

uHeight of Spreader Bar from Bottom of Back

Canes to Top of Spreader Bar Clamp.

CHANGING BACK HEIGHT

(FIGURE 2)

NOTE: If changing the back height, new back upholstery

may be needed as well. Refer to the following chart to deter-

mine if new back upholstery is needed:

BACK UPHOLSTERY HEIGHT RANGES

16-17-INCHES

18-19-INCHES

20-INCHES

21-22-INCHES

23-24-INCHES

If back height required is within the range of the origi-

nal back height, only new back canes will be needed.

If the back height required is NOT within the range of

the original back height, new back upholstery, as well

as new back canes will be needed.

NOTE: Existing hardware and inserts will be reused.

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

STALLING/REMOVING FLIP BACK ARMRESTS in

PROCEDURE 4 of the owners manual, 1081227.

NOTE: Note the correct mounting screw mounting positions

to ensure the proper back angle for reinstallation.

2. Remove the two (2) mounting screws and washers that

secure the existing back upholstery to the back canes.

3. Remove the four (4) mounting screws, washers, spac-

ers, and locknuts that secure the existing back canes to

the seat frame.

4. Remove the inserts from the existing back canes.

5. Remove the back assembly from the wheelchair.

6. If applicable, loosen, but do not remove the mounting

screws and locknuts that secure the spreader bar to the

existing back canes.

7. Remove existing back canes from the back assembly.

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

9. Line up the mounting holes of the inserts with the mount-

ing holes in the back canes.

NOTE: To keep the inserts lined up for reinstallation onto the

wheelchair, start one (1) of the mounting screws through the

back cane from inside of the wheelchair to hold the insert in

place.

10. Slide the NEW back canes through the existing/NEW

back upholstery and spreader bar.

11. If applicable, loosely tighten the mounting screws that

secure the spreader bar to the NEW back canes.

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

mounting holes in the seat frame.

BACK FRAMEPROCEDURE 8

FIGURE 2 - CHANGING BACK HEIGHT

Locknut

(STEPS 6,11)

Mounting Screw

Torque to 60 in/lbs

(STEPS 6,11)

Spreader Bar

(STEPS 6,17)

Mounting

Screw

(STEPS 2, 14)

Washer

(STEPS 2, 14)

Back

Upholstery

Back Cane

(STEPS 3, 10)

Insert

(STEPS 4,8)

Seat Frame

Mounting Screws

Torque to 75 in/lbs

(STEPS 3, 13)

Washers

(STEPS 3, 13)

Mounting Screws

(STEPS 3, 13)

Washers

(STEPS 3, 13)

Spacers

(STEPS 3, 13)

Locknuts

(STEPS 3, 13)

Locknut

(STEPS 6,11)

Mounting

Screw

(STEPS 6,11)

17. If necessary, reposition the spreader bar at the cor-

rect height for the corresponding back height and

torque the mounting hardware to 60-inch pounds.

18. Reinstall the armrest onto the wheelchair. Refer to

INSTALLING/REMOVING FLIP BACK ARMRESTS

in PROCEDURE 4 of the owners manual, 1081227.

BACK FRAME PROCEDURE 8

BACK ANGLE ADJUSTMENT

(FIGURE 3)

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

STALLING/REMOVING FLIP BACK ARMRESTS in

PROCEDURE 4 of the owners manual, 1081227.

2. Remove the mounting screw and washer from the top

mounting hole of back angle plate and back cane.

NOTE: To avoid losing the insert in each back cane, thread

the mounting screw through the cane from the inside of

wheelchair to hold the insert in place.

TO ACHIEVE A BACK ANGLE OF:

ANGLE BACK CANE MOUNTING HOLE BACK ANGLE PLATE HOLE

80OTop TOP Front

Bottom BOTTOM Rear

85OTop TOP Front

2nd from Bottom BOTTOM Center

90OTop TOP Front

Bottom BOTTOM Front

95OTop TOP Center

2nd from Bottom BOTTOM Front

100OTop TOP Rear

Bottom BOTTOM Front

FIGURE 3 - BACK ANGLE ADJUSTMENT

3. Remove the mounting screw and washer from the

bottom mounting hole of the back angle plate and

back cane.

4. Reposition the back canes into the correct mount-

ing holes of the back angle plate to obtain a back

angle between 80o and 100o in 5o increments.

5. Torque mounting screws to 75-inch pounds.

6. Reinstall the armrests onto the wheelchair. Refer

to INSTALLING/REMOVING FLIP BACK ARM-

RESTS in PROCEDURE 4 of the owners manual,

1081227.

BACK FRAMEPROCEDURE 8

NOTE: If there is battery acid in the bottom or on the sides of

the battery box(es) or battery(ies), apply baking soda to these

areas to neutralize the battery acid. Before reinstalling the

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

battery box(es) or battery(ies).

NOTE: When securing battery lifting strap to battery, ob-

serve polarity markings located on the ends of the battery

lifting strap, (+) side to POSITIVE (+) battery post and (-) side

to NEGATIVE (-) battery post.

1. If necessary, remove the battery boxes from the wheel-

chair. Refer to INSTALLING/REMOVING BATTERY

BOXES - GROUP 24 BATTERY BASE FRAMES in

this procedure of the manual.

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

(FIGURE 1).

CAUTION

Some battery manufacturers mold a carrying strap

and/or hold down flanges directly into the bat-

tery case. Batteries which interfere with the bat-

tery 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.

PROCEDURE 9BATTERIES

This Procedure Includes the Following:

Installing/Removing Batteries Into/From Battery

Box(es)

Connecting Battery Cables

When to Charge Batteries

Charging Batteries

Replacing Batteries

Installing/Removing Group 24 Battery Boxes

Installing/Removing Group 22NF Battery Boxes

WARNING

Make sure power to the wheelchair is OFF before

performing this procedure.

The use of rubber gloves and chemical

goggles or face shields is recommended

when working with batteries.

Invacare strongly recommends that battery instal-

lation and battery replacement ALWAYS be done

by a qualified technician.

After ANY adjustments, repair or service and BE-

FORE use, make sure all attaching hardware is

tightened securely - otherwise injury or damage

may result.

INSTALLING/REMOVING

BATTERIES INTO/FROM BATTERY

BOXES (FIGURE 1)

NOTE: To remove the battery(ies) from the battery box(es),

reverse the following procedure.

NOTE: Have the following tools available:

TOOL QTY COMMENTS

Battery Lifting Strap 1 Supplied

1/2-inch (6 pt) Box Wrench 1 Not Supplied

WARNING

ALWAYS use a battery lifting strap when lifting a bat-

tery. It is the most convenient method and assures

that the battery acid will not spill. It also helps to

prolong the life of the battery.

DO NOT tip the batteries. Keep the batteries in an

upright position.

Place the wheelchair in a well ventilated area

where work can be performed without risking

damage to carpeting or floor covering.

The warranty and performance specifications con-

tained in this manual are based on the use of deep

cycle gel cell or sealed lead acid batteries.

Invacare strongly recommends their use as the

power source for this unit.

Battery

Lifting

Strap

Group 22NF

Battery Box

Bottom

Group 24

Battery Box Bottom

Molded Carrying Straps (Must be

removed before installation)

FIGURE 1 - INSTALLING/REMOVING BATTERIES

INTO/FROM BATTERY BOXES

PROCEDURE 9 BATTERIES

CONNECTING BATTERY CABLES

(FIGURE 2)

WARNING

NEVER allow any of your tools and/or battery

cable(s) to contact BOTH battery post(s) at the

same time. An electrical short may occur and se-

rious personal injury or damage may occur.

The use of rubber gloves and chemical

goggles or face shields is recommended

when working with batteries.

When tightening the clamps, always use a

box wrench. Pliers will “round off” the nuts.

NEVER wiggle the battery terminal(s)/post(s)

when tightening. The battery may become

damaged.

The POSITIVE (+) RED battery cable MUST con-

nect to the POSITIVE (+) battery terminal(s)/

post(s), otherwise serious damage will occur

to the electrical system.

Group 24 Batteries

NOTE: Perform this procedure on one (1) battery and bat-

tery box at a time. Repeat procedure for other battery box.

1. Position battery box top next to battery box bottom as

shown in FIGURE 2.

2. Peel back battery clamp covers to expose battery clamp

on each battery cable as follows:

A. RED battery clamp cover from RED battery cable.

B. BLACK battery clamp cover from BLACK battery

cable.

3. Connect NEGATIVE N battery cable clamp to NEGA-

TIVE(-) battery post and connect POSITIVE P battery

cable clamp to POSITIVE (+) battery post (DETAIL A).

4. Secure the battery cable clamp(s) to the battery post(s)

with provided hex screws and nuts. Securely tighten.

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

and securely tightened.

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

7. Install the battery box top(s).

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

INSTALLING/REMOVING BATTERY BOX(ES) in this

procedure of this manual.

NOTE: New Battery(ies) MUST be fully charged BEFORE

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

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

ING BATTERIES in this procedure of the manual.

PROCEDURE 9BATTERIES

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

Battery Box Bottom

POSITIVE

(+)

Battery

Terminal/

Post

NEGATIVE

(-)

Battery

Terminal/

Post

Battery

ONE (1) CONNECTOR BATTERY BOXTWO (2) CONNECTOR BATTERY BOX

BLACK

Battery

Clamp

Cover

RED

Battery

Clamp

Cover

Red POSI-

TIVE (+)

Battery Cable

Clamp

Black NEGA-

TIVE (-)

Battery Cable

Clamp

Black NEGA-

TIVE (-)

Battery Cable

RED POSI-

TIVE (+)

Battery

Cable

One (1) Connector

Battery Box Top

Battery Box

Bottom

RED

Battery

Clamp

Cover

RED

POSITIVE (+)

Battery

Cable Clamp

Black

NEGATIVE (-)

Battery

Cable

Clamp

RED POSITIVE (+)

Battery Cable

BLACK

NEGATIVE (-)

Battery

Cable

Two (2) Connector

Battery Box Top

Battery Box

Bottom

DETAIL “A”

NEGATIVE (-)

Battery

Terminal/Post

POSITIVE (+)

Battery

Terminal/Post

NEGATIVE (-)

Battery Termi-

nal/Post POSITIVE (+)

Battery Terminal/Post

Group 22 Battery Base Frames (FIGURE 3)

NOTE: Refer to WARNINGSand CAUTIONS in the front

of this procedure.

NOTE: Note polarity of white battery cable (jumper)

battery terminal ends.

1. Remove battery terminal cap(s) from battery

terminal(s) ends. Refer to DETAIL A in FIGURE

2. Connect WHITE battery cable (jumper) NEGATIVE

N terminal end to NEGATIVE (-) battery terminal/

post of front battery and connect POSITIVE P ter-

minal end to POSITIVE (+) battery terminal/post of

rear battery.

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

tery.

4. Connect NEGATIVE (-) BLACK battery cable of

the battery box top to NEGATIVE (-) battery termi-

nal/post of rear battery.

5. Position battery box top right side up and rotate

outward toward right to expose POSITIVE (+) bat-

tery terminal/post of front battery.

6. Connect POSITIVE (+) RED battery cable on battery

box top to POSITIVE (+) battery terminal/post of front

battery.

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

terminal end(s).

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

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

INSTALLING/REMOVING 22NF BATTERY BOX in

the Owners Manual supplied with the chair.

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

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

be reduced.

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

CHARGING BATTERIES in the Owners Manual

supplied with the wheelchair.

PROCEDURE 9 BATTERIES

STEPS 3 AND 4

Battery

Box Top

(Under Side

shown)

NEGATIVE (-)

BLACK Battery

Cable

Front

Battery

Rear

Battery

STEPS 5 AND 6

Battery

Box Top

Front

Battery

Box Bottom

FRONT

POSITIVE (+)

RED Battery

Cable

Fuse

Block

POSITIVE (+) RED Battery Cable

Battery Box Bottom

Rear

Battery

NEGATIVE (-)

Battery

Terminal/Post

POSITIVE (+)

Battery

Terminal/Post

NOTE: Battery box top cut away for clarification pur-

poses only.

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

STEP 2

Single

Battery

Box

Bottom

WHITE Bat-

tery Cable

(Jumper)

Front

Battery

Rear

Battery

FRONT

REAR

DETAIL “A”

Terminal Cap

Terminal End

PROCEDURE 9 BATTERIES

FIGURE 6 - WHEN TO CHARGE BATTERIES

MKIV- A JOYSTICK MKIV- A+ JOYSTICK

Battery Discharge

Indicator (BDI) (in LCD

Readout)

MKIV- X JOYSTICK

Battery Discharge

Indicator (BDI)

Battery Discharge

Indicator (BDI)

CHARGING BATTERIES (FIGURE 7)

NOTE: New batteries MUST be fully charged prior to initial

use of the wheelchair.

WARNING

Never attempt to recharge the batteries

by attaching cables directly to the bat-

tery terminals or clamps. Always use the

recharging plug located on the side of the

wheelchair frame.

DO NOT attempt to recharge the batter-

ies and operate the power wheelchair at

the same time.

During use and charging, unsealed bat-

teries will vent hydrogen gas which is ex-

plosive in the right concentration with air.

CAUTION

Always charge new batteries before ini-

tial 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 bat-

teries when it is anticipated the wheelchair will not be

used for a long period of time.

The range per battery charge using recommended batter-

ies should be approximately 5 to 9 hours of typical opera-

tion. Extensive use on inclines may substantially reduce

per charge mileage.

WHEN TO CHARGE BATTERIES

(FIGURE 6)

The Battery Discharge Indicator (BDI) is a bar graph dis-

play located on the MKIV joystick. It will keep you informed

as to power availability. A visual warning is given before the

power becomes too low to operate the wheelchair. At full

charge the two (2) LEFT segments and the farthest RIGHT

segment of the bar graph will be illuminated. As the battery

becomes discharged, the farthest RIGHT segment will pro-

gressively 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.

Description and Use of Battery Chargers

The charger automatically reduces the charge from an ini-

tially high rate to a zero reading at a fully charged condition.

If left unattended, the charger should automatically shut-off

when full charge is obtained.

There are some basic concepts which will help you

understand this automatic process. They are:

The amount of electrical current drawn within a given time

to charge a battery is called the charge rate. If, due to

usage, the charge stored in the battery is low, the charge

rate is high, as indicated by the green light on the charger.

Initially, the green light will stay illuminated for a short period

of time followed by a longer period of off time. As a charge

builds up, the charge rate is reduced, and the green light will

stay illuminated for a longer period of time followed by a

shorter off time.

WARNING

If the charger circuit breaker is tripping ON

and OFF, unplug the charger and contact

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

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

uExtension Cord 1 Not Supplied

u(3-prong plug, 15 ampere current rating; industrial type)

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

battery harness.

NOTE: The battery charger connector is factory installed on

the RIGHT side of the wheelchair. It can be positioned on

either side of the wheelchair for user convenience.

NOTE FOR RECLINERS ONLY: If the wheelchair is a re-

cliner, the battery charger connector as well as the limit switch,

are factory set on the RIGHT side of the wheelchair. How-

ever, they can be positioned on either side for user conve-

nience. The limit switch MUST BE positioned on the same

side as the battery charger connector.

2. Plug the chargers AC power cord, or extension, into the

grounded 120 VAC wall outlet.

3. Wait until charging is complete.

FIGURE 7 - CHARGING BATTERIES

Charger Cable

Base Frame

Battery Charger Mount Bracket

RWD/MWD MODELS

ARROW FWD MODEL

NOTE: Shrouds and drive wheels not shown for

clarification purposes only.

From

Battery

Charger

Battery Charger Connector

From Battery Charger

Three (3)

Pronged Plug

Battery Charger Battery Boxes

Top View

of Wheelchair

Battery Charger

Mount Bracket

and Connector

REAR OF

WHEELCHAIR

NOTE: Allow eight (8) hours for normal charging. Larger

batteries (greater than 55 ampere-hours) or severely dis-

charged batteries may require up to sixteen (16) hours to

be properly charged and equalized. If charger operates

for sixteen (16) hours and is unable to fully charge the

batteries, an internal timer turns the charger off and be-

gins to fast blink the green light.

PROCEDURE 9BATTERIES

PROCEDURE 9 BATTERIES

It is advantageous to recharge frequently rather than only

when necessary. In fact, a batterys life is extended if the charge

level is maintained well above a low condition.

REPLACING BATTERIES

NOTE: Invacare recommends that both batteries be replaced

if one (1) battery is defective.

Recommended Battery Types

WARNING

The warranty and performance specifi-

cations contained in this manual are

based on the use of deep cycle gel cell

or sealed lead acid batteries. Invacare

strongly recommends their use as the

power source for this unit.

Failure to use the correct battery size and/

or voltage may cause damage to your

wheelchair and give you unsatisfactory

performance.

BATTERY SIZE

POWER CHAIR QTY VOLTS Standard Optional

Arrow

w/ motor/gearbox 2 12 Group 24 Group 22

w/ G/B motor 2 12 Group 22 Group 24

Torque

with motor/gearbox 2 12 Group 22 Group 24

with G/B motor 2 12 Group 22 Group 24

Torque SP

with motor/gearbox 2 12 Group 22 N/A

with G/B motor N/A N/A N/A N/A

Storm X

with motor/gearbox 2 12 Group 22 Group 24

with G/B motor 2 12 Group 22 Group 24

NOTE: G/B denotes gearless/brushless.

NOTE: Both battery sizes are deep cycle batteries.

NOTE: Charge batteries daily. It is critical not to let them run

low at any time.

1. Remove the battery box(es) from the wheelchair. Re-

fer to INSTALLING/REMOVING GROUP 24 BATTERY

BOXES or INSTALLING/REMOVING GROUP 22 BAT-

TERY BOX in this procedure of the manual.

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

Refer to INSTALLING/REMOVING BATTERIES INTO/

FROM BATTERY BOX(ES) in this procedure of the

manual.

3. Clean the new battery terminals. Refer to CLEANING

BATTERY TERMINALS in this procedure of the manual.

4. Install the new batteries into the battery box(es). Refer

to INSTALLING/REMOVING BATTERIES INTO/FROM

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

Cleaning Battery Terminals

WARNING

Most batteries are not sold with instructions.

However, warnings are frequently noted

on the cell caps. Read them carefully.

DO NOT allow the liquid in the battery to

come in contact with skin, clothes or other

possessions. It is a form of acid and harmful

or damaging burns may result. Should the

liquid touch your skin, wash the area IM-

MEDIATELY and thoroughly with cool wa-

ter. In serious cases or if eye contact is

made, seek medical attention IMMEDIATELY.

1. Examine the battery clamps and terminals for corrosion.

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

3. Clean the terminals and inside the battery clamps by

using a battery cleaning tool, wire brush, or medium grade

sand paper.

NOTE: Upon completion, these areas should be shiny,

not dull.

4. Carefully dust off all metal particles.

INSTALLING/REMOVING GROUP

24 BATTERY BOXES (FIGURE 8)

NOTE: To remove the battery boxes from the wheelchair,

reverse the following procedure.

Installing

NOTE: FWD wheelchairs only - Remove the counter-

weight before performing this procedure. Refer to REMOV-

ING/INSTALLING COUNTERWEIGHT in PROCE-

DURE 16 of this manual.

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

OFF position.

2. Place two (2) connector battery box onto the battery sub-

frame assembly with guide pins facing the inside of the

wheelchair.

3. Slide the two (2) connector battery box along the sub-

frame until its guide pins are engaged in the sub-frame

connector.

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

(2) connector battery box.

NOTE: Visually inspect to ensure the connection is prop-

erly made. Connectors MUST be fully engaged.

FIGURE 9 - INSTALLING/REMOVING GROUP

22 BATTERY BOX

Battery Box

Retention Strap

Arrows

FIGURE 8 - INSTALLING/REMOVING GROUP

24 BATTERY BOXES

Battery Box

Sub-Frame

Two (2) Connector

Battery Box

One (1) Connector Battery Box

NOTE: Position

carrying strap on top

of battery box

Guide Pins

Battery Box

Retainer Bar

INSTALLING/REMOVING GROUP

22 BATTERY BOX (FIGURE 9)

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

NOTE: To install the battery box onto the wheelchair, re-

verse the following procedure.

1. Place the wheelchair in a well ventilated area where

work can be performed without risking damage to car-

peting or floor covering.

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

OFF position.

3. Disconnect the battery cable from the outside of the

battery box.

4. Disconnect the battery box retention strap.

5. Remove the battery box.

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

to the battery box to the OPEN position.

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

position.

7. Remove battery box cover from the battery box.

*NOTE: Illustration depicts base frame for RWD and

MWD models. Batteries remove/Install for the Arrow

FWD in the same manner.

*Base Frame

NOTE: Make certain that the carrying strap of the first

battery box installed is positioned on top of the battery box

and will not interfere with the second battery box guide

pins during installation.

5. Place one (1) connector battery box onto battery sub-

frame.

6. Slide one (1) connector battery box along the sub-

frame until its guide pins are engaged in the connec-

tor of the two (2) connector battery box.

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

(1) connector battery box.

NOTE: Visually inspect to ensure the connection is

properly made. Connectors MUST be fully engaged.

CAUTION

The battery box retainer MUST be locked

(clipped) securely to hold the battery

boxes firmly in place or battery box con-

nectors may be damaged causing er-

ratic chair operation.

8. Pull the battery box retainer down over the end of

front battery box until it is securely clipped (locked)

into place.

PROCEDURE 9BATTERIES

PROCEDURE 10 WIRING HARNESS

REMOVING/INSTALLING THE

WIRING HARNESS (FIGURE 1)

NOTE: This procedure is for the FWD and MWD

models ONLY. For the removing and installing the wir-

ing harness on the Arrow FWD refer to REMOVING/

INSTALLING WIRING HARNESS in PROCEDURE

17 of this manual.

