3g storm series® wheelchairs - · pdf file3g storm series® wheelchairs ......

Service Manual

DEALER: Keep this manual. The procedures in this manual MUST be performed by a qualified technician.

For more information regarding Invacare products, parts, and services,

please visit www.invacare.com

3G Storm Series® Wheelchairs

Torque™ SP RWDTorque™ 3 RWD

REFERENCE DOCUMENTS

3G Storm Series® Wheelchairs 2 Part No. 1104849

� WARNING

� DANGERRisk of Injury, Damage or DeathImproper use of this product may cause injury or damage.If you are unable to understand the warnings, cautions or instructions, contact a health care professional or dealer before attempting to use this equipment.—DO NOT use this product or any available optional equipment without first completely reading and understanding these instructions and any additional instructional material such as user manual, service manuals or instruction sheets supplied with this product or optional equipment. Continued use of the wheelchair with damaged parts could lead to the wheelchair malfunctioning, causing injury to the user and/or caregiver.—Check all wheelchair components and carton for damage and test components before use. In case of damage or if the wheelchair is not working properly, contact a qualified technician or Invacare for repair.

REFERENCE DOCUMENTSRefer to the table below for part numbers of additional documents which are referenced in this manual.

MANUAL PART NUMBER

3G Storm Base User Manual 1143151

MK6i Field Reference Guide 1141471

MK6i Service Manual 1143203

NOTE: Updated versions of this manual are available on www.invacare.com.

SPECIAL NOTES

SPECIAL NOTESSignal words are used in this manual and apply to hazards or unsafe practices which could result in personal injury or property damage. Refer to the table below for definitions of the signal words.

NOTICETHE INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE.WHEELCHAIR USERAs a manufacturer of wheelchairs, Invacare endeavors to supply a wide variety of wheelchairs to meet many needs of the end user. However, final selection of the type of wheelchair to be used by an individual rests solely with the user and his/her healthcare professional capable of making such a selection. Invacare highly recommends working with a certified rehab technology supplier and/or a member of NRRTS or RESNA.NOTE: As of January 1, 2017. TRRO (Transport Ready Option) has been discontinued on this product. Please contact your dealer or Invacare for legacy information or to answer questions regarding TRRO.

As of this date, the Department of Transportation has not approved any tie-down systems for transportation of a user while in a wheelchair, in a moving vehicle of any type. It is Invacare’s position that users of wheelchairs should be transferred into appropriate seating in vehicles for transportation and use be made of the restraints made available by the auto industry. Invacare cannot and does not recommend any wheelchair transportation systems.• Wheelchair Transport Brackets (TRBKTS) includes four factory-installed wheelchair

transport brackets. TRBKTS have not been crash-tested in accordance with WC 19. Use these transport brackets only to secure an unoccupied wheelchair during transport.

• Transport Ready Option (TRRO) includes four factory-installed transport brackets and a wheelchair anchored pelvic belt. TRRO has been crash-tested in accordance with ANSI/RESNA WC Vol 1 Section 19 Frontal Impact Test requirements for wheelchairs with a 168 lb crash dummy, which corresponds to a person with a weight of 114 to 209 lbs.

• Battery support brackets MUST be installed at all times. Otherwise, the wheelchair will not be WC/19 compliant.

SIGNAL WORD MEANING

� DANGERDanger indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

� WARNINGWarning indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

� CAUTIONCaution indicates a potentially hazardous situation which, if not avoided, may result in property damage.

Part No. 1104849 3 3G Storm Series® Wheelchairs

SPECIAL NOTES

� DANGERRisk of Death, Serious Injury, or DamageCorroded electrical components due to water and/or, liquid exposure, or incontinent users can result in death, serious injury, or damage.Minimize exposure of electrical components to water and/or liquids. Electrical components damaged by corrosion MUST be replaced immediately.Wheelchairs that are used by incontinent users and/or are frequently exposed to water/liquids may require replacement of electrical components more frequently.

� DANGERRisk of Death or Serious InjuryNot wearing your seat positioning strap could result in death or serious injury.ALWAYS wear your seat positioning strap. Your seat positioning strap helps reduce the possibility of a fall from the wheelchair. The seat positioning strap is a positioning belt only. It is not designed for use as a safety device withstanding high stress loads such as auto or aircraft safety belts. If signs of wear appear, seat positioning strap MUST be replaced IMMEDIATELY.