Removing

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

MOVING GROUP 24 BATTERY BOXES or INSTALL-

ING/REMOVING GROUP 24 BATTERY BOX in PRO-

CEDURE 9 of this manual.

2. Perform one (1) of the following:

For Group 24 Batteries - remove the two mounting

screws and locknuts that secure the wiring harness

bracket to the base frame (DETAIL A).

For Group 22 Batteries - cut the tie wrap that se-

cures the rear portion of the wiring harness and joy-

stick cable to the rear of the seat frame (DETAIL B).

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

SECOND GENERATION WHEELCHAIRS

WITH MOTOR/GEARBOX ASSEMBLY

A. Cut tie-wraps A and B that secure the two (2)

motor/controller connections and the controller/

wiring harness connection (BLUE connectors)

together (DETAIL C).

B. Cut tie-wrap C that secures the battery charger

cable, motor connector cable, controller connec-

tor cable, and wiring harness cable to the base

frame (DETAIL C).

SECOND GENERATION WHEELCHAIRS

WITH GEARLESS/BRUSHLESS MOTOR

A. Cut tie-wrap A that secures the battery charger

cable to the base frame (DETAIL B).

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

This Procedure includes the following:

Removing/Installing the Wiring Harness

Adjusting Limit Switch

WARNING

After ANY adjustments, repair or service and BE-

FORE use, make sure that all attaching hardware

is tightened securely - otherwise injury or dam-

age may result.

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

from the controller connector (BLUE).

5. Remove the two mounting screws that secure the

charger cable to the mounting bracket.

6. Remove the wiring harness.

Installing

1. For Group 24 Batteries Only - Install NEW wir-

ing harness w/bracket to the rear of the sub-frame

and torque mounting screws to 160-inch pounds

(DETAIL A).

2. For Group 22 and Group 24 Batteries - Secure

the charger cable to the mounting bracket with the

two (2) mounting screws. Securely tighten (DE-

TAIL C OR D).

3. For Group 22 and Group 24 Batteries - Con-

nect the battery harness/charger cable (BLUE) to

the controller connector (BLUE) (DETAIL C or

D).

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

SECOND GENERATION WHEELCHAIRS

WITH MOTOR/GEARBOX ASSEMBLY

A. For Group 22 and Group 24 Batteries -

Group the two (2) motor/controller connections

together along with the controller/wiring har-

ness connection (BLUE) and secure with TIE-

WRAPS A and B (DETAIL C).

B. For Group 22 and Group 24 Batteries - Se-

cure the Wiring Harness Cable, Battery Charger

Cable, Controller Connector Cable, and Motor

Connector Cable to the suspension arm with

TIE-WRAP C (DETAIL C).

SECOND GENERATION WHEELCHAIRS

WITH GEARLESS/BRUSHLESS MOTOR

OPTION:

A. For Group 22 and Group 24 Batteries - Se-

cures the battery charger cable to the base

frame with TIE-WRAP A (DETAIL D).

5. For Group 22 Batteries Only - Tie-wrap NEW wir-

ing harness and joystick cable to the rear of the seat

frame (DETAIL B).

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

REMOVING GROUP 24 BATTERY BOXES or IN-

STALLING/REMOVING GROUP 22 BATTERY BOX

in PROCEDURE 9 of this manual.

FRONT OF

CHAIR

REAR OF

CHAIR

Wiring Harness

Bracket

Mounting

Screws

Battery Box

Sub-Frame

Base

Frame

Locknuts

DETAIL A - GROUP 24 BATTERIES DETAIL B - GROUP 22 BATTERIES

DETAIL “C” -SECOND GENERATION

WHEELCHAIRS

Tie-Wraps

A and B

Wiring Harness

Connector

(BLUE)

Tie-Wrap

Controller

Connector

(BLUE)

Charger

Mount

Bracket

Wiring

Harness

Connector

(BLUE)

Controller

Connector

(BLUE)

DETAIL “D” - SECOND GENERATION

WHEELCHAIRS WITH GEARLESS /BRUSHLESS

MOTOR

Tie-Wrap

NOTE: There is no

need to cut this

tie-wrap.

NOTE: Illustration depicts gearless/brushless motor.

Wiring harness is secured to the rear of the seat frame

in the same manner for wheelchairs with conventional

motor/gearbox assembly.

NOTE: Battery box sub-frame exploded away for clari-

fication purposes only.

FIGURE 1 - REMOVING/INSTALLING THE WIRING HARNESS

Joystick

Cable

Wiring

Harness

Motor

Connector

Controller

Connector

Mounting

Screws

Battery

Charger

Cable

Motor

Connector

Cable

Wiring

Harness

Cable

Motor

Connector

Controller

Connector

Mounting

Screws

Charger

Cable

PROCEDURE 10WIRING HARNESS

ADJUSTING LIMIT SWITCH

(FIGURE 2)

NOTE: The following procedure is for high back captains

van seat model wheelchairs only.

WARNING

NEVER operate the wheelchair while in any

recline position over 114o RELATIVE TO THE SEAT

FRAME. If the limit switch does not stop the

wheelchair from operating in a recline posi-

tion greater than 114o RELATIVE TO THE SEAT

FRAME, DO NOT operate the wheelchair. Ad-

just the limit switch BEFORE using the wheel-

chair, otherwise injury or damage can occur.

1. Place the wheelchair on a level surface.

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

the 114o angle relative to the seat frame. Refer to AD-

JUSTING CAPTAINS VAN SEAT in PROCEDURE 4 of

the owners manual, 1081227.

NOTE: The captains van seat frame is at a 5o angle relative

to the ground. When the back angle is adjusted to 114o rela-

tive to the seat, it will measure 61o relative to the ground.

NOTE: To determine 114o back angle relative to the seat

frame, place a magnetic protractor (available at any hard-

ware store) on the back as shown in FIGURE 2 and adjust

the back until the magnetic protractor reads 61o.

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

ON position.

NOTE: The wheelchair should not operate.

4. IF wheelchair operates, proceed to the following steps

to adjust the actuator on the upper limit switch bracket:

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

TAINS VAN SEAT in PROCEDURE 4 of the

Owners Manual, 1081227.

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

B. Loosen, but do not remove, the two (2) phillips

screws, washers and locknuts that secure the ac-

tuator 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 can occur.

D. Only tighten the two (2) phillips screws, washers

and locknuts that secure the actuator to the upper

limit switch bracket until the actuator does not move.

E. Repeat STEPS 1-3 until the wheelchair does not

operate when the captains van seat back is at a 24o

angle.

FIGURE 2 - ADJUSTING LIMIT SWITCH

24o Back

Recline Angle

61o

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

Locknuts

Actuator

5-3/4 inches

5o Seat Angle

114o

PROCEDURE 10 WIRING HARNESS

REPLACING BATTERY BOX

RETAINER BAR/RETAINER CLIP -

GROUP 24 BATTERY BASE FRAMES

(FIGURE 1)

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

MOVING GROUP 24 BATTERY BOXES in PROCE-

DURE 9 of this manual.

Replacing Retainer Clip

1. Perform one (1) the following:

A. RWD AND MWD MODELS - Remove the

mounting screw that secures the retainer clip and

shock (or rubber element) to the base frame.

B. FWD MODEL - Remove the mounting screw,

washer, spacer, and locknut that secure the re-

tainer clip to the battery box sub-frame.

2. Remove the existing retainer clip.

3. Perform one (1) the following:

A. RWD AND MWD MODELS - Position the NEW

retainer clip between the shock (or rubber ele-

ment) and the battery box sub-frame as shown

in FIGURE 1. Make sure the angled end of the

retainer clip is facing up.

B. FWD MODEL - Position the NEW retainer clip

between the spacer and the battery box sub-

frame as shown in FIGURE 1. Make sure the

angled end of the retainer clip is facing upwards.

WARNING

The Battery Box Retainer Bar/Retainer Clip MUST

be fastened securely in place before using the

wheelchair. Use Loctite 242 and torque to 160-

inch pounds.

4. Perform one (1) the following:

A. RWD AND MWD MODELS -Reinstall the mount-

ing screw that secures the retainer clip and shock

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

242 and torque to 160-inch pounds.

RETENTION STRAP/RETAINER PROCEDURE 11

This Procedure Includes the Following:

Replacing Battery Box Retainer Bar/ Retainer Clip

-Group 24 Battery Base Frames

WARNING

After ANY adjustments, repair or service and BE-

FORE use, make sure that all attaching hardware

is tightened securely - otherwise injury or dam-

age may result.

B. FWD MODEL - Reinstall the mounting screw,

washer, spacer, and locknut that secure the retainer

clip to the battery box sub-frame. Use Loctite 242

and torque to 160-inch pounds.

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

MOVING BATTERY BOXES - GROUP 24 BATTERY

BASE FRAMES in PROCEDURE 9 of this manual.

Replacing Retainer Bar

1. Perform one (1) the following:

A. RWD AND MWD MODELS -Remove the two (2)

mounting screws and spacers that secure the bat-

tery box retainer bar to the base frame.

B. FWD MODELS - Remove the two (2) mounting

screws, spacers, washers, and locknuts that se-

cure the retainer bar to the battery box sub-frame.

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

the base frame.

3. Install the two (2) existing spacers through the mounting

holes in the NEW battery box retainer bar.

WARNING

The Battery Box Retainer Bar/Retainer Clip MUST be

fastened securely in place before using the wheel-

chair. Use Loctite 242 and torque to 160-inch

pounds.

4. Perform one (1) the following:

A. RWD AND MWD MODELS - Line up the NEW

battery box retainer bar and spacers with the mount-

ing holes in the battery box sub frame and the base

frame.

B. FWD MODELS - Line up the NEW battery box

retainer bar and spacers with the mounting holes in

the battery box sub frame.

5. Perform one (1) the following:

A. RWD AND MWD MODELS - Reinstall the mount-

ing screws that secure the battery box retainer bar

between battery box sub frame and the base frame.

Use Loctite 242 and torque to 160-inch pounds.

B. FWD MODELS - Reinstall the mounting screws

that secure the battery box retainer bar onto battery

box sub frame. Use Loctite 242 and torque to 160-

inch pounds.

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

REMOVING GROUP 24 BATTERY BOXES in PRO-

CEDURE 9 of this manual.

PROCEDURE 12 WHEELS/MOTORS

Retainer

Clip

Mounting

Screws

Battery Box

Sub-frame

Base Frame

Angled End

(Facing Upward)

Retainer

Bar

Shock

Assembly

Top of Shock

Assembly

Spacer

RWD AND MWD MODELS

FWD MODELS

Retainer Bar

Mounting Screws

Washers

Spacer

Retainer

Clip

Spacer

Locknuts

Battery Box

Sub-Frame

ASSEMBLED VIEW

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

This Procedure includes the following:

Replacing Pneumatic Tires/Tubes - Drive Wheels/

Casters

Removing/Installing Drive Wheels

Removing/Installing Drive Wheel Hub

Installing Wheel Lock Bracket onto Wheelchair

Removing/Installing Casters

Replacing Forks

Motor Replacement

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. Keystock

*Locknut

*Washer

Four (4)

Beveled

Hex Nuts

Drive Wheel Assembly

Wheel Hub

Assembly

Gearbox Drive Shaft

FIGURE 1 - REMOVING/INSTALLING DRIVE WHEELS

2. Remove the four (4) beveled hex nuts that secure the

drive wheel assembly to the wheel hub assembly.

3. Remove existing drive wheel assembly from wheel hub.

Installing

1. Reinstall new/existing drive wheel assembly to the

wheel hub assembly and torque the four (4) beveled

hex nuts to 160-inch pounds.

2. Repeat procedure for opposite side of wheelchair, if

necessary.

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

REMOVING GROUP 24 BATTERY BOXES or IN-

STALLING/REMOVING GROUP 22 BATTERY

BOXES in PROCEDURE 9 of this manual.

CONVENTIONAL MOTOR WITH GEARBOX

GEARLESS/BRUSHLESS MOTOR

REPLACING PNEUMATIC TIRES/

TUBES - DRIVE WHEELS/CASTERS

WARNING

DO NOT use your wheelchair unless it has the

proper tire pressure (p.s.i.). DO NOT overinflate the

tires. Failure to follow these suggestions may cause

the tire to explode and cause bodily harm.

If tires are pneumatic, replacement of tire or tube

MUST be performed by an authorized Invacare

dealer or qualified technician.

NOTE: If drive wheels or casters are pneumatic, under-in-

flation causes excessive wear which results in poor perfor-

mance of the tires.

REMOVING/INSTALLING DRIVE

WHEELS (FIGURE 1)

CAUTION

Perform the following procedure in a designated

work area to prevent damage to flooring (car-

peting, tile, etc.).

Removing

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

REMOVING GROUP 24 BATTERY BOXES or IN-

STALLING/REMOVING GROUP 22 BATTERY

BOXES in PROCEDURE 9 of this manual.

Four (4) Beveled Hex Nuts

Drive Wheel

Assembly

Wheel Hub

Assembly

*NOTE: It is not required to remove the locknut and

washer to remove the drive wheel.

PROCEDURE 12WHEELS/ MOTORS

PROCEDURE 12 WHEELS/MOTORS

REMOVING/INSTALLING DRIVE

WHEEL HUB (FIGURE 1)

NOTE: This procedure can only be performed on sec-

ond generation storm wheelchairs with the conven-

tional motor/gearbox assembly. On second genera-

tion storm wheelchairs with the gearless/brushless

motor, the drive wheel hub CANNOT be removed.

Return motor to manufacturer for service.

Removing

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

REMOVING/INSTALLING DRIVE WHEELS in this

procedure of the manual.

2. Remove the locknut, washer, keystock and existing

drive wheel hub from the drive shaft of the gearbox.

Installing

1. Position the keystock on the gearbox drive shaft.

CAUTION

DO NOT apply more than a one (1)-inch (in length)

thin film of anti-seize compound to the drive shaft.

Applying more than one (1)-inch (in length) can

cause the anti-seize compound to leak resulting

in damage to flooring (carpet, tile, etc.).

2. Apply a thin film of anti-seize compound one (1) inch in

length to the end of the drive shaft.

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

NOTE: While installing the drive wheel hub onto the drive

shaft, spin the drive wheel hub to evenly distribute the anti-

seize compound over the entire drive shaft.

4. Reinstall the washer and locknut and torque locknut to

45 foot pounds (540-inch pounds).

5. Reinstall the drive wheel assembly to the wheelchair.

Refer to REMOVING/INSTALLING DRIVE WHEELS

in this procedure of the manual.

6. Repeat procedure for the opposite side of the wheel-

chair, if necessary.

Gearbox

Wheel Lock

Mounting

Bracket

Mounting

Screws

FIGURE 2 - INSTALLING WHEEL LOCK BRACKET

ONTO WHEELCHAIR

Suspension

Arm

INSTALLING WHEEL LOCK BRACKET

ONTO WHEELCHAIR (FIGURE 2)

NOTE: This procedure only pertains to second gen-

eration storm wheelchairs with the conventional mo-

tor and gearbox. On second generation storm wheel-

chairs with the gearless/brushless motor, the wheel

lock bracket is not required.

1. Remove the two (2) mounting screws closest to the large

wheel that secure the gearbox to the suspension arm.

2. Line up mounting holes in the wheel lock mounting bracket

with the gearbox mounting holes in the suspension arm.

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

4. Reinstall the two (2) mounting screws into the mounting

holes of the wheel lock mounting bracket and gear box

and torque to 75-inch pounds.

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

6. Adjust the wheel locks. Refer to ADJUSTING WHEEL

LOCKS in PROCEDURE 9 of the owners manual,

1081227.

REMOVING/INSTALLING THE

MOTOR (CONVENTIONAL MOTOR

WITH GEARBOX) (FIGURE 5)

Removing

RWD AND MWD MODELS.

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

the controller.

2. Remove the two (2) allen screws and washers that

secure the motor to the gearbox.

CAUTION

DO NOT damage the motor/gearbox coupling.

3. Carefully pull the motor away from the gearbox.

ARROW FWD MODEL.

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

STALLING SIDE SHROUD ASSEMBLY in PROCE-

DURE 17 of this manual.

2. Remove the counterweight. Refer to REMOVING/

INSTALLING COUNTERWEIGHT in PROCEDURE

17 of this manual.

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

MOVING GROUP 24 BATTERY BOXES in PROCE-

DURE 9 of this manual.

REMOVING/INSTALLING CASTERS

(FIGURE 3)

WARNING

DO NOT use your power wheelchair unless it has

the proper tire pressure (p.s.i.). DO NOT over-inflate

the tires. Failure to follow these suggestions may

cause the tire to explode and cause bodily harm.

The recommended tire pressure is listed on the side

wall of the tire.

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

puncture.

Removing Casters

1. Remove the mounting screw, spacers and locknut that

secure the existing caster to the fork.

2. Remove the existing caster from the fork.

Installing Casters

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

2. Reinstall the mounting screw, spacers and locknut that

secure the caster to the fork.

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

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

5. Move the caster side to side.

NOTE: If the caster moves side to side, tighten the locknut

slightly. Repeat STEP 4 until there is no side to side move-

ment of the caster.

Mounting

Screw

Locknut

Mounting

Screw

Locknut

6-INCH 8-INCH

Spacers

FIGURE 3 - REMOVING/INSTALLING CASTERS

Spacers

REPLACING FORKS (FIGURE 4)

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

REMOVING/INSTALLING CASTERS in this proce-

dure of the manual.

2. Remove the head tube cap.

3. Remove the locknut and nylon washer.

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

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

NOTE: Check bearing assemblies. Replace if necessary.

6. Ensure new fork slides completely into caster headtube.

7. Install nylon washer and secure with locknut.

WARNING

Improper positioning of the washer will prohibit the

free movement of the forks.

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

ING/INSTALLING CASTERS in this procedure of the

manual.

9. Adjust the forks. Refer to ADJUSTING FORKS in

PROCEDURE 9 of the owners manual, 1081227

FIGURE 4 - REPLACING FORKS

Dust Cover

Locknut

Nylon Washer

Caster Headtube

Fork

WHEELS/MOTORS PROCEDURE 12

PROCEDURE 12 WHEELS/MOTORS

4. Remove the two (2) mounting screws, spacers, and

washers that secure the MKIV controller to the base

frame. Set MKIV controller onto ground/floor.

NOTE: STEPS 5, 6, and 7 are necessary to obtain

easier access to the motor/controller connection.

5. Remove the mounting screw and spacer that secure

the top of the shock to the base frame.

6. Loosen, DO NOT remove, the mounting screw that se-

cures the bottom of the shock to the suspension arm.

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

]

8. Disconnect the motor connector from controller.

9. Remove the two (2) allen screws and washers that

secure the motor to the gearbox.

CAUTION

DO NOT damage the motor/gearbox coupling.

10. Carefully pull the motor away from the gearbox.

Installing

1. Perform one (1) of the following:

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

B. For FWD ONLY perform STEPS 2-10.

2. Perform the following:

A. Inspect the coupling for wear and damage. If dam-

age is evident, replace coupling.

B. Install coupling onto gearbox input shaft inserting cou-

pling drive plate onto slot on shaft.

C. Carefully align motor and coupling and place motor

against gearbox.

D. With motor against gearbox, turn gearbox drive shaft

until the coupler seats into gearbox.

NOTE: When properly aligned, motor will be seated into

gearbox.

E. Install two (2) allen screws. Use Loctite 242, tighten

allen screws evenly and then torque to 75-inch lbs.

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

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

of the wheelchair.

5. Install the mounting screw and spacer that secure the top

of the shock to the base frame. Torque to 156 - inch

pounds.

6. Tighten the mounting screw that secures the bottom of

the shock to the suspension arm. Torque to 156 - inch

pounds.

7. Install the two mounting screws that secure the MKIV

controller to the base frame. Torque to 156 - inch pounds.

FIGURE 5 - REMOVING/INSTALLING THE MOTOR -

CONVENTIONAL MOTOR/GEARBOX FOR RWD,

MWD AND FWD MODELS

Slots*

*NOTE: The following slot locations must line up for proper

installation: Slots on coupling of motor, the slots on the

coupling and the slots on the gearbox.

Gearbox

Motor

Allen

Screw

Washer

Coupling

Motor Connector

Motor

Connector

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

MOVING GROUP 24 BATTERY BOXES in PROCE-

DURE 9 of this manual.

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

STALLING THE COUNTERWEIGHT in PROCE-

DURE 17 of this manual.

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

ING FRONT SHROUD in PROCEDURE 17 of this

manual. ARROW FWD MODEL ONLY

RWD, MWD, AND ARROW FWD MODELS

Base

Frame

MKIV

Controller

Mounting

Screws

Washer

Shock

Suspension

Arm

Mounting Screw

(REMOVE)

Mounting Screw

(Loosen, DO NOT

REMOVE)

Locknut Spacer

3. Secure motor to the suspension arm with existing

four (4) mounting screws. Torque to 13 foot/pounds.

4. Slide the motor lock lever along brake release shaft

until the end is flush with the bushing guide.

5. Slide alignment pin, located inside of bushing guide,

into the end of the motor lock lever and secure in

place with existing mounting screw and washer. Se-

curely tighten.

6. Secure motor lock lever in place on the brake re-

lease shaft with existing mounting screw.

7. Install the drive wheel from the wheelchair. Refer to

REMOVING/INSTALLING DRIVE WHEELS in this

procedure of the manual.

8. If necessary, install the group 22 battery box tray. Re-

fer to REMOVING/INSTALLING GROUP 22 BAT-

TERY BOX TRAY in PROCEDURE 16 of this

manual.

9. Plug the wiring harness connector into the motor.

10. Secure the wiring harness connector to the motor

with the existing two (2) mounting screws.

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

REMOVING GROUP 24 BATTERY BOXES or IN-

STALLING/REMOVING GROUP 22 BATTERY

BOXES in PROCEDURE 9 of this manual.

REMOVING/INSTALLING THE

MOTOR (GEARLESS/BRUSHLESS

MOTOR) (FIGURE 6)

Removing

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

REMOVING GROUP 24 BATTERY BOXES or IN-

STALLING/REMOVING GROUP 22 BATTERY

BOXES in PROCEDURE 9 of this manual.

2. Unthread the mounting screws that secure the wiring

harness connector to the motor (DETAIL A).

3. Unplug the wiring harness connector from the motor.

4. If necessary, remove the group 22 battery box tray.

Refer to REMOVING/INSTALLING GROUP 22 BAT-

TERY BOX TRAY in PROCEDURE 16 of this

manual.

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

REMOVING/INSTALLING DRIVE WHEELS in this

procedure of the manual.

6. Note the mounting position of the motor on the sus-

pension arm before removing the motor.

7. Loosen adjustment screw that secures the motor lock

lever in place on the brake release shaft.

NOTE: Alignment pin is located inside of bushing guide

on the suspension arm.

8. Remove the mounting screw and washer that se-

cure the alignment pin in place.

9. Slide the alignment pin back out of the end of the

motor lock lever.

10. Remove the four (4) mounting screws and washers

that secure the motor to the suspension arm.

11. Remove motor with motor lock lever from suspen-

sion arm.

12. If replacing motor, remove the motor lock lever from

the brake release shaft of the existing motor.

Installing

NOTE: Do not tighten adjustment screw of motor lock le-

ver until motor is secured in place on the suspension arm.

1. If necessary, install motor lock lever onto new brake

release shaft of motor.

2. Position the new/existing motor with motor lock lever

onto the suspension arm in the mounting position

noted from STEP 4 of REMOVING THE GEARLESS/

BRUSHLESS MOTOR in this procedure of the

manual.

PROCEDURE 12WHEELS/MOTORS

Mounting Screw

Washer

Mounting

Screws

Mounting Screws

Washer

Motor

Suspension

Arm

Motor Lock

Lever

Adjustment

Screw

Mounting

Screw

Washer

*Alignment Pin

*NOTE: Alignment pin exploded away suspension arm for clarification purposes only.

Brake Release Shaft

Guide

Bushing

PROCEDURE 12 WHEELS/MOTORS

Mounting

Screws

DETAIL “A”

Wiring Harness

Connector

Motor

FIGURE 2 - REMOVING/INSTALLING MOTOR - GEARLESS/BRUSHLESS

FIGURE 2 - REMOVING/INSTALLING MKIV

CONTROLLER

Mounting

Plate

Mounting Screws

Hex

Bolts

MKIV Controller

Base Frame

NOTE: Controller for gearless/brushless motor re-

moves in the same manner.

FIGURE 1 - REPOSITIONING MKIV JOYSTICK -

VAN SEAT MODELS

Locknuts

(STEPS 3,16)

Phillips

Screws

(STEPS 4,

14)

Lug Bolt (STEPS 7, 9)

Joystick Mounting

Bracket (STEPS 3, 16)

Hex Bolts

(STEPS 3, 16)

Spacers

(STEPS 3, 16)

Armrest Insert

Phillips Screw

(STEPS 5, 13)

Armrest

Pad

Armrest Plate

Washer

(STEPS 7, 9)

Locknut

(STEPS 7, 9)

Washers

(STEPS 7, 9)

11. Position the armrest pad on the armrest plate.

12. Line up the mounting holes in the armrest insert, arm-

rest plate and armrest pad.

13. Reinstall rear phillips screw through the armrest insert,

armrest plate and armrest pad and tighten securely.

14. Reinstall the front phillips screw into the armrest plate

and new armrest pad and tighten securely.

15. Repeat STEPS 11-14 for opposite side of wheelchair.

16. Install the three (3) hex bolts, spacers and locknuts

that secure the joystick mounting bracket to the arm-

rest plate.

17. Slide the joystick mounting tube through the joystick

mounting bracket to the desired position.

18. Secure the adjustment lock to the joystick mounting

tube by turning the lever on the adjustment lock.

REMOVING/INSTALLING MKIV

CONTROLLER (FIGURE 2)

RWD and MWD Models

REMOVING.

1. Remove the shroud that covers the MKIV controller.

2. Disconnect the left/right motor leads and battery leads.

3. Remove the two (2) hex bolts that secure the existing

MKIV controller to the wheelchair.

4. Remove existing MKIV controller from the wheelchair.

5. Remove the three (3) mounting screws that secure

the mounting plate to the MKIV controller.

INSTALLING.

1. Install the three (3) mounting screws into the mounting

plate and secure to the MKIV controller.

2. Secure the new/existing MKIV controller to the wheel-

chair with two (2) hex bolts.

3. Connect the left/right motor leads and battery leads

4. Install shroud over the MKIV controller.

Armrest

Weldment

PROCEDURE 13ELECTRONICS

This Procedure Includes the Following:

Repositioning MKIV Joystick - Van Seat Models

Removing/Installing MKIV Controller

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.

REPOSITIONING MKIV JOYSTICK -

VAN SEAT MODELS (FIGURE 1)

1. Turn the lever on the adjustment lock to release the

adjustment lock from joystick mounting tube.

2. Remove the joystick mounting tube from wheelchair.

3. Remove the three (3) hex bolts, spacers and locknuts

that secure joystick mounting bracket to armrest plate.

4. Remove the phillips screws that secures the front of the

armrest pad to the armrest plate.

5. Remove the phillips screw that secures the rear of the

armrest pad and armrest insert to the armrest plate.

6. Remove the armrest pad from the armrest plate.

7. Remove the lug bolt, washers and locknut that secure

the existing armrest plate to the armrest weldment.

8. Repeat STEPS 4-7 for opposite side of the wheelchair.

9. Position armrest plate with joystick mounting holes on

desired side of armrest weldment and secure with lug

bolt, washers and locknut. Refer to FIGURE 1 for cor-

rect hardware orientation.

10. Position armrest plate without joystick mounting holes

on opposite side of the armrest weldment and secure

with lug bolt, washers and locknut. Refer to FIGURE

1 for correct hardware orientation.

Arrow Fwd Model

REMOVING.

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

STALLING FRONT SHROUD in PROCEDURE 17 of

this manual.

2. Remove the counterweight. Refer to REMOVING/IN-

STALLING COUNTERWEIGHT in PROCEDURE 17

of this manual.

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

MOVING GROUP 24 BATTERY BOXES in PROCE-

DURE 9 of this manual.

4. Disconnect the joystick cable from the top of the control-

ler.

5. Disconnect the battery wiring harness and controller con-

nection.

6. Remove the two (2) mounting screws, spacers, wash-

ers, and locknuts that secure the MKIV controller to the

base frame. Set MKIV controller onto ground/floor.

7. Remove the mounting screw and spacer that secure the

top of right shock to the base frame.

8. Loosen, DO NOT remove, the mounting screw that se-

cure the bottom of the right shock to the suspension arm.

9. Rotate top of right shock toward inside of the wheelchair.

10. Disconnect right hand motor/controller connection.

11. Rotate top of right shock back into position.

12. Loosely install mounting screw through top of shock and

into base frame. DO NOT tighten at this point.

13. To disconnect left hand motor/controller connection, per-

form STEPS 5-8 for opposite side of controller.

INSTALLING.

1. Connect left hand motor/controller connection of NEW

controller.

2. Rotate top of left shock into position.

3. Secure top of left shock to base frame with washer and

mounting screw. Torque to 360 - inch pounds.

4. Remove mounting screw and washer that secure the top

of the right shock to the base frame.

5. Rotate shock toward inside of wheelchair.

6. Connect right hand motor/controller connection.

7. Rotate shock back into position.

8. Secure top of right shock to base frame with washer and

mounting screw. Torque to 156 - inch pounds.

9. Torque the bottom mounting screw of each shock to 160

- inch pounds.

10. Secure the MKIV controller to the base frame with the

two (2) existing mounting screws, spacers, washers, and

locknuts.

11. Connect the joystick cable to the top of the controller.

12. Connect the battery wiring harness and controller con-

nection.

13. Install the battery box(es). Refer to INSTALLING/REMOV-

ING GROUP 24 BATTERY BOXES in PROCEDURE

9 of this manual.

14. Install the counterweight. Refer to REMOVING/INSTALL-

ING COUNTERWEIGHT in PROCEDURE 17 of this

manual.

15. Install the front shroud. Refer to REMOVING/IN-

STALLING FRONT SHROUD in PROCEDURE 17

of this manual.

FIGURE 2 - REMOVING/INSTALLING MKIV CONTROLLER - ARROW FWD MODEL

Mounting

Screw

Washer

Controller

Spacer

Locknut

Base Frame

Shock

Top Mounting

Screw and

Washer

Bottom Mounting

Screw

PROCEDURE 13 ELECTRONICS

Mounting

Screws

Mounting Screws

(DO NOT

Overtighten)

Actuator

Tie

Wraps

Wire

Retainer

Limit

Switch

Sensor

Seat

Frame

Mounting Screws (DO

NOT Over Tighten)

Washers

Limit Switch Sensor

FIGURE 1 - POSITIONING LIMIT SWITCH

Gas Cylinder

Pivot Block

Actuator

Washers

POSITIONING LIMIT SWITCH

(FIGURE 1)

NOTE: The battery charger connector, as well as, the limit

switch are factory set on the RIGHT side of the wheelchair.

However, they can be positioned on either side for user

convenience. The limit switch MUST BE positioned on the

same side as the battery charger connector.

1. Cut the two (2) tie wraps that secure the limit switch

wire to the seat frame.

2. Remove the two (2) mounting screws and washers

that secure the actuator to the gas cylinder pivot block.

3. Position actuator on opposite gas cylinder pivot block.

CAUTION

DO NOT over tighten the mounting screws that se-

cure the actuator to the pivot block. Damage to

actuator will occur.

4. Secure the actuator to the pivot block with the two (2)

mounting screws and washers. DO NOT overtighten.

5. Remove the mounting screw that secures the wire

retainer to the inside of the seat frame.

6. Remove the two (2) mounting screws and washers

that secure the limit switch sensor to the seat frame.

7. Turn limit switch sensor over so opposite side is facing

up and the wire is on the INSIDE of the seat frame.

8. Position the limit switch sensor onto the opposite side

of the seat frame.

CAUTION

DO NOT over tighten the mounting screws that

secure the limit switch sensor to the seat frame.

Damage to the limit switch sensor will occur.

This Procedure Includes the Following:

Positioning Limit Switch

Adjusting Limit Switch

Replacing Recliner Cable Assemblies

Replacing/Adjusting Gas Cylinders

Changing Back Height

Changing Seat Depth

Changing Seat Width

Installing/Replacing Adjustable 16 to 19-inch Deep

Recliner Seat Frame onto Arrow or X Base

WARNING

After ANY adjustments, repair or service and BEFORE

use, make sure that all attaching hardware is tight-

ened securely - otherwise injury or damage may

result.

PROCEDURE 14RECLINER

9. Secure limit switch sensor to the seat frame with the

two (2) mounting screws and washers.

10. Secure the wire retainer onto the INSIDE of the seat

frame with the mounting screw.

11. Tie wrap the limit switch wire to the seat frame.

12. Adjust the limit switch. Refer to ADJUSTING LIMIT

SWITCH in this procedure of the manual.

ADJUSTING LIMIT SWITCH

(FIGURE 2)

WARNING

NEVER operate the wheelchair while in any re-

cline position over 105o RELATIVE TO THE SEAT

FRAME. If the limit switch does not stop the wheel-

chair from operating in a recline position greater

than 105o RELATIVE TO THE SEAT FRAME, do not

operate the wheelchair. Adjust the limit switch

BEFORE using the wheelchair, otherwise injury

or damage can occur.

1. Recline the back of the wheelchair until the gas cylin-

der rod measures 3-21/32 of an inch.

2. Turn the power of the joystick to the ON position.

NOTE: ALL segments of the bar graph on the joystick should

start to flash on and off and the wheelchair should not op-

erate.

3. IF the wheelchair operates, proceed to the following

steps to adjust the actuator on the gas cylinder pivot

block:

A. Loosen, but do not remove, the two (2) mounting

screws and washers that secure the actuator to

the gas cylinder pivot block.

PROCEDURE 14 RECLINER

FIGURE 2 - ADJUSTING LIMIT SWITCH

Mounting Screws and Washers

(DO NOT Over-Tighten)

Actuator

Gas Cylinder

Rod Measures

3-21/32-inches

POSITION OVER

105O RELATIVE TO

THE SEAT FRAME

Gas Cylinder

Pivot Block

6. Remove the operator of the existing recliner cable

assembly from the pivot block.

7. Make sure the threads of the gas cylinder rod are

flush with the inside of the pivot block.

8. With the operator of the NEW recliner cable assem-

bly on the inside of the recliner seat frame, line up the

mounting hole in the operator of the new recliner cable

assembly with the gas cylinder rod.

CAUTION

DO NOT force the gas cylinder rod into the op-

erator of the recliner cable assembly.

DO NOT cross thread the operator of the recliner

cable assembly with the gas cylinder.

If slack in the recliner cable or movement in the

operator of the cable assembly can not be elimi-

nated, DO NOT use the recliner cable assembly.

9. Screw the NEW gas cylinder into the operator of the

cable assembly until the jam nut sits on the pivot block,

there is no slack in the recliner cable and there is no

movement in the operator of the recliner cable as-

sembly.

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

CAUTION

DO NOT over tighten the mounting screws that

secure the actuator to the pivot block. Damage

to the actuator will occur.

C. Only tighten the two (2) mounting screws and

washers that secure the actuator to the gas cylin-

der pivot block until the actuator does not move.

D. Repeat STEPS 1 and 2 until the wheelchair does

not operate when the gas cylinder rod is 3-21/32-

inch long.

REPLACING RECLINER CABLE

ASSEMBLIES (FIGURE 3)

NOTE: There are three (3) different cable lengths de-

pending on back height:

CABLE LENGTH BACK HEIGHT

Short 18-1/2 and 20-inches

Medium 22 and 24-inches

Long 26-inches

WARNING

Replace ONE (1) recliner cable assembly at a

time to avoid injury.

1. Cut the tie wraps that secure the existing recliner cable

assembly to the back cane.

2. Remove the pan screw that secures the handle of

the existing recliner cable assembly to the back cane.

3. Loosen the jam nut on the gas cylinder rod.

4. Remove the mounting screw, washer, nylon wash-

ers and locknut that secure the TOP of the gas cylin-

der to the mounting bracket on the back cane.

5. Unscrew the gas cylinder from the operator of the

existing recliner cable assembly but do not remove

the gas cylinder from the pivot block. FIGURE 3 - REPLACING RECLINER CABLE ASSEMBLIES

Jam

Nut

Washer

Handle

Nylon

Washers

Pivot

Block

Locknut

Back Cane

Gas Cylinder

Rod

Mounting Screw

Pan Screw

No Slack

in Cable

NO Movement in Operator

of the Recliner Cable

Assembly

Cable Fitting

Seated Properly

Handle

Cable

Snapped

into Slot

Cable

Operator

Tie

Wraps

Mounting Bracket

Gas Cylinder

Rod

Jam Nut

Gas

Cylinder

NO Movement in Operator

of the Recliner Cable

Assembly

Gas Cylinder

Rod Threads

Handle

No Slack

in Cable

FIGURE 4 - REPLACING/ADJUSTING GAS CYLINDERS

Handle

Cable Fitting

Seated Properly

Pivot Block

Cable

Snapped

into Slot

Nylon Washer

Locknut

Washer

Mounting

Screw

Mounting Bracket

If slack in the recliner cable or movement in the operator of

the cable assembly can not be eliminated, DO NOT use

the recliner cable assembly.

6. Screw the NEW gas cylinder into the operator of the

cable assembly until the jam nut sits on the pivot block,

there is no slack in recliner cable and there is no move-

ment in the operator of the recliner cable assembly.

7. Visually inspect the handle to make sure that the cable

is snapped completely into slot in handle and cable

fitting is seat properly in the handle.

8. Press the operator of the recliner cable assembly to

extend the NEW gas cylinder.

9. Line up the mounting holes of the NEW gas cylinder

and the bracket of the back cane.

10. Reinstall the mounting screw through the mounting

bracket of the back cane, nylon washer, NEW gas

cylinder, nylon washer, mounting bracket and washer

and securely tighten with the existing locknut. Torque

to 75-inch pounds.

11. Adjust the NEW gas cylinders. Refer to ADJUSTING

GAS CYLINDERS in this procedure of the manual.

10. Visually inspect the handle to make sure that the cable

is snapped completely into slot in handle and cable fit-

ting is seat properly in the handle.

11. Reinstall the mounting screw through the mounting

bracket of the back cane, nylon washer, gas cylinder,

nylon washer, mounting bracket and washer and se-

curely tighten with the existing locknut. Torque to 75-

inch pounds.

12. Line up the mounting hole in the handle of the recliner

cable assembly with the mounting hole in the back cane.

13. Insert the pan screw through the handle of the recliner

cable assembly and the back cane and torque to 9-inch

pounds.

14. Tie wrap the recliner cable assembly to the recliner back

cane.

15. Adjust the gas cylinder. Refer to ADJUSTING GAS

CYLINDERS in this procedure of the manual.

REPLACING/ADJUSTING GAS

CYLINDERS (FIGURE 4)

WARNING

Replace ONE (1) gas cylinder at a time to avoid

injury.

Both gas cylinders MUST be operational and ad-

justed properly BEFORE using the recliner. DO NOT

operate the recliner if only one (1) of the gas cylin-

ders is operational or adjusted properly.

Replacing Gas Cylinder

1. Remove the mounting screw, washer, nylon washers

and locknut that secure the TOP of the gas cylinder to

mounting bracket on back cane.

2. Loosen the jam nut on existing gas cylinder rod.

3. Unscrew the existing gas cylinder from the operator of

the recliner cable assembly and the pivot block and

remove the existing gas cylinder from the wheelchair.

4. Screw cylinder rod of the NEW gas cylinder into the

pivot block until the threads of the cylinder rod are flush

with inside of pivot block (FIGURE 4).

5. With the operator of the recliner cable assembly on

the inside of the recliner seat frame, line up the mount-

ing hole in the operator of the recliner cable assembly

with the new gas cylinder rod.

CAUTION

DO NOT force the gas cylinder rod into the opera-

tor of the recliner cable assembly.

DO NOT cross thread the operator of the recliner

cable assembly with the gas cylinder.

PROCEDURE 14RECLINER

Adjusting Gas Cylinder

1. To adjust the LEFT gas cylinder: Squeeze the handle

of the RIGHT recliner cable assembly and try to re-

cline the back. The back should not recline.

2. If the LEFT side of the back releases without

squeezing the handle of the LEFT recliner cable

assembly, perform the following steps:

A. Finger tighten the jam nut on the rod of the gas

cylinder until it bottoms out on the rod of the

cylinder (FIGURE 4).

B. Turn the jam nut on the LEFT gas cylinder

COUNTERCLOCKWISE approximately one-

half (1/2) revolution.

NOTE: The gas cylinder rod will turn.

C. Repeat STEP 1.

D. Repeat STEP B until the LEFT side of the back

DOES NOT recline.

3. To adjust the RIGHT gas cylinder: Repeat STEPS

1 and 2 for the LEFT handle of the cable assembly.

CAUTION

Damage to the gas cylinder rod WILL oc-

cur if the following steps are NOT followed

when the jam nut is torqued against the

pivot block.

4. Using NO LARGER than 1/4-inch wide, fine toothed

pliers, wrap masking tape around the teeth of the

pliers two (2) or (3) revolutions.

5. Using NO excessive force, hold the gas cylinder

rod just above the jam nut.

6. While holding the gas cylinder rod and using a 17mm

wrench, turn the jam nut CLOCKWISE and torque

the RIGHT and LEFT jam nuts against the RIGHT

and LEFT pivot blocks to 156-inch pounds.

CHANGING BACK HEIGHT

(FIGURE 5)

1. Press the push pins on the headrest extension tubes

in and remove headrest extension from back canes.

2. Remove the recliner cables from the back canes.

Refer to REPLACING RECLINER CABLE ASSEM-

BLIES in this procedure of the manual.

3. Remove the mounting screws, washers and lock-

nuts that secure the TOP of the gas cylinders to the

mounting bracket on the back canes.

4. Remove the mounting screws, washers and lock-

nuts that secure the back canes to the seat frame.

5. Remove the existing recliner back assembly from

the wheelchair. FIGURE 5 - CHANGING BACK HEIGHT

Mounting

Screw

Washers

Locknut

Mounting

Screw

Back Cane

Spreader

Bar

NOTE: Upholstery not shown for clarity.

Headrest

Extension

Tube

Push

Seat Frame

Mounting

Bracket

PROCEDURE 14 RECLINER

6. Turn the spreader bar on the existing back canes

CLOCKWISE (toward back upholstery) and remove

the spreader bar from the existing back canes.

7. Loosely install the spreader bar onto the NEW back

cane handles by rotating the spreader bar COUN-

TERCLOCKWISE (away from the back canes).

NOTE: If the spreader bar does not thread onto the back

canes, do not force. Turn the spreader bar around and

repeat STEP 7.

8. Line up two (2) bottom mounting holes of back canes

with the two (2) mounting holes in the seat frame.