� WARNINGRisk of Injury, Damage or DeathImproper setup, service, adjustment or programming may cause injury, damage or death.—Qualified technician MUST setup, service and program the wheelchair.—DO NOT allow non-qualified individuals to perform any work or adjustments on the wheelchair.—DO NOT setup or service the wheelchair while occupied except for programming or unless otherwise noted.—Turn off power BEFORE adjusting or servicing the wheelchair. Note that some safety features will be disabled.—Ensure all hardware is securely tightened after setup, service or adjustments.

� RECLINER WARNINGSTO HEALTHCARE PROFESSIONALS/ASSISTANTS:Make sure the occupant of the wheelchair is properly positioned.When returning the occupant of the wheelchair to the full upright position, more body strength will be required for approximately the last twenty degrees of incline (reverse recline). Make sure to use proper body mechanics (use your legs) or seek assistance if necessary to avoid injury.


TABLE OF CONTENTS

TABLE OF CONTENTS
REFERENCE DOCUMENTS ................................................................. 2
SPECIAL NOTES ................................................................................ 3

LABEL LOCATIONS ........................................................................... 8

All Wheelchairs...........................................................................................................................................8

Wheelchairs with O2 Holders...............................................................................................................10

Wheelchairs with TRRO ........................................................................................................................10

Wheelchairs without TRRO..................................................................................................................10

SPECIFICATIONS ............................................................................ 11

Torque SP (After 10/5/06)......................................................................................................................11

For All Model Wheelchairs ....................................................................................................................12

SECTION 1—GENERAL GUIDELINES ................................................. 13

Accessories ................................................................................................................................................13

G-Trac.........................................................................................................................................................14

Repair or Service Information ...............................................................................................................14

Operation Information ............................................................................................................................15

Wheelchairs with Powered Seating Systems Only ...........................................................................17

Tire Pressure .............................................................................................................................................18

Electrical .....................................................................................................................................................19

Batteries......................................................................................................................................................19

Rain Test.....................................................................................................................................................20

Weight Training ........................................................................................................................................21

SECTION 2—ELECTROMAGNETIC COMPATIBILITY (EMC) INFORMATION .................................................................... 22

SECTION 3—TROUBLESHOOTING .................................................... 24

Troubleshooting........................................................................................................................................24

Troubleshooting—Electrical ..................................................................................................................29

Checking Battery Charge Level.............................................................................................................34

Field Load Test..........................................................................................................................................34

Motor Testing............................................................................................................................................35

Motor Brush Inspection ..........................................................................................................................36

Electro-Mechanical Parking Brake Testing..........................................................................................36


SECTION 4—ARMS ......................................................................... 38

Installing/Removing Flip Back Armrests ..............................................................................................38

Adjusting Flip Back Armrests.................................................................................................................39

SECTION 5—UPHOLSTERY/POSITIONING STRAP ...................................................................... 41

Replacing Back Upholstery .....................................................................................................................41

Removing/Installing the Back Canes.....................................................................................................43

SECTION 6—FIXED AND ASBA SEAT FRAME ................................... 45

Preparation for Removing/Installing Seat Frame ...............................................................................45

Replacing the Seat Frame........................................................................................................................46

Changing Seat Depth ...............................................................................................................................48

Changing Seat Width (Standard and ASBA).......................................................................................52

Replacing Components of the ASBA Seat ..........................................................................................54

Removing/Installing Seat Pan ..................................................................................................................56

Adjusting the Seat Pan - ADJASBA.......................................................................................................58

Seat Angle Adjustment ............................................................................................................................58

Checking ASBA Seating System Mounting Position..........................................................................60

Adjusting the Seating System Mounting Position ..............................................................................61

SECTION 7—BASE FRAME ............................................................... 63

Replacing Seat Mounting Plates .............................................................................................................63

Replacing Seat Support Brackets ..........................................................................................................65

Replacing Seat Support Bracket T-Nuts..............................................................................................66