WARNING

The back canes MUST be fastened se-

curely to the seat frame BEFORE using the

wheelchair. Torque mounting screws to

156-inch pounds.

9. Reinstall the mounting screw, washer and locknut

through the back cane and seat frame mounting holes

and torque to 156-inch pounds.

10. Reinstall the mounting screw through the mounting

bracket of the back cane, nylon washer, mounting

hole in the TOP of the gas cylinder, nylon washer,

mounting bracket and washer and securely tighten

with the existing locknut. Torque to 75-inch pounds.

11. Reinstall the recliner cable assemblies onto the back

canes. Refer to REPLACING RECLINER CABLES

in this procedure of the manual.

PROCEDURE 14RECLINER

Hex Screws

Seat Pan

Seat

Frame

FIGURE 6 - CHANGING SEAT DEPTH

Locknuts

Seat

Positioning

Strap

CHANGING SEAT WIDTH

To change seat width, the seat frame must be changed to

the desired width. Refer to INSTALLING/REPLACING AD-

JUSTABLE 16 TO 19-INCH DEEP RECLINER SEAT

FRAME ONTO ARROW OR X BASE FRAME in this

procedure of the manual.

NOTE: If changing the seat width of the wheelchair, the

back and headrest upholstery, seat pan and cushion also

need to be changed.

NOTE: If changing the seat width of the wheelchair, the back

canes, spreader bar and headrest pillow may also need to

be changed. Refer to the following charts:

BACK CANES AND SPREADER BAR SEAT WIDTH

RANGES

14-17-INCHES OR 18-24-INCHES

HEADREST PILLOWS SEAT WIDTH RANGES (IN

INCHES)

14-15, 16-18, 19-20 OR 21-24

NOTE: There are three (3) different cable lengths depending

on back height:

BACK HEIGHT (in inches) 18-1/2, 20 22, 24 26

CABLE LENGTH Short Medium Long

NOTE: New recliner cables will be needed if back height is

changed to a height not within the length of the original cable.

12. Install the NEW back upholstery onto the back canes.

13. Install the ten (10) or twelve (12) mounting screws

(depending on back height) that secure the back up-

holstery to the recliner back canes.

14. Reinstall headrest extension onto recliner back canes.

15. Adjust the tautness of the back and headrest uphol-

stery. Refer to ADJUSTING BACK OR HEADREST

UPHOLSTERY in this procedure of the manual.

CHANGING SEAT DEPTH (FIGURE 6)

NOTE: 16-inch, 17-inch, 18-inch or 19-inch seat depths CAN

NOT be increased to 20-inches or deeper. If needing to in-

crease to a seat depth of 20-inches or deeper, the base frame

MUST be converted from a STANDARD base frame to a

LONG base frame as well.

NOTE: 20-inch, 21-inch or 22-inch seat depths CAN NOT

be decreased to 19-inches or less. If needing to decrease to

a seat depth of 19-inches or less, the base frame MUST be

converted from a LONG base frame to a STANDARD base

frame.

To adjust seat depth of wheelchair, use following guidelines:

If the current seat depth is an ODD number, i.e., 17-inches,

19-inches or 21-inches, the seat depth CANNOT be IN-

CREASED without changing the seat frame. Refer to IN-

STALLING/REPLACING ADJUSTABLE 16 TO 19-INCH

DEEP RECLINER SEAT FRAME ONTO ARROW OR X

BASE FRAMES in this procedure of the manual.

If the current seat depth is an ODD number, i.e., 17-inches,

19-inches or 21-inches, the seat depth can be DECREASED

by 1-inch by installing a 1-inch shorter seat pan. Refer to the

following procedures:

If the current seat depth is an EVEN number, i.e., *16-inches,

18-inches, 20-inches or 22-inches, the seat depth CANNOT

be DECREASED without changing the seat frame. Refer to

INSTALLING/REPLACING ADJUSTABLE 16 TO 19-INCH

DEEP RECLINER SEAT FRAME ONTO ARROW OR X

BASE FRAME in this procedure of the manual.

*NOTE: 16-inch seat depth is the smallest seat depth avail-

able on recliner seat frames.

If the current seat depth is an EVEN number, i.e., 16-inches,

18-inches, 20-inches or *22-inches, the seat depth can be

INCREASED by 1-inch by installing a 1-inch deeper seat

pan. Refer to the following procedures:

*NOTE: 22-inch seat depth is the deepest seat depth avail-

able on recliner seat frames.

Seat Pan Removal/Replacement Procedures:

1. Remove the seat cushion from the wheelchair.

2. Remove the six (6) mounting screws and locknuts

that secure seat pan, seat positioning strap to the

seat frame.

3. Install new 1-inch deeper/shorter seat pan onto seat

frame.

4. Reinstall the mounting screws, spacers and lock-

nuts and torque to 75-inch pounds.

5. Remove the protective strips on the seat pan and

reinstall the seat cushion onto the seat pan.

NOTE: Clean upholstery with a warm damp cloth and mild

detergent to remove superficial soil.

WARNING

Laundering or moisture will reduce the flame

retardation of the upholstery.

PROCEDURE 14 RECLINER

FIGURE 7 - INSTALLING/REPLACING ADJUSTABLE 16

TO 19-INCH DEEP RECLINER SEAT FRAME ONTO

ARROW OR X BASE

Mounting

Screws

Base

Frame

Spacer

Recliner

Seat Assembly

Seat Mount

Plate

Locknuts

If the seat width required is within the range of the original

back canes, spreader bar and headrest pillow, the original

components can still be used.

If the seat width required is NOT within the range of the origi-

nal back canes, spreader bar and headrest pillow, the origi-

nal components can not be used.

EQUIPMENT OPTION

INSTALLING/REPLACING

ADJUSTABLE 16 TO 19-INCH DEEP

RECLINER SEAT FRAME ONTO

ARROW OR X BASE FRAME

(FIGURE 7)

1. Perform instructions outlined in PREPARATIONS FOR

REMOVING/INSTALLING SEAT FRAME (STANDARD

FRAME, ADJUSTABLE FRAME, AND CAPTAINS VAN

SEAT) in PROCEDURE 6 of this manual:

2. Perform one (1) of the following in PROCEDURE 7 of

this manual:

A. Remove standard seat frame subassembly. Refer

to REMOVING/INSTALLING STANDARD SEAT

FRAME SUBASSEMBLY.

B. Remove adjustable seat frame subassembly. Re-

fer to INSTALLING/REMOVING ADJUSTABLE

SEAT FRAME ASSEMBLY AND OR COMPO-

NENT REPLACEMENT.

C. Remove captains van seat. Refer to INSTALLING/

REMOVING CAPTAINS VAN SEAT ASSEMBLY.

3. Remove seat pan on recliner.

4. Install new recliner seat assembly onto seat mount plates.

5. Secure recliner seat assembly to seat mount plates with

the mounting screws, spacers and locknuts. Torque the

mounting screws to 156-inch pounds.

NOTE: There are three (3) types of seat mount plates; low,

medium, and high heights. The seat mount plate shown in

this illustration represents the medium height. Refer to

MOUNTING PLATE - SEAT ANGLE ADJUSTMENT AND

INSTALLATION ORIENTATION in PROCEDURE 6 of this

manual for illustrations of the low and high heights.

6. Position limit switch onto wheelchair. Refer to POSITION-

ING LIMIT SWITCH in this procedure of the manual.

7. Reinstall recliner seat pan with existing six (6) mount-

ing screws.

8. Install the two (2) warnings labels onto the two (2)

suspension arm assemblies. Refer to FIGURE 7 for

correct label placement.

9. Install battery box(es). Refer to INSTALLING/REMOV-

ING BATTERY BOXES- GROUP 24 BATTERY

BASE FRAMES or INSTALLING/REMOVING BAT-

TERY BOX - GROUP 22 BATTERY BASE FRAMES

in PROCEDURE 9 of this manual.

10. Perform instructions outlined in PREPARATIONS

FOR REMOVING/INSTALLING SEAT FRAME

(STANDARD FRAME, ADJUSTABLE FRAME, AND

CAPTAINS VAN SEAT) in PROCEDURE 6 of this

manual:

Warning Label

Inside of

Suspension Arm

Assembly

PROCEDURE 15MWD WHEELCHAIRS

This Procedure includes the following:

Removing/Installing Group 24 Battery Box Sub-Frame

Removing/Installing Group 22 Battery Box Tray

Converting Group 22 Batteries To Group 24 Batteries

Shock Replacement

Shock Spring Replacement

Replacing Stabilizer Fork Assembly

Replacing Stabilizer Wheels

Replacing Stabilizer Cylinder Springs

Adjusting Weight Distribution

Adjusting Stabilizers

Installing/Removing Gearbox

Replacing Suspension Arm

Spacer

Battery Box

Retainer

Bar

Retainer Clip

FIGURE 1 - REMOVING/INSTALLING GROUP 24 BATTERY

BOX SUB-FRAME

Battery Box Sub-frame

REMOVING/INSTALLING GROUP 24

BATTERY BOX SUB-FRAME (FIGURE 1)

Removing

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

MOVING GROUP 24 BATTERY BOXES in PROCE-

DURE 9 of this manual.

2. Remove the two (2) mounting screws and locknuts

that secure the wiring harness w/bracket and the rear

of the existing sub-frame to the base frame. Refer to

REMOVING/INSTALLING WIRING HARNESS in

PROCEDURE 10 of this manual.

3. Remove the four (4) mounting screws that secure the

shocks, retainer bar, spacers and retainer clips to the

base frame. Refer to REPLACING BATTERY BOX

RETAINER/RETAINER CLIP - GROUP 24 BATTERY

BASE FRAMES in PROCEDURE 11 of this manual.

4. Remove the existing sub-frame assembly.

Installing

1. Install the two (2) mounting screws and locknuts that

secure the wiring harness w/bracket and the back of

the NEW sub-frame to the base frame. Refer to RE-

MOVING/INSTALLING THE WIRING HARNESS in

PROCEDURE 10 of this manual. Use Loctite 242 and

torque mounting screws to 160-inch pounds.

Mounting

Screws

Wiring Harness

w/Bracket

Sub-Frame

Locknuts

REAR OF CHAIR

REAR OF

CHAIR

FRONT OF CHAIR

Mounting

Screws

FRONT OF

CHAIR

2. Reinstall the four (4) mounting screws that secure the

shocks, retainer bar, spacers and retainer clips to the

base frame. Refer to REPLACING BATTERY BOX

RETAINER/RETAINER CLIP - GROUP 24 BATTERY

BASE FRAMES in PROCEDURE 11 of this manual.

Use Loctite 242 and torque mounting screws to 160-

inch pounds.

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

MOVING GROUP 24 BATTERY BOXES in PRO-

CEDURE 9 of this manual. Use Loctite 242 and torque

mounting screws to 160-inch pounds.

WARNING

After ANY adjustments, repair or service and BE-

FORE use, make sure that all attaching hardware

is tightened securely - otherwise injury or dam-

age may result.

REMOVING/INSTALLING GROUP

22 BATTERY BOX TRAY (FIGURE 2)

Removing

1. Remove battery box. Refer to INSTALLING/REMOV-

ING GROUP 22 BATTERY BOX in PROCEDURE 9

of this manual.

2. Remove the two (2) mounting screws and locknuts

that secure rear of battery box tray to the base frame.

3. Remove the two (2) front locknuts that secure the bat-

tery box tray to battery mount brackets.

4. Remove the battery box tray.

PROCEDURE 15 MWD WHEELCHAIRS

Battery

Box Tray

Base

Frame

Front Locknuts

Mounting

Screws

FIGURE 2 - REMOVING/INSTALLING GROUP 22

BATTERY BOX TRAY

REAR OF

CHAIR

FRONT OF

CHAIR

Rear Locknuts

Battery Mount

Bracket

EQUIPMENT OPTION

CONVERTING GROUP 22 BATTERY

BOX TRAY TO GROUP 24 BATTERY

BOX SUB FRAME

NOTE: The battery box tray and battery mount brackets will

not be used with this option. Keep for future use.

Removing Group 22 Components (FIGURE 3)

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

MOVING GROUP 22 BATTERY BOX in PROCE-

DURE 9 of this manual.

2. Remove the existing battery box tray. Refer to REMOV-

ING/INSTALLING THE GROUP 22 BATTERY BOX

TRAY in this procedure of the manual.

FIGURE 3 - REMOVING GROUP 22 COMPONENTS

Battery Mount Bracket

Mounting

Screws

Spacer

Base Frame

Locknut

Shock

Tie Wrap

Motor Connector

Charger Cable/

Bracket

Motor

Connector

3. Disconnect the right and left motor connectors from

the controller connectors.

4. Remove the two (2) mounting screws that secure

the charger cable to the mount bracket.

5. Remove the charger cable from the mount bracket.

5. Cut the tie-wrap that secures the wiring harness to

the seat frame.

6. Remove the wiring harness.

7. Remove the four (4) mounting screws that secure

the battery mount brackets to the base frame and

remove the battery mount brackets.

Installing Group 24 Components (FIGURE 4)

1. Align the mounting holes of the NEW wiring harness

w/bracket, the NEW battery box sub-frame and the

mounting holes in the base frame.

2. Install the two (2) mounting screws through all three (3)

parts and secure with locknuts. Torque to 160-inch

pounds.

Installing

1. Install battery box tray onto base frame.

2. Secure the front of the battery box tray to battery

mount brackets with existing locknuts. Torque to

160-inch pounds.

3. Secure the rear of the battery box tray to the base

frame with existing mounting screws and locknuts.

Torque to 160-inch pounds.

4. Reinstall the battery box. Refer to INSTALLING/REMOV-

ING GROUP 22 BATTERY BOX in PROCEDURE 9

of this manual.

FIGURE 4 - INSTALLING GROUP 24 COMPONENTS

Mounting

Screws

Wiring Harness

w/Bracket

Battery Box

Sub-Frame

Locknuts

REAR OF CHAIR

FRONT OF

CHAIR

Spacer

Battery Box

Retainer

Bar

Battery Box

Sub-frame

REAR OF

CHAIR

Mounting Screws

Base Frame

Shock

Closed End

Retainer

Clip

STEPS 1-2

STEPS 3-6

FRONT OF

CHAIR

WARNING

The Battery Box Retainer/Retainer Clip

MUST be fastened securely in place be-

fore using the wheelchair. Use Loctite 242

and torque to 160-inch pounds.

3. Position the NEW retainer clip between the NEW bat-

tery box sub-frame and shock making sure the retainer

clip mounting hole is towards the bottom and the closed

end of the clip is against the battery box retainer bar.

4. Install the mounting screw that secures the retainer

clip to the battery box sub-frame. Use Loctite 242 and

torque to 160-inch pounds.

5. Align the NEW battery box retainer and spacers with

the mounting holes in the base frame making sure the

closed end of the battery box retainer is pointing up.

6. Reinstall the mounting screws that secure the battery

box retainer to the base frame. Use Loctite 242 and

torque to 160-inch pounds.

7. Install charger cable to existing mounting bracket se-

cure with existing two (2) mounting screws.

8. Tie-wrap NEW wiring harness to the seat frame.

9. Connect the following cables:

a. The right and left motor connectors to the control-

ler connectors.

b. The battery harness/charger cable (BLUE) to the

controller connector (BLUE).

10. Install the NEW battery boxes. Refer to INSTALLING/

REMOVING GROUP 22 BATTERY BOX in PROCE-

DURE 9 of this manual.

SHOCK REPLACEMENT

Group 24 Battery Base Frames (FIGURE 5)

1. Remove the front battery box. Refer to INSTALLING/

REMOVING GROUP 24 BATTERY BOXES in PRO-

CEDURE 9 of this manual.

2. Remove the drive wheel assembly. Refer to REMOV-

ING/INSTALLING THE DRIVE WHEEL in PROCE-

DURE 12 of this manual.

3. Loosen the mounting screw that secures the battery

box retainer between the battery box sub frame as-

sembly and the base frame.

4. Remove the mounting screw that secures the top of

the shock and retainer clip between the battery box

sub frame assembly and the base frame.

NOTE: Remove and hold onto the retainer clip for instal-

lation of the NEW shock.

5. Remove the mounting screw, two (2) flat washers,

two (2) spring washers, two (2) inner link spacers,

and locknut that secures the bottom of the shock,

suspension arm, and stabilizer bracket together.

6. Remove the existing shock.

7. Install the NEW shock.

MWD WHEELCHAIRS PROCEDURE 15

PROCEDURE 15 MWD WHEELCHAIRS

8. Secure the bottom of the NEW shock, suspension arm,

and stabilizer bracket together with the mounting screw,

two (2) flat washers, two (2) spring washers, two (2) inner

link spacers, and locknut. Torque to 160-inch pounds.

WARNING

The Battery Box Retainer/Retainer Clip

MUST be fastened securely in place be-

fore using the wheelchair. Use Loctite 242

and torque to 160-inch pounds.

9. Position retainer clip between shock and battery box

sub-frame making sure the retainer clip mounting hole

is towards the bottom and the closed end of clip is

against battery box retainer.

10. Secure top of shock and retainer clip between battery

box sub frame and base frame. Apply Loctite 242 and

torque to 160-inch pounds.

11. Apply Loctite 242 and torque the mounting screw that

secures the battery box retainer between the battery box

sub frame and base frame. Torque to 160-inch pounds.

12. Reassemble large wheel to hub assembly and Torque

to 160-inch pounds.

13. Repeat this procedure for the opposite shock.

14. Reinstall the front battery box. Refer to INSTALLING/

REMOVING GROUP 24 BATTERY BOXES in PRO-

CEDURE 9 of this manual.

Group 22 Battery Base Frames (FIGURE 6)

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

MOVING GROUP 22 BATTERY BOX in PROCE-

DURE 9 of this manual.

2. Remove the four (4) nuts that secure the large wheel

assembly to the to the hub assembly and remove the

large wheel assembly.

3. Loosen the mounting screw that secures the spacer

between battery mount bracket and the base frame.

4. Remove mounting screw that secures top of the shock

between battery mount bracket and base frame.

5. Remove the mounting screw, two (2) flat washers,

two (2) spring washers, two (2) inner link spacers,

and locknut that secures the bottom of the shock,

suspension arm, and stabilizer bracket together.

6. Remove the existing shock.

7. Install the NEW shock.

8. Secure the bottom of the NEW shock, suspension arm,

and stabilizer bracket together with the mounting screw,

two (2) flat washers, two (2) spring washers, two (2) inner

link spacers, and locknut. Torque to 160-inch pounds.

9. Secure the top of shock between battery mount

bracket and base frame. Apply Loctite 242 and torque

to 160-inch pounds.

Mounting Screw

Loosen, DO NOT

REMOVE (STEPS

3,11)

Battery Box

Retainer Bar

Battery Box

Sub- Frame

Base Frame

FIGURE 5 - SHOCK REPLACEMENT - GROUP 24

BATTERY BASE FRAMES

Stabilizer

Assembly*

Shock

Battery Box Sub-Frame

Inner Link

Spacer

Spring

Washer

Mounting

Screw

Retainer Clip

Top of Shock

Mounting

Screw

Base

Frame

Flat Washer

Locknut

NOTE: Top of stabilizer*

exploded away for clarity only.

Suspension

Arm Stabilizer

Bracket

Shock

NOTE: The spacer and retainer are not shown for clarity.

*NOTE: The spring shown on the stabilizer is for wheel-

chair models built before 7/1/1999

10. Apply Loctite 242 and torque the mounting screw that

secures the spacer between the battery mount bracket

and base frame. Torque to 160-inch pounds.

11. Reassemble large wheel to hub assembly and Torque

to 160-inch pounds.

12. Repeat this procedure for the opposite shock.

13. Reinstall the battery box. Refer to INSTALLING/RE-

MOVING GROUP 22 BATTERY BOX in PROCE-

DURE 9 of this manual.

FIGURE 6 - SHOCK REPLACEMENT - GROUP 22

BATTERY BASE FRAMES

Shock

Base Frame

Flat Washer

Locknut

Spring

Washer

NOTE: Top of stabilizer exploded away for clarity only.

*NOTE: The spring shown on the stabilizer is for wheel-

chair models built before 7/1/1999

Inner Link Spacer

Mounting

Screw

Stabilizer*

Mounting

Screw

Stabilizer Bracket

Suspension

Arm

Battery Mount Bracket

B. (Group 22 Battery Base Frames) Loosen the

mounting screw that secures the battery box

spacer between the battery box tray mount bracket

and the base frame.

3. Remove the mounting screw that secures the top of

the stabilizer cylinder to the base frame.

4. Perform one (1) of the following:

A. (Group 24 Battery Base Frames) Remove the

mounting screw that secures the top of the shock

between the battery box sub-frame and the base

frame.

B. (Group 22 Battery Base Frames) Remove the

mounting screw that secures the top of the shock

between retainer clip and the battery box tray

mount bracket and the base frame.

NOTE: (Group 24 Battery Base Frames Only) Remove

and hold onto the retainer clip for reinstallation of shock.

5. Swing the top of both the stabilizer cylinder and the

shock forward.

6. Hold the spring retainer and turn the shock eyelet as-

sembly COUNTERCLOCKWISE to unthread it from

the shock.

7. Remove the spring retainer and spring.

8. Place the NEW spring onto the shock.

9. Reinstall the shock eyelet assembly and the spring

retainer onto the NEW spring.

10. While holding the spring retainer, torque the shock

eyelet assembly to 245-inch pounds.

11. (Group 24 Battery Base Frames) Position the re-

tainer clip between the shock and the battery box sub-

frame making sure the retainer clip mounting hole is

towards the bottom and the closed end of the clip is

against the battery box retainer.

12. Perform one (1) of the following:

A. (Group 24 Battery Base Frames) Apply Loctite

242 and torque the mounting screw that secures

the battery box retainer to the base frame to 160-

inch pounds.

B. (Group 22 Battery Base Frames) Apply Loctite

242 and torque the mounting screw that secures

the battery mount bracket to the base frame to

160-inch pounds.

13. Secure the top of the shock and retainer clip (Group

24) to base frame. Apply Loctite 242 and torque to

160-inch pounds.

SHOCK SPRING REPLACEMENT

(FIGURE 7)

NOTE: Heavy Duty Models Only. Shock springs on stan-

dard models cannot be individually replaced. A new shock

assembly must be installed. Refer to SHOCK REPLACE-

MENT in this procedure of the manual.

1. Remove the front battery box. Refer to INSTALLING/

REMOVING GROUP 24 BATTERY BOXES or IN-

STALLING/REMOVING GROUP 22 BATTERY BOX

in PROCEDURE 9 of this manual.

2. Perform one (1) of the following:

A. (Group 24 Battery Base Frames) Loosen the

mounting screw that secures the battery box re-

tainer between the battery box sub frame assem-

bly and the base frame.

MWD WHEELCHAIRS PROCEDURE 15

PROCEDURE 15 MWD WHEELCHAIRS

FIGURE 8 - REPLACING STABILIZER FORK ASSEMBLY/REPLACING STABILIZER WHEELS

Base Frame

Stabilizer

Fork

Assembly*

Mounting Screw

Flat

Washer

Spring Washer Outer Link Spacers

Locknut

NOTE: Remove this mounting screw and

locknut only when replacing the stabilizer

fork assembly.

Stabilizer

Bracket

Locknut Mounting Screw

Stabilizer Wheel

Washer

FIGURE 7 - SHOCK SPRING REPLACEMENT

Shock Eyelet

Assembly Spring

Retainer

Shock

Spring

Base

Shock

14. Reinstall the front battery box. Refer to INSTALLING/

REMOVING GROUP 24 BATTERY BOXES or IN-

STALLING/REMOVING GROUP 22 BATTERY BOX

in PROCEDURE 9 of this manual.

2. Remove the mounting screw, two (2) washers, two

(2) spring washers, two (2) outer link spacers, two

(2) flat washers, and locknut that secure the stabi-

lizer fork assembly, stabilizer bracket, and stabi-

lizer wheel together.

3. Secure NEW stabilizer fork assembly to stabilizer

bracket and stabilizer wheel with existing mount-

ing screw, two (2) washers, two (2) spring wash-

ers, two (2) outer link spacers, two (2) flat wash-

ers, and locknut. Securely tighten.

4. Secure top of stabilizer fork assembly to base frame

with existing mounting screw and locknut. Torque to

40 in/lbs.

REPLACING STABILIZER WHEELS

(FIGURE 8)

1. Remove the mounting screw, two (2) washers, two

(2) spring washers, two (2) outer link spacers, two

(2) flat washers, and locknut that secure the stabi-

lizer wheel, stabilizer bracket, and stabilizer fork

assembly together.

2. Secure NEW stabilizer wheel to stabilizer bracket

and stabilizer fork assembly with existing mount-

ing screw, two (2) washers, two (2) spring wash-

ers, two (2) outer link spacers, two (2) flat wash-

ers, and locknut. Securely tighten.

REPLACING STABILIZER FORK

ASSEMBLY (FIGURE 8)

1. Remove the mounting screw and locknut that secures

the top of the stabilizer fork assembly to the base frame.

*NOTE: The spring shown on the stabilizer fork assembly is for wheelchair models built before 7/1/1999

FIGURE 9 - REPLACING STABILIZER CYLINDER SPRING

Base Frame

Adjustment

Barrel

Stabilizer

Rod

Jam Nut

Adjustment

Nut

Spring

Retainer

Stabilizer

Spring

REPLACING STABILIZER

CYLINDER SPRING (FIGURE 9)

NOTE: Stabilizer springs are only on wheelchair mod-

els built before 7/1/1999.

1. Remove mounting screw and locknut that secures

top of the stabilizer fork assembly to the base frame.

2. Unthread adjustment barrel and remove from stabi-

lizer rod.

3. Unthread jam nut and remove from stabilizer rod.

4. Unthread adjustment nut and remove from stabilizer

rod.

5. Remove spring retainer from stabilizer rod.

6. Remove existing stabilizer spring.

7. Install NEW stabilizer spring.

8. Reinstall spring retainer.

9. Reinstall adjustment nut.

10. Reinstall jam nut.

11. Reinstall adjustment barrel.

12. Adjust stabilizer. Refer to ADJUSTING STABILIZERS

in this procedure of the manual.

Locknut

Mounting

Screw

ADJUSTING WEIGHT DISTRIBUTION

(FIGURE 10)

NOTE: The seat mount plates and seat support brackets

allow seat frame to be repositioned along the base frame.

NOTE: The position of the seat support brackets is factory

set at 5-1/2-inches from the front end of the base frame.

Use the following chart as a starting point.

Weight of Distance of Seat

User Support Bracket*

under 200-lbs 5-7-inches

over 200-lbs 6-8-inches

* Distance measured from the front of the base frame to

the front of the seat support bracket.

NOTE: Following the above chart will put 85-90% of the

total weight of the chair and user over the large wheels.

However, these settings may not be the most desirable in

terms of maneuverability and comfort for the user.

Adjustment for Optimum Performance

1. Loosen the four (4) mounting screws that secure the

seat support brackets to the base frame.

2. Adjust seat back until one (1) of the following occurs:

A. The clearance of the front riggings and the stabi-

lizers is at a minimum or

B. The rear stop is contacted.

WARNING

DO NOT adjust seat beyond limit stops.

3. Retighten mounting screws securing the seat support

brackets to the base frame.

4. Test wheelchair for handling.

5. If handling of the power wheelchair is drifting, repeat

this procedure moving seat up in small increments until

the chair handles properly.

6. Once the seat is adjusted to the point of proper han-

dling, comfort adjustments can be made

7. Check distance the stabilizer wheels are off the floor.

A. If distance is between 3/8 and 1/2-inches off of the

floor the user will experience a normal amount of

rocking when stopping or negotiating steeper in-

clines, depending on the amount of braking.

B. If distance is greater than 1/2-inches off of floor

the amount of rocking the user experiences when

stopping or negotiating steeper inclines will in-

crease.

MWD WHEELCHAIRS PROCEDURE 15

WARNING

The threaded rod must be engaged in the

adjustment barrel at least eight (8) full threads.

Otherwise, injury or damage may occur.

5. Realign the top of stabilizer fork assembly with the

mounting hole in the base frame noted earlier.

NOTE: Further height adjustment can be accomplished

by using the alternate mounting hole in the base frame.

See DETAIL A.

6. Secure stabilizer to base frame with existing mount-

ing screw and locknut.

7. To increase spring compression, refer to ADJUST-

ING SPRING COMPRESSION in this procedure of

the manual.

NOTE: Adjust both stabilizers equally to maintain proper

handling.

8. Repeat for opposite stabilizer.

9. Test wheelchair for handling/maneuverability.

10. Repeat STEPS 1-7 until desired comfort and ma-

neuverability is achieved

Adjusting Spring Compression

1. Perform one (1) of the following

A. To increase spring compression, turn adjustment

nut CLOCKWISE two (2) to four (4) revolutions.

B. To decrease spring compression, turn adjustment

nut COUNTERCLOCKWISE two (2) to four (4)

revolutions.

FIGURE 11 - ADJUSTING STABILIZERS

Adjustment

Barrel

Spring

Mounting Screw

Top of

Stabilizer Fork

Assembly

Base

Frame

Locknut

Jam Nut

Alternate Mounting Hole

DETAIL A

Adjustment Nut Threaded

Rod

Top of Stabilizer

Fork Assembly

NOTE: This setting would allow the wheelchair to

roll better on thicker carpeting and minimize scuff-

ing.

C. If distance is between 0 and 3/8-inch, along with

an increase in spring compression, the amount

of rocking the user experiences will decrease. Al-

though, this setting would minimize rocking, ob-

stacles protruding from the ground as well as ne-

gotiating steeper inclines will be more difficult.

8. Adjust the stabilizers to the desired setting determined

in STEP 7. Refer to ADJUSTING STABILIZERS in

this procedure of the manual.

Mounting Screws

(Two (2) on each

bracket)

Seat Support Bracket

Front of

Base Frame

Front of Seat

Support Bracket

FIGURE 10 -ADJUSTING WEIGHT DISTRIBUTION

ADJUSTING STABILIZERS

(FIGURE 11)

NOTE: Adjust the stabilizers to the desired handling/ma-

neuverability determined in ADJUSTING WEIGHT DIS-

TRIBUTION in this procedure of the manual.

NOTE: Note the mounting position of the stabilizer to the

base frame for proper reinstallation.

Height Adjustment

1. Remove the mounting screw and locknut that secures

the top of the stabilizer fork assembly to the base

frame.

2. Swing top end of stabilizer fork assembly forward.

3. Loosen jam nut, located below adjustment barrel.

4. Perform one (1) of the following:

Turn the adjustment barrel CLOCKWISE to raise the

stabilizer wheel.

Turn the adjustment barrel COUNTERCLOCKWISE

to lower the stabilizer wheel.

MWD WHEELCHAIRSPROCEDURE 15

2. Count the number of exposed threads and repeat this

procedure for the opposite shock.

3. Proceed to STEP 9 in HEIGHT ADJUSTMENT OF

STABILIZERS in this procedure of the manual.

REMOVING/INSTALLING GEARBOX

(FIGURE 12)

CAUTION

Perform the following procedure in a des-

ignated work area to prevent damage to

flooring (carpeting, tile, etc.).

Removing

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

REMOVING/INSTALLING DRIVE WHEELS in PRO-

CEDURE 12 of this manual.

2. Remove the drive wheel hub from the existing gearbox

drive shaft. Refer to REMOVING/INSTALLING DRIVE

WHEEL HUBS in PROCEDURE 12 of this manual.

NOTE: Note the mounting position of gearbox to the sus-

pension arm before gearbox disassembly.

3. Remove the four (4) mounting screws that secure the

motor/gearbox to the suspension arm.

4. If necessary, remove existing motor from gearbox. Re-

fer to REMOVING/INSTALLING THE MOTOR in PRO-

CEDURE 12 of this manual.

5. If necessary, install existing motor onto NEW gearbox.

Refer to REMOVING/INSTALLING THE MOTOR in

PROCEDURE 12 of this manual.

Installing

WARNING

When reinstalling the gearbox ALWAYS use

the mounting holes furthest back on the sus-

pension arm. DO NOT reposition the motors.

CAUTION

The FRONT mounting screws that secure the

gearbox to the suspension arm MUST be 5/

16-18 x 2-1/2-inches long and the REAR hex

screws that secure the gearbox to the sus-

pension arm MUST be 5/16-18 x 1-1/4-inches

long. Otherwise damage to the gearbox

casting can result.

1. Position the NEW gearbox with the mounting holes fur-

thest back on the suspension arm.

2. When reassembling the gearbox to the suspension arm,

use Loctite 242 and torque mounting screws to 160-

inch pounds.

NOTE: Replace any parts that show signs of wear or dam-

age.

3. Reinstall the drive wheel hub to the new gearbox drive

shaft. Refer to REMOVING/INSTALLING DRIVE

WHEEL HUBS in PROCEDURE 12 of this manual.

4. Reinstall the drive wheels onto the wheelchair. Refer to

REMOVING/INSTALLING DRIVE WHEELS in PRO-

CEDURE 12 of this manual.

FIGURE 12 - REMOVING/INSTALLING GEARBOX

5/16-18 x 2-1/2-inch

Mounting Screws

5/16-18 x 1-1/4-inch

Mounting Screws

Gearbox

Suspension Arm

Motor

WARNING

When reinstalling the

gearbox ALWAYS

use the mounting

holes furthest back

on the suspension

arm. DO NOT reposi-

tion the motors.

REPLACING SUSPENSION ARM

(FIGURE 13)

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

REMOVING/INSTALLING DRIVE WHEELS in PRO-

CEDURE 12 of this manual.

2. Perform one (1) of the following:

A. (GROUP 24) - Loosen the mounting screws that

secures the wiring harness and the battery sub-

frame to the base frame assembly.

B. (GROUP 22) - Loosen the two (2) mounting

screws that secures the rear of the battery tray to

the sub-frame assembly.

PROCEDURE 15MWD WHEELCHAIRS

NOTE: When installing the tubular end of the NEW sus-

pension arm, the beveled washer MUST be placed on

the inside and outside of the base frame, with the bevels

facing each other.

10. Secure tubular end of the NEW suspension arm as-

sembly to base frame with existing mounting screw.

11. Torque suspension arm mounting screw (1/2 x 7-

inches) to 85 FOOT pounds (approximately 1,020-

inch pounds) and replace plug buttons.

12. Reinstall the gearbox onto the existing suspension arm.

Refer to REMOVING/INSTALLING GEARBOX in this

procedure of the manual.

13. Perform one (1) of the following:

A. (GROUP 24) - Tighten the mounting screws that

secures the wiring harness and the battery sub-

frame to the base frame assembly.

B. (GROUP 22) - tighten the two (2) mounting

screws that secures the rear of the battery tray to

the sub-frame assembly.

14. Reinstall the drive wheel onto the wheelchair. Refer

to REMOVING/INSTALLING DRIVE WHEELS in

PROCEDURE 12 of this manual.

15. Repeat STEPS 1-14 for the opposite side of the

wheelchair, if necessary.

FIGURE 13 - REPLACING SUSPENSION ARM

STEPS 4,8, AND 9

Plug Button (STEP 5)

Mounting Screw (STEPS 6,10)

Beveled

Washer

(STEPS

6,10)

Hex Nut

(STEPS 6,11)

Mounting

Screw

Base Frame

NOTE: Top of shock and stabi-

lizer exploded away for clarifica-

tion purposes only. Removal from

base frame is not required.

Flat

Washer

Locknut

Inner Link

Spacer

Spring Washer

Tubular End of

Suspension Arm

Bracket End of

Suspension Arm

Bracket End of Suspension Arm

Stabilizer Bracket

Bottom of Shock

Tubular End of

Suspension Arm

(STEPS 6,10)

3. Remove gearbox from the existing suspension arm. Re-

fer to REMOVING/INSTALLING GEARBOX in this proce-

dure of the manual.

4. Remove the mounting screw, two (2) flat washers,

two (2) spring washers, two (2) inner link spacers,

and locknut that secures the bracket end of the sus-

pension arm, the bottom of the shock, and stabilizer

bracket together.

5. Remove plug button from the middle of base frame.

6. Remove the mounting screw and the beveled wash-

ers that secures the tubular end of the suspension

arm assembly to the base frame.

7. Remove the suspension arm from the wheelchair.

8. Position bracket end of NEW suspension arm around

shock.

9. Thread existing mounting screw through stabilizer

bracket, bracket end of suspension arm, and bottom

of shock with mounting screw, two (2) flat washers,

two (2) spring washers, two (2) inner link spacers,

and locknut. See DETAIL A for proper hardware ori-

entation.

MWD WHEELCHAIRSPROCEDURE 15

RWD WHEELCHAIRS PROCEDURE 16

This Procedure includes the following:

Removing/Installing Group 24 Battery Box Sub-Frame

Removing/Installing Group 22 Battery Box Tray

Converting Group 22 Batteries to Group 24 Batteries

Shock Replacement

Shock Spring Replacement

Rubber Element Replacement

Converting Torque and X Rubber Elements to Shocks

Anti-Tipper Wheel Replacement

Removing/Installing Gearbox

Adjusting Weight Distribution

Repositioning Motor/Gearbox Assembly

Repositioning Gearless/Brushless Motor

Replacing Suspension Arm for Wheelchairs with

Motor/Gearbox assembly

Replacing Suspension Arm for Wheelchairs with

Gearless/Brushless Motor

Removing/Installing the Anti-tip Assembly

FIGURE 1 - REMOVING/INSTALLING GROUP 24 BATTERY

BOX SUB-FRAME

Spacer

Battery Box

Retainer

Bar Retainer Clip

Battery Box

Sub-frame

Mounting

Screws

Wiring Harness

w/Bracket

Sub-Frame

Locknuts

REAR OF

CHAIR

REAR OF CHAIR

FRONT OF

CHAIR

Mounting

Screws

FRONT OF CHAIR

REMOVING/INSTALLING GROUP

22 BATTERY BOX TRAY (FIGURE 2)

Removing

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

ING GROUP 24 BATTERY BOX in PROCEDURE 9

of this manual.

2. Remove the two (2) rear locknuts that secure the battery

box tray to battery mount brackets.

3. Remove the two (2) front bolts and locknuts that secure

the battery box tray to the base frame.

4. Remove the battery tray from the base frame.

REMOVING/INSTALLING GROUP 24

BATTERY BOX SUB-FRAME (FIGURE 1)

Removing

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

MOVING GROUP 24 BATTERY BOXES in PROCE-

DURE 9 of this manual.

2. Remove the two (2) mounting screws and locknuts

that secure the wiring harness w/bracket and the rear

of the existing sub-frame to the base frame. Refer to

REMOVING/INSTALLING THE WIRING HARNESS

in PROCEDURE 10 of this manual.

3. Remove the four (4) mounting screws that secure the

shocks, retainer bar, spacers and retainer clips to the

base frame. Refer to REPLACING BATTERY BOX

RETAINER/RETAINER CLIP - GROUP 24 BATTERY

BASE FRAMES in PROCEDURE 11 of this manual.

4. Remove the existing sub-frame assembly.

Installing

1. Install the two (2) mounting screws and locknuts that

secure the wiring harness w/bracket and the back of

the NEW sub-frame to the base frame. Refer to RE-

MOVING/INSTALLING THE WIRING HARNESS in

PROCEDURE 10 of this manual. Use Loctite 242 and

torque mounting screws to 160-inch pounds.

2. Reinstall the four (4) mounting screws that secure the shocks,

retainer bar, spacers and retainer clips to the base frame.

Refer to REPLACING BATTERY BOX RETAINER/RE-

TAINER CLIP - GROUP 24 BATTERY BASE FRAMES in

PROCEDURE 11 of this manual. Use Loctite 242 and

torque mounting screws to 160-inch pounds.

3. Reinstall the battery boxes. Refer to INSTALLING/REMOV-

ING GROUP 24 BATTERY BOXES in PROCEDURE 9

of this manual. Use Loctite 242 and torque mounting screws

to 160-inch pounds.

WARNING

After ANY adjustments, repair or service and BE-

FORE use, make sure that all attaching hardware

is tightened securely - otherwise injury or dam-

age may result.

RWD WHEELCHAIRSPROCEDURE 16

Battery Tray

Locknuts Bolts

FIGURE 2 - REMOVING/INSTALLING GROUP 22

BATTERY BOX TRAY

*NOTE: Illustration depicts the rubber element. Battery Box

Tray removes in the same manner for shock assembly.

*Rubber

Element

4. Remove the four (4) mounting screws that secure

the battery mount brackets to the base frame.

5. Remove the battery mount brackets.

Spacer

Battery Mount

Bracket

*Rubber Element

(or Shock Assembly)

Mounting

Screws Base

Frame

FIGURE 3 - REMOVING GROUP 22 COMPONENTS

*NOTE: Illustration depicts rubber element. Battery

Mount Brackets remove in the same manner for the

shock assembly.

EQUIPMENT OPTION

CONVERTING GROUP 22 BATTERY

BOX TRAY TO GROUP 24 BATTERY

BOX SUB FRAMA ASSEMBLY

Removing Group 22 Components (FIGURE 3)

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

MOVING GROUP 22 BATTERY BOX/BATTERIES

in PROCEDURE 9 of this manual.

2. Remove the battery box tray. Refer to REMOVING/

INSTALLING THE GROUP 22 BATTERY BOX TRAY

in this procedure of the manual.

3. Remove the wiring harness. Refer to REMOVING/

INSTALLING THE WIRING HARNESS in PROCE-

DURE 10 of this manual.

NOTE: The battery box tray and the battery mount brackets will

not be reused. Mounting screws and spacers will be reused.

Installing Group 24 Components (FIGURE 4)

1. Line up the mounting holes in the front of the NEW

battery box sub-frame and the NEW wiring harness

w/bracket with the mounting holes in the base frame

(FIGURE 5).

2. Install the two (2) mounting screws through the wiring

harness w/bracket, battery box sub-frame, and base

frame (FIGURE 5).

3. Install the locknuts onto mounting screws. Torque to

160-inch pounds (FIGURE 5).

WARNING

The Battery Box Retainer/Retainer Clip

MUST be fastened securely in place be-

fore using the wheelchair. Use Loctite 242

and torque to 160-inch pounds.

4. Position the retainer clip between the NEW battery box

sub-frame and the top of the rubber element or shock

assembly making sure the retainer clip mounting hole is

towards the bottom and the closed end of the clip is

against the battery box retainer bar (FIGURE 5).

NOTE: Make sure the closed end of the battery box re-

tainer clip is pointing up.

5. Install the mounting screw that secures the retainer

clip to the battery box sub-frame. Use Loctite® 242

and torque to 160-inch pounds (FIGURE 5).

6. Line up the NEW battery box retainer bar and spacers

with mounting holes in the base frame (FIGURE 5).

Base

Frame

Installing

1. Install battery tray onto base frame.

2. Secure the rear of the battery tray to battery mount

brackets with existing locknuts. Torque to 160-inch

pounds.

3. Secure the front of the battery tray to the base frame

with existing mounting screws and locknuts. Torque

to 160-inch pounds.