Replacing Battery Charger Bracket and T-Nut .................................................................................67

Removing/Installing Seat Stop Screws..................................................................................................68

Adjusting Weight Distribution ..............................................................................................................69

Repositioning the Motor.........................................................................................................................71

Replacing Suspension Arm for Wheelchairs with Motor/Gearbox Assembly ...........................73

SECTION 8—BACK FRAME .............................................................. 74

Removing/Installing CJ Back Brackets ..................................................................................................74

Changing Back Height on Fixed and ASBA Seat Frames .................................................................76

Adjusting the Back Height on ADJASBA Seat Frames.....................................................................78

Back Angle Adjustment ...........................................................................................................................79


TABLE OF CONTENTS

TABLE OF CONTENTS
SECTION 9—BATTERIES .................................................................. 80
Warnings for Handling and Replacing Batteries ................................................................................80

Using the Proper Batteries.....................................................................................................................80

Installing/Removing Batteries into/from Battery Boxes...................................................................82

Disconnecting/Connecting Battery Cables .........................................................................................84

When to Charge Batteries .....................................................................................................................89

Charging Batteries ....................................................................................................................................90

Replacing Batteries ...................................................................................................................................92

Removing/Installing Battery Boxes .......................................................................................................93

Removing/Installing Group 24 Battery Box Sub-Frame...................................................................97

SECTION 10—WIRING HARNESS ................................................... 101

Removing/Installing the Wiring Harness .......................................................................................... 101

SECTION 11—WHEELS/MOTORS ..................................................... 106

Replacing Pneumatic Tires/Tubes - Drive Wheels/Casters......................................................... 107

Removing/Installing Drive Wheels..................................................................................................... 107

Removing/Installing Drive Wheel Hub ............................................................................................. 108

Removing/Installing the SSD Motor Drive Wheel/Wheel Hub .................................................. 109

Installing Wheel Lock Bracket onto Wheelchair ........................................................................... 111

Removing Casters.................................................................................................................................. 112

Installing Casters.................................................................................................................................... 114

Replacing Forks ...................................................................................................................................... 116

Removing/Installing the SSD Motor/Gearbox Assembly .............................................................. 117

Replacing the SSD Motor or Gearbox Only................................................................................... 118

Aligning the SSD Motor to the Gearbox ......................................................................................... 119

Installing the SSD Brake Lever............................................................................................................ 120

Installing the SSD Motor Push/Drive Label ..................................................................................... 120

Installing/Removing Fenders................................................................................................................ 121

SECTION 12—ANTI-TIPPERS/SHOCKS ............................................ 123

Shock or Rubber Element Replacement .......................................................................................... 123

Shock Spring Replacement .................................................................................................................. 126

Anti-Tipper Wheel Replacement....................................................................................................... 128

Removing/Installing the 3-inch Anti-Tip Assembly......................................................................... 128

LIMITED WARRANTY ................................................................... 132


LABEL LOCATIONS

LABEL LOCATIONS

All Wheelchairs

� DANGERRisk of Death, Serious Injury or DamageMissing or damaged labels may contribute to injury, damage or death.—Ensure labels are present and legible. Replace if necessary.

LABELS ARE SUBJECT TO CHANGE WITHOUT NOTICE.NOTE: The battery labels shown on this page are found on the inside of the battery box lids.

Rear Battery Box Lid

Front Battery Box Lid

Group 24 Batteries Only

4 Pole Motors with Group 24 Batteries Only

Gearless Brushless GB™Motors with Group 24 Batteries Only

Elevate Systems with Group 24 Batteries Only


LABEL LOCATIONS

P/N

111

4835DRIVE

PUSH

DANGER

Suspension Arm Used with Conventional Motor/

Gearbox Assembly

Suspension Arm Used with Standard Gearless/Brushless

Motor

Suspension Arm Used with Gearless/Brushless Motor Shown

This stop MUST be in place BEFORE using. DO NOT remove.

1070497

WARNINGNOTE: Warning label also found on side frame near the front of the wheelchair.

Serial number label is located on the inside of the front or rear frame.


LABEL LOCATIONS

Wheelchairs with O2 Holders

Wheelchairs with TRRO

Wheelchairs without TRRO

ASBA Seats Captain’s Seats

NOTE: Also on opposite side.NOTE: Also on opposite side.