4. Reinstall the battery box. Refer to INSTALLING/REMOV-

ING BATTERY BOX - GROUP 22 BATTERY BASE

FRAMES in PROCEDURE 9 of this manual.

SHOCK REPLACEMENT (FIGURE 5)

1. Remove the group 22 battery box or group 24 battery

boxes. Refer to INSTALLING/REMOVING GROUP

22 BATTERY BOX or INSTALLING/REMOVING

GROUP 24 BATTERY BOXES in PROCEDURE 9

of this manual.

2. Remove the drive wheel from the wheel hub. Refer to

REMOVING/INSTALLING THE DRIVE WHEELS in

PROCEDURE 12 of this manual.

3. GROUP 24 BATTERIES ONLY - Loosen the hex

screw that secures the battery box retainer bar to the

base frame.

4. Remove the mounting screw that secures the top of

the shock to the base frame.

5. Remove the mounting screw and locknut from the bot-

tom of the suspension arm.

6. Remove the shock from the base frame.

7. Install the NEW shock.

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

A. GROUP 24 BATTERIES -

●Position retainer clip between shock and bat-

tery box sub-frame making sure the retainer clip

mounting hole is towards the bottom and the

closed end of clip is against battery box retainer

bar.

●Secure the top of shock and retainer clip

to base frame. Apply Loctite 242 and torque

to 160-inch pounds.

●Apply Loctite 242 and torque the hex screw

that secures the battery box retainer bar to

the base frame to 160-inch pounds.

B. GROUP 22 BATTERIES - Secure the top of

shock to base frame. Apply Loctite 242 and

torque to 160-inch pounds.

9. Secure the bottom of the new shock to the sus-

pension arm with the existing mounting screw and

locknut. Apply Loctite 242 and torque to 160-inch

pounds.

10. Install the drive wheel from the wheel hub. Refer to

REMOVING/INSTALLING THE DRIVE WHEELS in

PROCEDURE 12 of this manual.

11. Remove the group 22 battery box or group 24 battery

boxes. Refer to INSTALLING/REMOVING GROUP

22 BATTERY BOX or INSTALLING/REMOVING

GROUP 24 BATTERY BOXES in PROCEDURE 9

of this manual.

STEPS 1 - 3

STEPS 4 - 7

Spacer

Battery Box

Retainer

Bar

Mounting Screws

Retainer

Clip

REAR OF

CHAIR

FRONT OF

CHAIR

Battery Box

FRONT OF

CHAIR

REAR OF

CHAIR

Wiring Harness

w/Bracket

Mounting

Screws

Battery Box

Sub-Frame

Base

Frame

Locknuts

7. Reinstall the mounting screws that secure the bat-

tery box retainer bar to the base frame. Use Loctite

242 and torque to 160-inch pounds (FIGURE 5).

8. Perform STEPS 2-7 of REMOVING/INSTALLING

THE WIRING HARNESS in PROCEDURE 10 of this

manual to complete the wiring harness installation.

9. Install the group 24 battery boxes. Refer to INSTALL-

ING/REMOVING GROUP 24 BATTERY BOXES in

PROCEDURE 9 of this manual.

Closed End

RWD WHEELCHAIRS PROCEDURE 16

Shock Assembly

(or Rubber Element)

FIGURE 4 -INSTALLING GROUP 24 COMPONENTS

Battery Box

Sub-frame

REAR OF

CHAIR

FRONT OF

CHAIR

Spacer

Mounting Screw

(LOOSEN)

Retainer Clip

(Closed End)

GROUP 24 BATTERIES GROUP 22 BATTERIES

Mounting

Screw

Shock

Mounting

Screw

Locknut

Suspension

Arm

FIGURE 5 - SHOCK REPLACEMENT

Top of

Shock

Battery Box

Retainer

Bar

TOP OF SHOCK

BOTTOM OF SHOCK

GROUP 22 AND GROUP 24 BATTERIES

NOTE: Suspension arm for conventional motor shown.

Shock removes in the same manner for gearless/

brushless motor.

NOTE: Suspension arm shown is for conventional motors. Shock removes in the same manner for gearless/

brushless motor.

Shock

Suspension

Arm

RWD WHEELCHAIRSPROCEDURE 16

SHOCK SPRING REPLACEMENT

(FIGURE 6)

1. Remove the group 22 battery box or group 24 battery

boxes. Refer to INSTALLING/REMOVING GROUP

22 BATTERY BOX or INSTALLING/REMOVING

GROUP 24 BATTERY BOXES in PROCEDURE 9

of this manual.

2. GROUP 24 BATTERIES ONLY - Loosen the mount-

ing screw that secures the battery box retainer bar to the

base frame.

3. Remove the mounting screw that secures the top of

the shock to the suspension arm.

4. Swing the top of the shock rearward.

5. Hold the spring retainer and turn the shock eyelet as-

sembly counterclockwise to unthread it from the shock.

6. Remove the spring retainer and spring.

7. Place the NEW spring onto the shock.

8. Reinstall the shock eyelet assembly and the spring re-

tainer onto the NEW spring.

9. While holding the spring retainer, torque the shock eyelet

assembly to 245-inch pounds.

10. Position the retainer clip between the shock and the bat-

tery box sub-frame making sure the retainer clip mount-

ing hole is towards the bottom and the closed end of the

clip is against the battery box retainer.

11. Secure top of shock and retainer clip to base frame.

Apply Loctite 242 and torque to 160-inch pounds.

12. GROUP 24 BATTERIES ONLY - Apply Loctite 242

and torque the hex screw that secures the battery box

retainer bar to the base frame to 160-inch pounds.

13. Reinstall the group 22 battery box or group 24 battery

boxes. Refer to INSTALLING/REMOVING GROUP

22 BATTERY BOX or INSTALLING/REMOVING

GROUP 24 BATTERY BOXES in PROCEDURE 9

of this manual.

Battery Box

Retainer

Bar

Hex

Screws

Spacer

FIGURE 6 - SHOCK SPRING REPLACEMENT

Shock Eyelet

Assembly

Retainer Clip

Shock Eyelet

Assembly

Spring

Retainer

Shock

Spring

Base

Shock

RWD WHEELCHAIRS PROCEDURE 16

GROUP 22 BATTERIES

NOTE: Shock exploded away for clarity. There is no

need to remove shock from suspension arm.

Suspension

Arm

Mounting

Screw

Shock

GROUP 24 BATTERIES

Spacer

Battery Mount

Bracket

Rubber Element

Mounting

Screw

Base

Frame

FIGURE 7 - RUBBER ELEMENT REPLACEMENT

Mounting Screw

(LOOSEN)

EQUIPMENT OPTION

CONVERTING TORQUE AND X

RUBBER ELEMENTS TO ARROW

SHOCKS (FIGURE 8)

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

ING GROUP 22 BATTERY BOX in PROCEDURE 9

of this manual.

2. Remove the existing Torque and X rubber element. Re-

fer to RUBBER ELEMENT REPLACEMENT -

TORQUE AND X BASE FRAMES in this procedure of

the manual.

3. Line up the bottom of the new Storm Arrow shock with

the BOTTOM hole in the rubber element mount plate.

4. Install the new hex screw and locknut through the bot-

tom hole of the mount bracket and shock. Torque to

160-inch pounds.

NOTE: The original hardware that secured the BOTTOM of

the Torque and X rubber element to the shock mount bracket

will not be used with this option. Keep for future use.

5. Reinstall the hex screw that secures the top of the shock

assembly and battery mount bracket to the base frame.

Use Loctite 242 and torque to 160-inch pounds.

6. Torque the hex screw that secures the battery mount

bracket to the base frame to 160-inch pounds.

7. Reinstall the battery box tray onto the battery mount

bracket and torque the locknut to 160-inch pounds.

8. Reinstall the battery box. Refer to INSTALLING/REMOV-

ING GROUP 22 BATTERY BOX in PROCEDURE 9

of this manual.

Battery Mount

Bracket

Shock Hex Screw

FIGURE 8 - CONVERTING TORQUE AND X RUBBER

ELEMENTS TO ARROW SHOCKS

RWD WHEELCHAIRSPROCEDURE 16

RUBBER ELEMENT REPLACEMENT

(FIGURE 7)

NOTE: Rubber elements are only found on Storm

Torque and Storm X wheelchairs.

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

ING GROUP 22 BATTERY BOX in PROCEDURE 9

of this manual.

2. Remove the battery box tray. Refer to REMOVING THE

BATTERY BOX TRAY in this procedure of the

manual.

3. Loosen the mounting screw that secures the battery

mount bracket to the base frame, but do not remove.

4. Remove the mounting screw that secures the top of

the rubber element and battery mount bracket to the

base frame.

6. Remove the three (3) mounting screws and locknuts

that secure the bottom of the rubber element to the rub-

ber element mount bracket.

7. Remove the existing rubber element and install the new

rubber element.

8. Resecure the bottom of the rubber element to the rub-

ber element mount bracket with the existing three (3)

mounting screws. Use Loctite 242 and torque to 160-

inch pounds.

9. Reinstall the hex screw that secures the top of the rub-

ber element and battery mount bracket to the base frame.

Use Loctite 242 and torque to 160-inch pounds.

10. Torque the hex screw that secures the battery mount

bracket to the base frame to 160-inch pounds.

11. Reinstall the battery box tray onto the hanger bracket

and torque the locknut to 160-inch pounds.

12. Reinstall the battery box. Refer to INSTALLING/REMOV-

ING GROUP 22 BATTERY BOX in PROCEDURE 9

of this manual.

REMOVING/INSTALLING

GEARBOX

(FIGURE 10)

CAUTION

Perform the following procedure in a des-

ignated work area to prevent damage to

flooring (carpeting, tile, etc.).

Removing

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

REMOVING/INSTALLING DRIVE WHEELS in PRO-

CEDURE 12 of this manual.

2. Remove the drive wheel hub from the existing gearbox

drive shaft. Refer to REMOVING/INSTALLING DRIVE

WHEEL HUBS in PROCEDURE 12 of this manual.

NOTE: Note mounting position of gearbox to suspension

arm before disassembly.

NOTE: To reposition the gearbox on the suspension arm,

refer to WEIGHT DISTRIBUTION in this procedure of the

manual.

3. Remove the four (4) hex screws that secure the existing

motor/gearbox to the suspension arm.

4. Remove existing motor from gearbox. Refer to MOTOR

REPLACEMENT in PROCEDURE 12 of this manual.

5. Install existing motor onto new gearbox. Refer to MOTOR

REPLACEMENT in PROCEDURE 12 of this manual.

Installing

CAUTION

The REAR hex screws that secure the gear-

box to the suspension arm MUST be 5/16-

18 x 2-1/2-inches long and the FRONT hex

screws that secure the gearbox to the sus-

pension arm MUST be 5/16-18 x 1-1/4-inches

long. Otherwise damage to the gearbox

casting can result.

1. Position NEW gearbox with noted mounting holes.

2. When reassembling gearbox to suspension arm, use

Loctite 242 and torque hex screws to 160-inch pounds.

NOTE: Replace any parts that show signs of wear or dam-

age.

3. Reinstall the drive wheel hub to the new gearbox

driveshaft. Refer to REMOVING/INSTALLING DRIVE

WHEEL HUBS in PROCEDURE 12 of this manual.

4. Reinstall the drive wheels onto the wheelchair. Refer to

REMOVING/INSTALLING DRIVE WHEELS in PRO-

CEDURE 12 of this manual.

5/16-18 x

1-1/4-inch

Hex

Screws

Gearbox

Suspension

Arm

FIGURE 10 - REMOVING/INSTALLING GEARBOX

Motor

5/16-18 x

2-1/2-inch

Hex

Screws

RWD WHEELCHAIRS PROCEDURE 16

ADJUSTING WEIGHT

DISTRIBUTION (FIGURE 11)

NOTE: Seat mount plates and seat support brackets al-

low the seat frame to be repositioned along the base frame.

The range is determined by position of the seat stop

screws. The front seat stop screw is positioned at 4-inches

and the rear seat stop screw is positioned at 10-inches.

Both seat stop screw positions are measured from the

front of the base frame.

NOTE: The position of the seat support brackets is factory

set at 7-inches, this measured from the front of the base

frame to the front of the seat support bracket. This will put

about 70% of the total weight of the chair and user over the

large wheels. However, this setting may not be the most de-

sirable in terms of maneuverability, front rigging clearance

and comfort for the user.

Adjustment Options

NOTE: This section will provide the user with some knowl-

edge of what to expect if the following adjustments are made.

1. Moving the seat forward.

Advantage: This adjustment allows more clear-

ance for front riggings and a more stable

feel for the user.

Disadvantage: More weight is put on front casters and

makes turning more difficult.

NOTE: This option can also be accomplished by moving

the motor backward on the suspension arm. Refer to RE-

POSITIONING GEARBOX in this procedure of the manual.

Washer

Base

Frame

FIGURE 11 - ADJUSTING WEIGHT DISTRIBUTION

Seat Support

Bracket

REPOSITIONING THE MOTOR/

GEARBOX (FIGURE 12)

NOTE: The motor/gearbox assembly can be repositioned to

lengthen or shorten the wheelbase by 2-inches in 1-inch in-

crements.

STANDARD POSITION - LENGTHENS the wheelbase and

gives you the most stability and standard maneuverability.

1 - INCH FORWARD - CENTERS the wheelbase and gives

you standard stability and maneuverability.

2 - INCH FORWARD - SHORTENS the wheelbase and in-

creases maneuverability and distributes additional weight on

rear wheels.

FIGURE 12 - REPOSITIONING MOTOR/GEARBOX

Standard -

Approximately 65% of

weight over rear

wheels

1 - Inch Forward -

Approximately 70% of

weight over rear

wheels

2 - Inch Forward -

Approximately 75% of

weight over rear

wheels

Mounting Screws

MOTOR/GEARBOX ASSEMBLY

2. Moving the seat rearward.

Advantage: Makes turning easier and provide bet-

ter traction for the large wheels.

Disadvantage: This adjustment, however, allows less

clearance for front riggings and the user

will experience more engagement of

the anti-tippers.

NOTE: This option can also be accomplished by moving

the motor forward on the suspension arm. Refer to REPO-

SITIONING GEARBOX in this procedure of the manual.

Adjusting Weight Distribution Procedure

1. Loosen the four (4) mounting screws that secure the

seat support brackets to the base frame.

WARNING

DO NOT adjust seat beyond limit stops.

2. Adjust seat forward or back to the position determined

from the previous section ADJUSTMENT OPTIONS.

3. Retighten the four (4) mounting screws securing the

seat support brackets to the base frame.

4. Test wheelchair maneuverability, comfort, and handling.

5. Repeat STEPS 1-4 for further adjustment, if necessary.

RWD WHEELCHAIRSPROCEDURE 16

WARNING

When using a recliner/high back van seat,

the motor/gearbox or motor MUST use most

REARWARD mounting holes on the suspen-

sion arm assembly.

1. Determine the desired position for the gearbox on the

wheelchair.

2. Remove the drive wheels from the wheelchair. Refer to

REMOVING/INSTALLING DRIVE WHEELS in PRO-

CEDURE 12 of this manual.

3. Remove gearbox from the suspension arm. Refer to

REMOVING/INSTALLING GEARBOX in this procedure

of the manual.

4. Move gearbox to the position determine in STEP 1.

NOTE: If the wheelchair is equipped with 9-inch casters on a

standard or heavy duty base, the 2-inch forward position CAN

NOT be utilized.

5. Reinstall the gearbox onto the existing suspension arm.

Refer to REMOVING/INSTALLING GEARBOX in this pro-

cedure of the manual.

6. Repeat STEPS 3-5 for opposite side of the wheelchair.

7. Reinstall the drive wheel onto the wheelchair. Refer to

REMOVING/INSTALLING DRIVE WHEELS in PRO-

CEDURE 12 of this manual.

RWD WHEELCHAIRS PROCEDURE 16

Standard -

Approximately 65%

of weight over

rear wheels

1 - Inch Forward -

Approximately 70%

of weight over

rear wheels

2 - Inch Forward -

Approximately 75%

of weight over

rear wheels

REPOSITIONING THE GEARLESS/BRUSHLESS MOTOR (FIGURE 13,14)

Acceptable mounting positions for the gearless/brushless motor.

NOTE: The motor/gearbox assembly or gearless/brushless motor can be repositioned to lengthen or shorten the wheel-

base by 2-inches in 1-inch increments.

ARROW AND STORM X

NOTE: These mounting positions apply to the Arrow

and Storm X with fixed back or recliner and torque

with manual recline option

STANDARD POSITION - LENGTHENS the wheel-

base and gives you the most stability and standard

maneuverability.

1-INCH FORWARD - CENTERS the wheelbase and

gives you standard stability and maneuverability.

2-INCH FORWARD - SHORTENS the wheelbase and

increases maneuverability and distributes additional

weight on rear wheels.

TORQUE

NOTE:These mounting positions apply to the Torque

with fixed back.

STANDARD POSITION - SHORTENS the wheelbase and

increases maneuverability and distributes additional weight

on rear wheels.

1-INCH REARWARD - CENTERS the wheelbase and

gives you standard stability and maneuverability.

2-INCH REARWARD - LENGTHENS the wheelbase

and gives you the most stability and standard maneu-

verability.

1 - Inch Rearward -

Approximately 70%

of weight over

rear wheels

2 - Inch Rearward -

Approximately 65%

of weight over

rear wheels

Standard -

Approximately 75%

of weight over

rear wheels

FIGURE 13 - REPOSITIONING THE GEARLESS/BRUSHLESS MOTOR

Suspension Arm Hex Screw

(1/2 x 7-inches)

FIGURE 15 - REPLACING SUSPENSION ARM FOR

WHEELCHAIRS WITH MOTOR/GEARBOX ASSEMBLY

Suspension Arm

Plug

Button

Beveled

Washers

REPLACING SUSPENSION ARM FOR

WHEELCHAIRS WITH MOTOR/

GEARBOX ASSEMBLY (FIGURE 15)

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

REMOVING/INSTALLING DRIVE WHEELS in PROCE-

DURE 12 of this manual.

2. Loosen the hex screws that secure wiring harness to

sub-frame assembly.

3. Remove gearbox from the existing suspension arm. Re-

fer to REMOVING/INSTALLING GEARBOX in this proce-

dure of the manual.

4. Remove plug buttons from the middle of the base frame.

5. Remove the hex screws and the beveled washers that

secure the suspension arm assembly to the base frame.

6. Remove existing suspension arm from the wheelchair.

NOTE: When installing the NEW suspension arm, the

beveled washers MUST be placed on the inside and out-

side of the base frame, with the bevels facing each other.

7. Install the NEW suspension arm assembly onto the

base frame.

1. Determine the desired mounting position of the gear-

less/brushless motor. Refer to ACCEPTABLE

MOUNTING POSITIONS FOR THE GEARLESS/

BRUSHLESS MOTOR in this procedure of the

manual.

2. Remove the group 22 battery box or group 24 battery

boxes. Refer to INSTALLING/REMOVING BATTERY

BOX - GROUP 22 BATTERY BASE FRAMES or IN-

STALLING/REMOVING BATTERY BOXES - GROUP

24 BATTERY BASE FRAMES in PROCEDURE 9 of

this manual.

3. If necessary, remove the battery box tray. Refer to RE-

MOVING THE BATTERY BOX TRAY in this proce-

dure of the manual.

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

REMOVING/INSTALLING DRIVE WHEELS in PROCE-

DURE 12 of this manual.

5. Loosen the adjustment screw that secures the motor

release handle to the brake release shaft.

6. Remove the four (4) mounting screws and washers

that secure the motor to the suspension arm.

7. Slide the motor forward or backward to the desired

mounting position.

8. Secure the motor to the mounting position determined

in STEP 1 and secure with the four (4) existing mount-

ing screws and washers. Torque to 13 foot/pounds.

9. Securely tighten adjustment screw.

FIGURE 14 - REPOSITIONING THE GEARLESS/

BRUSHLESS MOTOR

10. Reinstall the drive wheel to the wheelchair. Refer to RE-

MOVING/INSTALLING DRIVE WHEELS in PROCE-

DURE 12 of this manual.

11. Repeat STEPS 1-9 for opposite side of wheelchair.

12. If necessary, reinstall the battery box tray. Refer to RE-

MOVING THE BATTERY BOX TRAY in this proce-

dure of the manual.

13. Remove the group 22 battery box or group 24 battery

boxes. Refer to INSTALLING/REMOVING BATTERY

BOX - GROUP 22 BATTERY BASE FRAMES or IN-

STALLING/REMOVING BATTERY BOXES - GROUP

24 BATTERY BASE FRAMES in PROCEDURE 9 of

this manual.

Motor Release

Lever

Brake Release

Shaft

Adjustment

Screw

Mounting

Screws

Washer

Suspension Arm

Motor

RWD WHEELCHAIRSPROCEDURE 16

12. Install the shock onto the new suspension arm. Refer

to REMOVING/INSTALLING THE SHOCK ASSEM-

BLY in this procedure of the manual.

13. Install the motor onto the new suspension arm. Refer

to REMOVING/INSTALLING THE MOTOR in PRO-

CEDURE 12 of this manual.

14. Install anti-tip assembly onto the rear of the new sus-

pension arm. Refer to REMOVING/INSTALLING THE

ANTI-TIP ASSEMBLY in this procedure of the manual.

15. Perform one (1) of the following:

A. Remove the seating system. Refer to the seating

systems owners manual for removal/installation

instructions.

B. Remove the seat pan. Refer to REMOVING/IN-

STALLING THE SEAT PAN in PROCEDURE 6 of

this manual.

RWD WHEELCHAIRS PROCEDURE 16

8. Torque suspension arm hex screws (1/2 x 7-inches) to

85 FOOT pounds (approximately 1,020-inch pounds)

and replace plug buttons.

9. Reinstall the gearbox onto the existing suspension arm.

Refer to REMOVING/INSTALLING GEARBOX in this

procedure of the manual.

10. Tighten the hex screws that secure wiring harness to

sub-frame assembly securely.

11. Reinstall the drive wheel onto the wheelchair. Refer to

REMOVING/INSTALLING DRIVE WHEELS in PRO-

CEDURE 12 of this manual.

12. Repeat STEPS 1-12 for the opposite side of the wheel-

chair, if necessary.

REPLACING SUSPENSION ARM

FOR WHEELCHAIRS WITH

GEARLESS/BRUSHLESS MOTORS

(FIGURE 16)

1. Perform one (1) of the following:

A. Remove the seating system. Refer to the seating

systems owners manual for removal/installation

instructions.

B. Remove the seat pan. Refer to REMOVING/IN-

STALLING THE SEAT PAN in PROCEDURE 6 of

this manual.

2. Remove the motor. Refer to REMOVING/INSTALLING

THE MOTOR in PROCEDURE 12 of this manual.

3. Cut the tie-wrap(s) that secure the wiring harness/

charger cable to the suspension arm.

4. Remove the anti-tip assembly from the rear of the sus-

pension arm. Refer to REMOVING/INSTALLING THE

ANTI-TIP ASSEMBLY in this procedure of the manual.

5. Remove the shock from the suspension arm. Refer to

REMOVING/INSTALLING THE SHOCK ASSEMBLY

in this procedure of the manual.

6. Remove the plug buttons from the side of the base

frame.

7. Remove the mounting screw and beveled washers

that secure the front of the suspension arm to the base

frame.

8. Remove the existing suspension arm from the base

frame.

9. Install the new suspension arm onto the base frame.

10. Install mounting screw and beveled washers that se-

cure the front of the suspension arm to the base frame.

11. Install the plug buttons into the side of the base frame

Suspension Arm Hex Screw

(1/2 x 7-inches)

FIGURE 16 - REPLACING SUSPENSION ARM FOR

WHEELCHAIRS WITH GEARLESS/BRUSHLESS MOTOR

Suspension Arm

Plug

Button

Beveled

Washers

Anti-Tipper Wheel Locknut

ANTI-TIPPER WHEEL

REPLACEMENT (FIGURE 9)

1. Remove the locknuts, hex screws and spacers that

secure the anti-tipper wheels to the shock mount plates.

2. Replace anti-tipper wheel(s) and torque existing hard-

ware to 30-35-inch pounds. DO NOT overtighten.

Spacer

FIGURE 9 - ANTI-TIPPER WHEEL REPLACEMENT

Hex Screw Shock Mount Plates

REMOVING/INSTALLING THE

ANTI-TIP ASSEMBLY

Removing

1. Remove the mounting screw, washers, and spacers

that secure the top of the anti-tip bracket to the suspen-

sion arm.

2. Remove the mounting screw and locknut that secure

the extension spring in place.

3. Remove the mounting screw, washers, and spacers

that secure the bottom of the anti-tip bracket to the sus-

pension arm.

Installing

1. Align top mounting hole of anti-tip bracket with top mount-

ing slot in rear of suspension arm.

RWD WHEELCHAIRSPROCEDURE 16

Suspension

Arm

Anti-Tip

Bracket Spacers

Extension

Spring

Mounting

Screw

Locknut

Mounting

Screws

DO NOT use this mounting hole. This

mounting hole is used to secure the

shock assembly.

FIGURE 17 - REMOVING/INSTALLING THE ANTI-TIP ASSEMBLY

NOTE: Suspension arm shown is for gearless/brushless motor. The Anti-tip assembly removes/installs in the

same manner on the suspension arm used with the conventional motor/gearbox assembly.

Locknuts

Washers

Lower

Mounting

Hole

DO NOT

USE THIS

MOUNTING

HOLE

DO NOT

USE THIS

MOUNTING

SLOT

DO NOT

USE THIS

MOUNTING

HOLE

Lower

Mounting

Hole

2. Secure top of anti-tip bracket to suspension arm with

existing mounting screw, washers, spacers, and lock-

nut. Securely tighten.

3. Align lower mounting hole of the anti-tip mounting bracket

with the lower slot of the suspension arm.

4. Secure the anti-tip bracket to the suspension arm

with the existing mounting screw, washers, spac-

ers, and locknuts. Securely tighten.

5. Hook one end of the extension spring around

mounting screw.

6. Install mounting screw through lower mounting

hole in suspension arm, other end of extension

spring and opposite side of suspension arm. Se-

curely tighten with locknut.

Top

Mounting

Hole

Lower

Mounting

Slot

FWD WHEELCHAIRS PROCEDURE 17

This Procedure includes the following:

Removing/Installing Rear Shroud

Removing/Installing Front Shroud

Removing/Installing Side Shroud Assembly

Removing/Installing Counterweight

Replacing Group 24 Battery Box Sub-Frame

Removing/Installing Shocks

Shock Spring Replacement

Tie Rod Replacement

Removing/Installing Gearbox

Sensor Cable Assembly Replacement

Replacing Suspension Arm

Removing/Installing The Wiring Harness

Adjusting Weight Distribution

FIGURE 2 - REMOVING/INSTALLING FRONT

SHROUD

Front

Shroud

Wing Nut

Mounting

Bracket

REMOVING/INSTALLING REAR

SHROUD (FIGURE 1)

Removing

1. Turn the two (2) wing nuts COUNTERCLOCKWISE

and lift up on the rear shroud.

Installing

1. Position the rear shroud on the wheelchair frame align-

ing the two (2) wing nuts with the mounting brackets.

2. Turn the two (2) wing nuts CLOCKWISE to secure

rear shroud in place.

Wing

Nut

Rear

Shroud

Wing

Nut

FIGURE 1 - REMOVING/INSTALLING REAR

SHROUD

REMOVING/INSTALLING FRONT

SHROUD (FIGURE 2)

Removing

1. Turn the two (2) wing nuts on the TOP of the front

shroud COUNTERCLOCKWISE.

2. Turn the wing nut on the BOTTOM of the front shroud

COUNTERCLOCKWISE and lift up on the front

shroud.

Installing

1. Position the front shroud on the wheelchair frame.

2. Align the wing nut on the BOTTOM of the front shroud

with the mounting bracket on the wheelchair frame.

3. Align the two (2) wing nuts on the TOP of the front

shroud with the mounting holes in the wheelchair frame.

4. Turn the wing nut on the BOTTOM of the front shroud

CLOCKWISE to secure front shroud in place.

5. Turn the two (2) wing nuts on the TOP of the front

shroud CLOCKWISE to secure front shroud in place.

WARNING

After ANY adjustments, repair or service

and BEFORE use, make sure that all at-

taching hardware is tightened securely -

otherwise injury or damage may result.

REMOVING/INSTALLING SIDE

SHROUD ASSEMBLY (FIGURE 3)

Removing

1. Remove the rear shroud. Refer to REMOVING/INSTALL-

ING REAR SHROUD in this procedure of the manual.

2. Remove the drive wheel from the wheelchair. Refer

to REMOVING/INSTALLING DRIVE WHEEL in PRO-

CEDURE 12 of this manual.

FWD WHEELCHAIRSPROCEDURE 17

3. Remove the two (2) socket screws that secure the

side shroud bracket to the suspension arm.

4. Remove the mounting screw and washer that se-

cures the REAR of the side shroud to the suspension

arm.

5. Remove the side shroud assembly.

Installing

1. Position the side shroud on the wheelchair frame.

2. Install the two (2) socket screws that secure the side

shroud bracket into the mounting holes of the sus-

pension arm. Securely tighten.

3. Install the mounting screw and washer that secures

the REAR of the side shroud to the suspension arm.

4. Repeat STEPS 1-3 for the opposite side shroud as-

sembly, if necessary.

5. Reinstall the drive wheel from the wheelchair. Refer

to REMOVING/INSTALLING DRIVE WHEEL in PRO-

CEDURE 12 of this manual.

6. Reinstall the rear shroud. Refer to REMOVING/IN-

STALLING REAR SHROUD in this procedure of the

manual.

FIGURE 3 - REMOVING/INSTALLING SIDE

SHROUD ASSEMBLY

Socket

Screws

Side Shroud Bracket

Mounting

Screw

Washer

Suspension Arm

REMOVING/INSTALLING

COUNTERWEIGHT (FIGURE 4)

WARNING

The sensor on the wheelchair should pre-

vent the wheelchair from operating with-

out the counterweight secured to the rear

of the wheelchair. If the wheelchair oper-

ates without the counterweight, DO NOT op-

erate the wheelchair. Have the wheelchair

serviced by a dealer or qualified technician.

The counterweight weighs 42 pounds. Use

proper lifting techniques (lift with your legs)

to avoid injury.

Removing

1. Remove the rear shroud. Refer to REMOVING/INSTALL-

ING REAR SHROUD in this procedure of the manual.

2. While using proper lifting techniques, use ONE hand

to firmly grasp the handle and the OTHER hand to

firmly grasp the OUTSIDE LOWER EDGE of the

counterweight.

3. Pull the outside lower edge toward you, releasing the

bottom shoulder screws on the counterweight from the

bottom slots in the mounting brackets.

4. Lift the counterweight up and remove the top shoulder

screws from the top slots in the mounting brackets.

Installing

1. While using proper lifting techniques, use ONE hand

to firmly grasp the handle and the OTHER hand to

firmly grasp the OUTSIDE LOWER EDGE of the

counterweight.

2. Hold the counterweight at an angle (DETAIL C) and

position the top shoulder screws into the top slots on the

mounting brackets.

3. Lower the counterweight down until the bottom shoulder

screws engage in the bottom slots on the mounting brack-

ets.

4. Push in the bottom rear of the counterweight to se-

cure the counterweight to the wheelchair until it locks

into place (DETAIL A).

5. Install the rear shroud. Refer to REMOVING/INSTALL-

ING REAR SHROUD in this procedure of the manual.

Front

Mounting

Hole

Rear

Mounting

Hole

FWD WHEELCHAIRS PROCEDURE 17

FIGURE 4 - REMOVING/INSTALLING

COUNTERWEIGHT

Bottom Shoulder Screw

Bottom Slot in Mounting Bracket

Top Shoulder

Screw

Counterweight

DETAIL “C” - REMOVING - STEP 4;

INSTALLING - STEP 2

DETAIL “B” - REMOVING - STEP 3;

INSTALLING - STEPS 3, 4

DETAIL “A” - REMOVING - STEP 2;

INSTALLING - STEP 5

Outside

Lower Edge

Handle

Bottom Shoulder Screw

Mounting Bracket

Top Slot in

Mounting

Bracket

REPLACING GROUP 24 BATTERY

BOX SUB-FRAME (FIGURE 5)

Removing

1. Remove the rear shroud. Refer to REMOVING/INSTALL-

ING REAR SHROUD in this procedure of the manual.

2. Remove the counterweight. Refer to REMOVING/INSTALL-

ING COUNTERWEIGHT in this procedure of the manual.

3. Remove the battery boxes. Refer to INSTALLING/RE-

MOVING GROUP 24 BATTERY BOXES in PRO-

CEDURE 9 of this manual.

4. Cut tie wrap A, which secures the sensor cable AND

the LEFT motor cable to the battery box sub-frame.

5. Cut tie-wrap B, which secures the battery charger cable

AND the RIGHT motor cable to the battery box sub-frame.

6. Remove the two (2) mounting screws and locknuts

that secure the wiring harness w/bracket to the bat-

tery box sub-frame.

7. Remove the wiring harness w/bracket from the bat-

tery box sub-frame.

8. Remove the four (4) mounting screws and washers

that secure the battery box sub-frame to the mount-

ing brackets.

9. Remove the EXISTING sub-frame assembly.

10. Remove the four (4) mounting screws and wash-

ers that secure the two (2) mounting brackets to

the sub-frame.

11. Install the four (4) mounting screws and washers

that secure the two (2) NEW mounting brackets

to the sub-frame.

12. Install the four (4) mounting screws that secure the

NEW battery box sub-frame to the mounting brack-

ets. Use Loctite 242 and torque mounting screws to

156-inch pounds.

13. Install the two (2) mounting screws and locknuts that

secure the wiring harness w/bracket to the NEW bat-

tery box sub-frame. Use Loctite 242 and torque mount-

ing screws to 160-inch pounds.

14. Secure the sensor cable AND the LEFT motor cable

to the NEW battery box sub-frame using tie wrap A.

Refer to FIGURE 5 for tie wrap positioning.

15. Secure the battery charger cable AND the RIGHT

motor cable to the NEW battery box sub-frame using

tie wrap B. Refer to FIGURE 5 for tie wrap positioning.

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

MOVING GROUP 24 BATTERY BOXES in PRO-

CEDURE 9 of this manual.

Counterweight

Bottom

Slot

FWD WHEELCHAIRSPROCEDURE 17

FIGURE 5 - REMOVING/INSTALLING GROUP 24 BATTERY BOX SUB-FRAME

REAR OF

CHAIR

FRONT OF

CHAIR

Mounting

Screw

(STEPS 6

and 13)

Locknut

Wiring Harness

W/ Bracket

Battery Box

Sub-frame

Sub-Frame

Mounting Screw

(STEPS 8 and 12) Washer (STEP 8 and 12)

Position

Tie Wrap

A Here

REMOVING/INSTALLING SHOCKS

(FIGURE 6)

Removing

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

STALLING FRONT SHROUD in this procedure of the

manual.

2. Remove the rear shroud. Refer to REMOVING/IN-

STALLING REAR SHROUD in this procedure of the

manual.

3. Remove the counterweight. Refer to REMOVING/IN-

STALLING COUNTERWEIGHT in this procedure of

the manual.

4. Remove the battery boxes. Refer to INSTALLING/RE-

MOVING GROUP 24 BATTERY BOXES in PRO-

CEDURE 9 of this manual.

5. Remove the mounting screw and washer that se-

cures the top of the EXISTING shock to the base frame.

6. Remove the mounting screw and locknut that secures

the bottom of the EXISTING shock to the suspension

arm.

7. Remove the EXISTING shock.

Position

Tie Wrap

B Here

Mounting

Bracket (Only

One (1) Shown

For Clarity)

17. Reinstall the counterweight. Refer to REMOVING/IN-

STALLING COUNTERWEIGHT in this procedure of

the manual.

18. Reinstall the rear shroud. Refer to REMOVING/IN-

STALLING REAR SHROUD in this procedure of the

manual.

Installing

1. Secure the top of the NEW shock to base frame us-

ing the existing washer and mounting screw. Apply

Loctite 242 and torque to 156-inch pounds.

2. Secure the bottom of the NEW shock to the suspen-

sion arm with the existing mounting screw and lock-

nut. Apply Loctite 242 and torque to 160-inch pounds.

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

MOVING GROUP 24 BATTERY BOXES in PRO-

CEDURE 9 of this manual.

4. Reinstall the counterweight. Refer to REMOVING/IN-

STALLING COUNTERWEIGHT in this procedure of

the manual.

5. Reinstall the rear shroud. Refer to REMOVING/IN-

STALLING REAR SHROUD in this procedure of the

manual.

6. Reinstall the front shroud. Refer to REMOVING/IN-

STALLING FRONT SHROUD in this procedure of

the manual.

Mounting

Screw

(STEPS 10

and 11)

Washer

(STEP 10

and 11)

FWD WHEELCHAIRS PROCEDURE 17

SHOCK SPRING REPLACEMENT

(FIGURE 7)

1. Remove the shock. Refer to REMOVING/INSTALL-

ING SHOCKS in this procedure of this manual.

2. Hold the spring retainer and turn the shock eyelet as-

sembly counterclockwise to unthread it from the shock.

3. Remove the spring retainer and spring.

4. Place the NEW spring onto the shock.

5. Reinstall the shock eyelet assembly and the spring

retainer onto the NEW spring.

6. While holding the spring retainer, torque the shock

eyelet assembly to 245-inch pounds.

FIGURE 7 - SHOCK SPRING REPLACEMENT

Shock Eyelet

Assembly

Spring

Base

Shock

7. Secure top of shock and spring retainer to base frame.

Apply Loctite 242 and torque to 160-inch pounds.

8. Reinstall the shock. Refer to REMOVING/INSTALL-

ING SHOCKS in this procedure of this manual.

TIE ROD REPLACEMENT (FIGURE 8)

Removing

1. Remove the front shroud. Refer to REMOVING/INSTALL-

ING FRONT SHROUD in this procedure of the manual.

2. Remove the rear shroud. Refer to REMOVING/INSTALL-

ING REAR SHROUD in this procedure of the manual.

3. Remove the counterweight. Refer to REMOVING/IN-

STALLING COUNTERWEIGHT in this procedure of

the manual.

4. Remove the battery boxes. Refer to INSTALLING/RE-

MOVING GROUP 24 BATTERY BOXES in PRO-

CEDURE 9 of this manual.

5. Remove the shocks. Refer to REMOVING/INSTALL-

ING SHOCKS in this procedure of this manual.

6. Remove the MKIV controller. Refer to REMOVING/

INSTALLING MKIV CONTROLLER in PROCEDURE

13 of this manual.

7. Remove the locknut, small washer, larger washer and

mounting screw that secures the tie rod to the sus-

pension arm.

8. Remove the locknut, small washer, large washer and

mounting screw that secures the tie rod to the base frame.

9. Remove the tie rod from the wheelchair.

NOTE: In order to ensure that the replacement tie rod(s)

are adjusted properly, it is necessary to remove ALL

of the tie rods from the wheelchair and install both the

NEW and the EXISTING tie rods as described in the

section below.

10. Repeat STEPS 7-9 to remove the three (3) remain-

ing tie rods.

Adjusting/Installing

1. Before installing, adjust the collar on one (1) tie rod

until the length of the tie rod is approximately five (5)

inches (DETAIL A).

NOTE: The length of the tie-rod is measured from the

center of one eyelet to the center of the opposite eyelet.

NOTE: Turn the collar CLOCKWISE to shorten the tie

rod and COUNTER-CLOCKWISE to lengthen the tie rod.

2. Lock the collar on the tie rod into place by turning

the nut on the tie rod until it is FLUSH against the

collar (DETAIL A).

Locknut

Mounting Screw

Washer

Mounting Screw

FIGURE 6 - REMOVING/INSTALLING SHOCKS

Base Frame

Suspension Arm

Shock

Spring

Retainer

FWD WHEELCHAIRSPROCEDURE 17

REMOVING/INSTALLING

GEARBOX (FIGURE 9)

CAUTION

Perform the following procedure in a des-

ignated work area to prevent damage to

flooring (carpeting, tile, etc.).

Removing

1. Remove the rear shroud. Refer to REMOVING/IN-

STALLING REAR SHROUD in this procedure of the

manual.

2. Remove the counterweight. Refer to REMOVING/IN-

STALLING COUNTERWEIGHT in this procedure of

the manual.

3. Remove the battery boxes. Refer to INSTALLING/RE-

MOVING GROUP 24 BATTERY BOXES in PRO-

CEDURE 9 of this manual.

4. Remove the drive wheel from the wheelchair. Refer

to REMOVING/INSTALLING DRIVE WHEELS in

PROCEDURE 12 of this manual.

5. Remove the side shroud assembly. Refer to REMOV-

ING/INSTALLING THE SIDE SHROUD in this proce-

dure of the manual.

6. Remove the six (6) socket screws that secure the

existing motor/gearbox to the suspension arm.

7. Remove existing motor from gearbox. Refer to MO-

TOR REPLACEMENT in PROCEDURE 12 of this

manual.

Mounting

Screw

Base

Frame

Locknut

FIGURE 8 - TIE ROD ASSEMBLIES

Small

Washer

Large

Washer

Suspension

Arm

Tie Rod

Suspension Arm

DETAIL “A”

Tie Rod

Collar

(Turn CLOCKWISE To

Shorten And COUNTER-

CLOCKWISE To Lengthen)

Nut

5 inches

Center

8. Securely tighten the tie rods to the base frame AND to

the suspension arm. Apply Loctite 242 and torque to

360-inch pounds.

9. Reinstall the MKIV controller. Refer to REMOV-

ING/INSTALLING MKIV CONTROLLER in PRO-

CEDURE 13 of this manual.

10. Reinstall the shocks. Refer to REMOVING/INSTALL-

ING SHOCKS in this procedure of this manual.

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

MOVING GROUP 24 BATTERY BOXES in PRO-

CEDURE 9 of this manual.

12. Reinstall the counterweight. Refer to REMOVING/IN-

STALLING COUNTERWEIGHT in this procedure of

the manual.

13. Reinstall the rear shroud. Refer to REMOVING/INSTALL-

ING REAR SHROUD in this procedure of the manual.

14. Reinstall the front shroud. Refer to REMOVING/INSTALL-

ING FRONT SHROUD in this procedure of the manual.

3. Install the tie rod onto the base frame using the mount-

ing screw, large washer, small washer and locknut.

HAND TIGHTEN ONLY.

4. Install the tie rod in the suspension arm using the

mounting screw, large washer, small washer and lock-

nut. HAND TIGHTEN ONLY.

5. Repeat STEPS 1-4 to install the three (3) remain-

ing tie rods.

NOTE: To complete proper tie rod adjustment, Per-

form STEPS 6-7 on the TOP TWO (2) tie rods ONLY.

6. Turn the collar COUNTER-CLOCKWISE for one (1)

complete revolution on the TOP TWO (2) tie rods.