NOTE: Also on opposite side.

NOTE: Auto style seat positioning strap shown. This label is also on the airline style seat positioning strap.


SPECIFICATIONS

SPECIFICATIONSTorque SP (After 10/5/06)

*NOTE: Weight limitation is total weight (user weight plus any additional items that the user may require [back pack, ventilator, etc.]). Example: If weight limitation of the wheelchair is 300 lbs and additional items equal 25 lbs, subtract 25 lbs from 300 lbs. This means the maximum weight limitation of the user is 275 lbs.

Values for range are calculated for maximum chair weight rating using largest batteries applicable (GP24), per test procedures described in ANSI/RESNA WC/VOL2-1998 Section 4 and meet federal reimbursement requirements for this product. While considered typical, they are derived based on certain ideal conditions. Variances in battery condition, user weight, usage pattern or overall terrain conditions will result in actual values for range that differ from these stated values. Users should become accustomed to how their unique conditions impact their individual results. Users should become familiar with the battery discharge indicator on the joystick to determine the range of their wheelchair. Refer to When to Charge Batteries on page 89 for more information about the battery discharge indicator.

TORQUE SPSEAT-TO-FLOOR: Standard 17½-inches Optional 19¾ or 21 inches

OVERALL WIDTH OF BASE: (W/O JOYSTICK) 25 inches

OVERALL HEIGHTSTANDARD:MINIMUM:MAXIMUM:

34¼ inches34¼ inches44¼ inches

OVERALL LENGTHSTANDARD:LONG FRAME:

Without front riggings29½ inches32½ inches

WEIGHTWITHOUT BATTERIES:WITH GROUP 24 BATTERIES:SHIPPING (APPROX.):

154 lbs258 lbs194 lbs

DRIVE AXLE: Adjustable (Non-Recliners ONLY)

DRIVE WHEELS/TIRES: Foam filled or pneumatic14 x 3 inches (Std), 14 x 4 inches

CASTERS W/ PRECISION SEALED BEARINGSSEMI-PNEUMATIC:PNEUMATIC OR FOAM FILLED:

8 x 1¼ inches (Std), 6 x 2 inches with shock fork (Opt)8 x 2 inches (Std), 9 x 2¾ inches (Opt)

ANTI-TIPPER: 3-inch wheels (Std)

CASTER FORKS: Standard, Shock Fork (Opt)

SEAT ANGLE ADJUSTMENT: Adjustable (0° to 10°)

BATTERY REQUIREMENTS: Group 24

*WEIGHT LIMITATION: Up to 300 lbs

PERFORMANCERating:Speed:*Range:

Up to 300 lbs with 18:1 ratio 4 pole motorUp to 6½ mph

Up to 19


SPECIFICATIONS

For All Model WheelchairsOPERATING TEMPERATURE 122 F (50 C) Maximum to -13 F (-25 C) Minimum

STORAGE TEMPERATURE 149 F (65 C) Maximum to -58 F (-40 C) Minimum


SECTION 1—GENERAL GUIDELINES


� DANGERRisk of Death, Serious Injury or DamageImproper use of this product may cause injury or damage.If you are unable to understand the warnings, cautions or instructions, contact a health care professional or dealer before attempting to use this equipment.—DO NOT use this product or any available optional equipment without first completely reading and understanding these instructions and any additional instructional material such as user manual, service manuals or instruction sheets supplied with this product or optional equipment.Continued use of the wheelchair with damaged parts could lead to the wheelchair malfunctioning causing injury to the user and/or caregiver.—Check all wheelchair components and carton for damage and test components before use. In case of damage or if the wheelchair is not working properly, contact a qualified technician or Invacare for repair.—DO NOT use this product or any available optional equipment without first completely reading and understanding these instructions and any additional instructional material such as user manual, service manuals or instruction sheets supplied with this product or optional equipment.

Accessories

� WARNINGRisk of Serious Injury or DamageUse of non-Invacare accessories may result in serious injury or damage.Invacare products are specifically designed and manufactured for use in conjunction with Invacare accessories. Accessories designed by other manufacturers have not been tested by Invacare and are not recommended for use with Invacare products.—DO NOT use non-Invacare accessories.—To obtain Invacare accessories, contact Invacare by phone or at www.invacare.com.