7. Lock the collar on the TOP TWO (2) tie rods into

place by turning the nuts on the TOP TWO (2) tie

rods until they are FLUSH against the collars.

Mounting

Screw

PROCEDURE 17

Installing

CAUTION

The longer socket screws MUST be posi-

tioned in the mounting holes on the OUT-

SIDE of the suspension arm, and the SHORTER

socket screws MUST be positioned in the

mounting holes on the INSIDE of the sus-

pension arm. Otherwise, damage to the

gearbox may result.

1. Install the EXISTING motor onto the NEW gearbox.

Refer to MOTOR REPLACEMENT in PROCEDURE

12 of this manual.

2. Secure the gearbox to the suspension arm using the

six (6) socket screws. Use Loctite 242 and torque

the socket screws to 75-inch pounds.

NOTE: Replace any parts that show signs of wear or dam-

age.

3. Reinstall the side shroud assembly. Refer to REPLAC-

ING THE SIDE SHROUD in this procedure of the

manual.

4. Reinstall the drive wheels onto the wheelchair. Refer

to REMOVING/INSTALLING DRIVE WHEELS in

PROCEDURE 12 of this manual.

SHORT

Socket

Screw

FIGURE 9 - REMOVING/INSTALLING

GEARBOX

SENSOR CABLE ASSEMBLY

REPLACEMENT (FIGURE 10)

1. Remove the rear shroud. Refer to REMOVING/INSTALL-

ING REAR SHROUD in this procedure of the manual.

2. Remove the counterweight. Refer to REMOVING/IN-

STALLING COUNTERWEIGHT in this procedure of

the manual.

3. Remove the battery boxes. Refer to INSTALLING/RE-

MOVING GROUP 24 BATTERY BOXES in PRO-

CEDURE 9 of this manual.

4. Cut tie-wrap A, which secures the EXISTING sensor

cable to the sensor bracket (DETAIL A).

5. Cut tie-wrap B, which secures the EXISTING sensor

cable AND the LEFT motor cable to the battery box

sub-frame (DETAILB).

6. Cut tie-wrap C, which secures the EXISTING Lego

block connector of the sensor cable and the Lego

block connector of the battery wiring harness to the

base frame.

7. Disconnect the EXISTING Lego block connector of

the sensor cable from the Lego block connector of

the battery wiring harness (DETAIL C).

]

8. Remove the two (2) mounting screws, washers and

locknuts that secure the EXISTING sensor to the sen-

sor bracket (DETAIL D).

9. Remove the EXISTING sensor cable assembly.

10. Install the two (2) mounting screws, washers and lock-

nuts to secure the NEW sensor to the sensor bracket

(DETAIL D). Securely tighten.

11. Connect the NEW Lego block connector of the sen-

sor cable assembly to the Lego block connector of

the wiring harness (DETAIL C).

12. Secure the two (2) Lego block connectors to the

base frame with a NEW tie wrap (DETAIL C).

13. Secure the NEW sensor cable AND the LEFT motor

cable to the battery box sub-frame with a NEW tie

wrap (DETAILB).

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

MOVING GROUP 24 BATTERY BOXES in PRO-

CEDURE 9 of this manual.

6. Reinstall the counterweight. Refer to REMOVING/IN-

STALLING COUNTERWEIGHT in this procedure of

the manual.

7. Reinstall the rear shroud. Refer to REMOVING/INSTALL-

ING REAR SHROUD in this procedure of the manual.

Gearbox

Suspension

Arm

Motor

LONG

Socket

Screw

FWD WHEELCHAIRS

FWD WHEELCHAIRSPROCEDURE 17

Tie Wrap A

Sensor

Cable

Sensor

Bracket

LEFT Motor

Cable Sensor

Cable

Tie Wrap B

Battery

Box Sub-

Frame

Lego

Block

Connector

Of The

Battery

Wiring

Harness

Base Frame

Mounting

Screw

Washer

Locknut

Sensor

Bracket

FIGURE 10 - SENSOR CABLE ASSEMBLY REPLACEMENT

Tie Wrap C

Battery Box

Sub-Frame

Base

Frame

DETAIL A

DETAIL B

DETAIL C

DETAIL D

Lego

Block

Connector

Of The

Sensor

Cable

REPLACING SUSPENSION ARM

(FIGURE 11)

1. Remove the rear shroud. Refer to REMOVING/IN-

STALLING REAR SHROUD in this procedure of the

manual.

NOTE: Seat frame and drive wheels removed for clarification purposes ONLY.

REAR OF

CHAIR

FRONT OF

CHAIR

2. Remove the counterweight. Refer to REMOVING/IN-

STALLING COUNTERWEIGHT in this procedure of

the manual.

16. Reinstall the counterweight. Refer to REMOVING/IN-

STALLING COUNTERWEIGHT in this procedure of

the manual.

17. Reinstall the rear shroud. Refer to REMOVING/IN-

STALLING REAR SHROUD in this procedure of the

manual.

14. Secure the NEW sensor cable to the sensor bracket

with a NEW tie wrap (DETAIL A).

15. Reinstall the battery boxes. Refer to INSTALLING/

REMOVING GROUP 24 BATTERY BOXES in PRO-

CEDURE 9 of this manual.

REMOVING/INSTALLING WIRING

HARNESS (FIGURE 12)

Removing

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

MOVING GROUP 24 BATTERY BOXES in PRO-

CEDURE 9 of this manual.

2. Remove the two (2) mounting screws that secure

the battery charger port to the mounting bracket and

remove the battery charger port (DETAIL A).

3. Remove the two (2) mounting screws and locknuts

that secure the wiring harness w/bracket to the battery

box sub-frame (DETAIL B).

4. Cut tie-wrap A, which secures the Lego block

connectors to the base frame (DETAIL C).

5. Disconnect the Lego block connector of the bat-

tery wiring harness from the Lego block connec-

tor of the sensor cable assembly (DETAIL C).

6. Cut tie-wrap B, which secures the battery charger

cable and the RIGHT motor cable to the battery

box sub-frame (DETAIL  D).

7. Disconnect the battery harness/charger cable

(BLUE) from the controller connector (BLUE)

(DETAILE).

8. Remove the wiring harness.

Installing

1. Connect the battery harness/charger cable (BLUE)

to the controller connector (BLUE) (DETAILE).

2. Connect the Lego block connector of the battery wir-

ing harness to the Lego block connector of the sen-

sor cable assembly (DETAIL C).

3. Secure the Lego block connectors to the base frame

with a NEW tie wrap (DETAIL C).

4. Install the two (2) mounting screws and locknuts that

secure the wiring harness w/bracket to the battery

box sub-frame. Use Loctite 242 and torque mounting

screws to 160-inch pounds (DETAIL B).

5. Secure the battery charger cable and the RIGHT mo-

tor cable to the battery box sub-frame with a NEW tie

wrap (DETAIL D).

Base

Frame

FIGURE 11 - REPLACING THE SUSPENSION ARM

Locknut

Suspension Arm

Spacer

Mounting

Screw

Spacer

WasherWasher

FWD WHEELCHAIRS PROCEDURE 17

3. Remove the battery boxes. Refer to INSTALLING/RE-

MOVING GROUP 24 BATTERY BOXES in PRO-

CEDURE 9 of this manual.

4. Remove the drive wheel from the wheelchair. Refer

to REMOVING/INSTALLING DRIVE WHEELS in

PROCEDURE 12 of this manual.

5. Remove the shock. Refer to REMOVING/INSTALL-

ING SHOCKS in this procedure of this manual.

6. Remove the tie rods from the EXISTING suspension

arm. Refer to TIE ROD REPLACEMENT in this pro-

cedure of the manual.

7. Remove the side shroud assembly. Refer to RE-

PLACING SIDE SHROUD ASSEMBLY in this proce-

dure of the manual.

8. Remove the gearbox from the EXISTING suspension

arm. Refer to REMOVING/INSTALLING GEARBOX

in this procedure of the manual.

9. Remove the locknut, two (2) spacers, two (2) wash-

ers and the mounting screw that secures the EXIST-

ING suspension arm to the base frame.

10. Remove EXISTING suspension arm from the base

frame.

11. Secure the NEW suspension arm to the base frame

using the mounting screw, two (2) washers, two (2)

spacers and the locknut. Torque the locknuts to 85

-inch pounds.

12. Reassemble the wheelchair by reversing STEPS 1-8.

100

Lego Block

Connector

Of The

Battery

Wiring

Harness

Base Frame

Tie Wrap A

RIGHT

Motor

Cable Battery Charger

Cable

Tie Wrap B

Battery

Box Sub-

Frame

FIGURE 12 - REMOVING/INSTALLING WIRING HARNESS

DETAIL B

DETAIL C

DETAIL D

Mounting Screws

Locknuts

Wiring

Harness W/

Bracket Battery

Box Sub-

Frame

DETAIL E

Battery

Harness/

Charger

Cable (Blue)

Controller

Connector

(Blue)

FWD WHEELCHAIRSPROCEDURE 17

Lego

Block

Connector

Of The

Sensor

Cable

Mounting

Screw

Mounting

Bracket

Battery

Charger

Port

DETAIL A

6. Reinstall the mounting screw that secures the battery

charger port to the mounting bracket (DETAILA). Se-

curely Tighten.

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

MOVING GROUP 24 BATTERY BOXES in PRO-

CEDURE 9 of this manual.

101

PROCEDURE 17FWD WHEELCHAIRS

ADJUSTING WEIGHT

DISTRIBUTION (FIGURE 13)

NOTE: Depending on the seat depth ordered, the position

of the seat support brackets is factory set between 2.25 and

6 inches (measured from the front of the base frame to the

front of the seat support brackets). This will put approximately

65% of the total weight of the chair and user over the drive

wheels (large wheels), allowing for the best performance of

the chair.

In order to achieve maximum comfort and maneuverability

for the end user, it may be necessary to adjust the seat

support brackets slightly forward or backward. It is recom-

mended that the seat support brackets be set as close to

2.25 - 6 inch mark (depending on seat depth) as possible,

while allowing maximum comfort and maneuverability to

the end user.

Adjusting Weight Distribution For New Seat

Depth

NOTE: When changing the seat depth of the chair, it is

necessary to adjust the seat support brackets in order to

achieve optimum weight distribution (65%). Perform the

following procedure to adjust the seat brackets:

1. Refer to the following chart to determine the correct

position of the two (2) seat support brackets to achieve

optimum weight distribution (65%).

2. Loosen the four (4) mounting screws that secure the

two (2) seat support brackets to the base frame.

3. Adjust the two (2) seat support brackets forward or

backward until the position determined in STEP 1 is

achieved.

NOTE: When the front of the seat aligns with the controller,

approximately 65% of the total weight of the chair and user is

over the drive wheels (large wheels).

4. Adjust the two (2) seat brackets slightly forward or

backward, until maximum comfort and maneuver-

ability for the end user is acheived.

5. Retighten the four (4) mounting screws securing the

two (2) seat support brackets to the base frame.

Seat Support

Brackets

Mounting Screws

Seat

Depth

(Inches)

Position Of The Seat Support

Brackets (Inches) To Achieve

Optimum Weight Distribution (65%)

14 to 16 inches 2.25-inches

17 to 18 inches 4.25-inches

19 to 20 inches 6-inches

INSTALLING 90o FOOTBOARD

(FIGURE 14)

WARNING

DO NOT remove detent pin from footrest

assembly. Otherwise, injury may result.

1. Remove the existing footrests. Refer to FRONT RIG-

GINGS in PROCEDURE 3 of the Owners manual,

part number 1081227.

2. Remove the telescoping front rigging supports. Refer

to ADJUSTING/REPLACING TELESCOPING

FRONT RIGGING SUPPORT in PROCEDURE 3 of

the Owners Manual, part number 1081227.

3. Remove existing front and rear shrouds. Refer to RE-

MOVING/INSTALLING THE REAR SHROUD and

REMOVING/INSTALLING THE FRONT SHROUD in

this procedure of the Manual.

4. Remove the seat. Refer to REMOVING/INSTALLING

THE SEAT FRAME in PROCEDURE 6 of this Manual.

5. Position the 90o footboard on the base frame as shown

in FIGURE 14.

6. Loosely install one (1) mounting screw into the back

of the footboard and into the base frame.

7. Loosely install two (2) mounting screws and washers

through the top of the footboard and into the base frame.

8. Torque all three (3) mounting screw between 15 and

19-foot pounds.

Front Of

Base

Frame

FIGURE 13 - ADJUSTING WEIGHT

DISTRIBUTION

2.25 Inches (For a

seat depth of 14 to

16 inches)

NOTE: Seat/seat frame not shown for clarity.

102

PROCEDURE 17

FIGURE 14 - INSTALLING 90o FOOTBOARD

Flat Screws

Washers

Locknuts

90o Footrest

Support

Mounting

Screws

(STEP 7)

Washer

90o

Footboard

Mounting

Screw (STEP 6)

FOOTBOARD ADJUSTMENTS-

DEPTH/HEIGHT/ANGLE

(FIGURE 15)

WARNING

DO NOT remove detent pin from footrest

assembly. Otherwise, injury may result.

Depth

1. Remove the four (4) flat screws, washers and locknuts

that secure 90o footboard to the two (2) half clamps.

NOTE: Observe the angle of the footboard for reinstallation.

2. Move

footboard to one (1) of two (2) mounting positions.

3. Secure the footboard to the half clamps with the four

(4) flat screws, washers and locknuts. Securely tighten.

Angle

1. Loosen, but do not remove the four (4) flat screws,

washers and locknuts that secure the footplate to the

half clamps.

2. Position the 90o footboard to the desired angle.

3. Retighten four (4) flat screws, washers and locknuts.

Height

1. Remove the two (2) hub caps.

2. Remove the mounting screw, washers, caplug

washers, and locknut that secure the footboard to

the footrest support.

3. Adjust footboard to desired height.

4. Secure the footboard with the mounting screw,

washers, caplug washers, and locknut. Tighten

mounting screw and locknut to 12 foot pounds. See

FIGURE 15 for hardware orientation.

9. Adjust angle of footrest. Refer to FOOTREST ANGLE

ADJUSTMENTS in this procedure of the Manual.

10. Install the seat. Refer to REMOVING/INSTALLING

THE SEAT FRAME in PROCEDURE 6 of this manual.

11. Install NEW front shroud and existing rear shroud.

Refer to REMOVING/INSTALLING THE REAR

SHROUD and REMOVING/INSTALLING THE

FRONT SHROUD in this procedure of the Manual.

12. Install the two (2) end caps provided into the ends of

the seat frame where the telescoping front rigging sup-

ports were mounted.

13. Adjust footboard. Refer to DEPTH/HEIGHT/ANGLE

ADJUSTMENT in this procedure of the manual.

FWD WHEELCHAIRS

103

FWD WHEELCHAIRS PROCEDURE 17

FOOTREST ANGLE ADJUSTMENTS

WARNING

DO NOT remove detent pin from footrest

assembly. Otherwise, injury may result.

Footrest Angle Adjustment Relative to the

Vertical Position of the Front Shroud

(FIGURE 16)

NOTE: The angle of the footrest relative to the vertical

position of the front shroud can be increased or decreased

by adjusting both cams located at the top of the footrest

support.

1. Loosen the mounting screw and locknut that secure

the cams to the upper mounting bracket. Refer to

DETAIL A.

NOTE: Both cams MUST be rotated to the same posi-

tion to keep the footrest square to the base.

2. Rotate both cams either direction until footrest is at

desired angle. Refer to DETAIL B and C

3. Tighten mounting screw and locknut to 12 foot pounds.

Footrest Angle Adjustment Relative to the

Horizontal Position of the Front Shroud

(FIGURE 16)

NOTE: The footrest is factory set to be square to the base

when installed. The footrest can be positioned to be out of

square by adjusting only one (1) of the cams located at the

top of the footrest support.

1. Loosen the mounting screw and locknut that secure the

cams to the upper mounting bracket. Refer to DETAIL

A.

2. Perform one (1) of the following:

NOTE: Right and Left are determined by sitting in the

wheelchair.

A. Turning the right cam will rotate the footrest counter-

clockwise. Refer to DETAIL D.

B. Turning the left cam will rotate the footrest clock-

wise. Refer to DETAIL D.

3. When footrest is at desired position, tighten mounting

screw and locknut to 12 foot pounds.

FIGURE 15 - DEPTH/HEIGHT/ANGLE

ADJUSTMENT

Half Clamp

Side View Of 90o Footboard

Flat Screws

(Loosen

Here)

Flat Screws

Washers

Locknuts

Footboard

Caplug Mounting Screw

Washer

Hub Cap

Locknut

Footrest

Support

DEPTH

ANGLE/HEIGHT

Two (2)

Mounting

Positions

Flat Screws

Washers

Locknuts

Footboard

Washer/

Locknut

104

FIGURE 16 - FOOTREST ANGLE ADJUSTMENTS

Mounting

Screw

Locknut

Cams Cam

Upper

Mounting

Bracket

DETAIL “A”DETAIL “B”

DETAIL “C” - SIDE VIEW OF FOOTREST

DETAIL “D” - TOP VIEW OF FOOTREST

Vertical Position

of Front Shroud

NOTE: Angle is

increased or

decreased depending

on direction of footrest

rotation

Right

Cam

Left

Cam

Footrest

COUNTER-

CLOCKWISE

Direction of

Footrest Rotation

Horizontal Position

of Front Shroud

CLOCKWISE

Direction of

Footrest

Rotation

PROCEDURE 17

FWD WHEELCHAIRS

105

NOTES

106

NOTES

107

LIMTIED WARRANTY

LIMITED WARRANTY

PLEASE NOTE: THE WARRANTY BELOW HAS BEEN DRAFTED TO COMPLY WITH FEDERAL LAW

APPLICABLE TO PRODUCTS MANUFACTURED AFTER JULY 4, 1975.

This warranty is extended only to the original purchaser/user of our products.

This warranty gives you specific legal rights and you may also have other legal rights

which vary from state to state.

Invacare warrants seat frame to be free from defects in materials and workmanship

for a period of three (3) years from date of purchase; that electrical components are

warranted for a period of one (1) year; gearbox/motors for a period of 18 months; and

gearless/brushless motors for five (5) years from the date of purchase; and the base

frame for the life of the product; all remaining components (including gas cylinders and

motor lock pads) for one (1) year from the date of purchase except upholstered mate-

rials, padded materials and tires/wheels. If within such warranty period any such prod-

uct 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 in-

curred in replacement part installation or repair of any such product. Invacare's sole

obligation and your exclusive remedy under this warranty shall be limited to such repair

and/or replacement.

This warranty pertains to Arrow Series, Ranger X Series and Torque Series Only!

For warranty service, please contact the dealer from whom you purchased your In-

vacare product. In the event you do not receive satisfactory warranty service, please

write directly to Invacare at the address at the bottom of the back cover. Provide

dealer’s name, address, date of purchase, indicate nature of the defect and, if the

product is serialized, indicate the serial number. Do not return products to our factory

without our prior consent.

LIMITATIONS AND EXCLUSIONS: THE FOREGOING WARRANTY SHALL NOT APPLY TO SERIAL

NUMBERED PRODUCTS IF THE SERIAL NUMBER HAS BEEN REMOVED OR DEFACED, PROD-

UCTS SUBJECTED TO NEGLIGENCE, ACCIDENT, IMPROPER OPERATION, MAINTENANCE OR

STORAGE, COMMERCIAL OR INSTITUTIONAL USE, PRODUCTS MODIFIED WITHOUT

INVACARE'S EXPRESS WRITTEN CONSENT INCLUDING, BUT NOT LIMITED TO, MODIFICA-

TION THROUGH THE USE OF UNAUTHORIZED PARTS OR ATTACHMENTS; PRODUCTS DAM-

AGED BY REASON OF REPAIRS MADE TO ANY COMPONENT WITHOUT THE SPECIFIC CON-

SENT OF INVACARE, OR TO A PRODUCT DAMAGED BY CIRCUMSTANCES BEYOND

INVACARE'S CONTROL, AND SUCH EVALUATION WILL BE SOLELY DETERMINED BY INVAC-

ARE. THE WARRANTY SHALL NOT APPLY TO PROBLEMS ARISING FROM NORMAL WEAR OR

FAILURE TO ADHERE TO THESE INSTRUCTIONS.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS WARRAN-

TIES. IMPLIED WARRANTIES, IF ANY, INCLUDING THE IMPLIED WARRANTIES OF MERCHANT-

ABILITY AND FITNESS FOR A PARTICULAR PURPOSE, SHALL NOT EXTEND BEYOND THE DURA-

TION OF THE EXPRESS WARRANTY PROVIDED HEREIN AND THE REMEDY FOR VIOLATIONS OF

ANY IMPLIED WARRANTY SHALL BE LIMITED TO REPAIR OR REPLACEMENT OF THE DEFEC-

TIVE PRODUCT PURSUANT TO THE TERMS CONTAINED HEREIN. INVACARE SHALL NOT BE

LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES WHATSOEVER.

THIS WARRANTY SHALL BE EXTENDED TO COMPLY WITH STATE/PROVINCIAL LAWS AND RE-

QUIREMENTS.

Invacare Corporation www.invacare.com

U S A Canada Invacare, Storm Series, and Arrow are registered trademarks of

One Invacare Way 5970 Chedworth Way Invacare Corporation.

Elyria, Ohio USA Mississauga, Ontario Yes, You can., Ranger X, and Torque are trademarks of

44036-2125 L5R 3T9, Canada Invacare Corporation.

800-333-6900 905-890-8838 Loctite is a registered trademark of Loctite Corporation.

Form No. 98-266 Part No. 1081229 Rev C (1)-4/01

Invacare Wheelchair Arrow Users Manual

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