G-Trac

� WARNINGRisk of Serious Injury or Damage Improperly connecting the motor leads to the controller may cause injury or damage.—WHEELCHAIRS WITH G-TRAC: Crossing the motor leads (for example: connecting the left motor lead into the right motor connector on the controller) may result in unintended movement.—DO NOT cross the motor leads when connecting the motors to the controller - otherwise injury or damage may occur.

Repair or Service Information

� DANGERRisk of Death, Serious Injury or DamageUse of incorrect or improper replacement (service) parts may cause death, serious injury, or damage.—Replacement parts MUST match original Invacare parts.—ALWAYS provide the wheelchair serial number to assist in ordering the correct replacement parts.

� WARNINGPOWERED SEATING SYSTEMS ONLY - Pinch point may occur when lowering the elevating seat and/or returning the tilted seat to the full upright position. Make sure the hands and body of both the occupant and attendants/bystanders are clear of all pinch points before lowering seat or returning the tilted seat to the full upright position.—Before adjusting, repairing or servicing the wheelchair, ALWAYS turn the wheelchair power OFF, otherwise, injury or damage may occur.

� CAUTION!Risk of DamageCleaning or maintenance may cause damage to carpeting or flooring.—Place the wheelchair in a well ventilated area where cleaning or maintenance can be performed without risk of damage to carpeting or flooring.



Operation Information

� WARNINGRisk of Serious Injury or DamageMoving the seating system from the factory setting may reduce driver control, wheelchair stability, traction and increase caster wear resulting in serious injury or damage.—Move the seating system ONLY when necessary to fit the wheelchair to the user.—If the seating system must be moved, ALWAYS inspect the wheelchair to ensure the front rigging DOES NOT interfere with the front casters.—If the seating system must be moved, ALWAYS inspect to ensure the wheelchair DOES NOT easily tip forward or backward.

� WARNINGRisk of Death, Serious Injury, or DamageContinued use of the wheelchair that is not set to the correct specifications may cause erratic behavior of the wheelchair resulting in death, serious injury, or damage.—Performance adjustments should only be made by professionals of the healthcare field or persons fully conversant with this process and the driver's capabilities. —After the wheelchair has been set up/adjusted, check to make sure that the wheelchair performs to the specifications entered during the set up procedure. If the wheelchair does not perform to specifications, turn the wheelchair Off immediately and reenter set up specifications. Contact Invacare, if wheelchair still does not perform to correct specifications.

� WARNINGRisk of Serious Injury or DamageAttaching hardware that is loosely secured could cause loss of stability resulting in serious injury or damage.—After ANY adjustments, repair or service and before use, make sure that all attaching hardware is tightened securely.



� WARNINGRisk of Injury or DamageTo avoid injury or damage from moving parts:—ALWAYS keep hands and fingers clear of moving parts.—Closely supervise children, pets or people with physical/mental disabilities.

� DANGERRisk of Death or Serious InjuryElectric shock can cause death or serious injury.—To avoid electric shock, inspect plug and cord for cuts and/or frayed wires. Replace cut cords or frayed wires immediately.

� WARNINGRisk of Minor to Serious InjuryPinch points can cause minor to serious injury.—Be mindful of potential pinch points and use caution when using this product.

� WARNING!Risk of Injury, Damage or DeathStorage or use near heat sources and combustible products may result in injury or damage.—DO NOT store or use wheelchair near open flames or other heat sources.—DO NOT store or use wheelchair near combustible products.



� WARNINGRisk of Injury, Damage or DeathMalfunctioning or damaged joystick may cause unintended/erratic movement resulting in injury, damage or death.—Ensure the joystick is securely connected to controller.—DO NOT use if joystick does not spring back to the neutral position or becomes sticky or sluggish.—DO NOT use if joystick boot is torn or damaged.—DO NOT use with a broken or missing control knob.—If unintended/erratic movement occurs, stop using the wheelchair immediately and contact a qualified technician.—Ensure control knobs are secure before using the wheelchair. Stop using the wheelchair immediately and contact a qualified technician if control knobs are not secure.

Wheelchairs with Powered Seating Systems Only

� WARNINGRisk of Death or Serious InjuryOperating the wheelchair with the seat tilted/reclined/back angle position beyond 20° can cause instability resulting in death or serious injury from the wheelchair tipping over.—NEVER operate the wheelchair or elevate/lower the seat while in any tilted/reclined/back angle position over 20° relative to the vertical position. If the drive lock-out does not stop the wheelchair from operating or the seat from elevating/lowering in a tilt/recline/back angle position over 20° relative to vertical, DO NOT operate the wheelchair or elevate/lower the seat. DO NOT attempt to adjust the drive lock-out. Have the wheelchair serviced by a qualified technician. —The wheelchair user MUST have a clear line of sight to drive safely. On initial chair delivery and after adjusting the back angle, drive lock-out switch tilt system or recline system, tilt and recline the seat back to the farthest driving position IMMEDIATELY before drive lock-out engages and ensure there is a clear line of sight present in which to drive the wheelchair. If a clear line of sight is not present, have the back angle repositioned or readjust the lockout angle such that safe driving with a clear line of sight is achieved.



� WARNINGRisk of Injury, Damage or DeathLoss of traction or stability on inclines/grades or ramps may cause injury, damage or death. Lighter weight users may be at an increased risk. Surfaces that that may be wet, icy, oily, slippery, painted, treated wood, rotten wood, rusted metal or other similar surfaces or materials may also increase risk.—DO NOT use on inclines or ramps where surface is uncertain or compromised. —Do not use on steep inclines greater than 9°.—Do not use on inclines where line of sight is impaired or with seat in reclined position.—Travel at a reduced, constant speed. Traveling at high speeds reduces traction and increases stopping distance.—Do not make sudden stops or hard brake.—Release the joystick and allow the wheelchair to come to a full stop if necessary while on an incline.—DO NOT drive in an elevated position while on an incline.—DO NOT leave elevating legrests in the fully extended position when proceeding down inclines/grades.—To determine and establish your particular safety limits, practice use of this product on various sloping surfaces in the presence of a qualified healthcare provider before attempting active use of this wheelchair.

—DO NOT leave an unoccupied wheelchair unattended on inclines or ramps.

Tire Pressure

� DANGERRisk of Injury, Damage or DeathOverinflation of tires may cause tires to explode.—Inflate tire to the proper tire pressure (P.S.I./ kilopascals) listed on the side wall of the tire.—Only use wheelchair with tires at proper tire pressure.—The wheels and tires should be checked periodically for cracks and wear and should be replaced if necessary.



Electrical

Grounding Instructions:

� WARNINGPower wheelchairs 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 replaced with a properly grounded three-prong wall receptacle in accordance with the National Electrical code. If you must use an extension cord, use only a three-wire extension cord having the same or higher elec-trical rating as the device being connected. DO NOT, under any circumstances, cut or remove the round grounding prong from any plug used with or for Invacare prod-ucts. In addition, Invacare has placed RED warning tags on some equipment. DO NOT remove these tags.

BatteriesNote: Failure to use the correct battery size and/or voltage may cause damage to your wheelchair and give you unsatisfactory performance. The warranty and performance specifications contained in this manual are based on the use of deep cycle gel cell batteries. Invacare strongly recommends their use as the power source for this unit.

Charging Batteries

� DANGERRisk Of Death, Injury, Or Damage Shock hazards and risk of fire exist due to use of improper extension cord and use of three prong adapters. —To avoid injury or product damage, when using an extension cord, use only a three wire extension cord having at least 16 AWG (American Wire Gauge) wire and the same or higher electrical rating as the device being connected.—DO NOT use three prong to two prong adapters.



� WARNINGRisk of Injury, Damage or DeathImproper charging may cause injury or damage.Charge battery in a cool, dry and well-ventilated area. —DO NOT attempt to charge the battery by attaching cables directly to the battery terminals.—DO NOT attempt to charge the battery and operate the wheelchair at the same time.—DO NOT attempt to charge the battery when the wheelchair has been exposed to any type of moisture.—DO NOT sit in the wheelchair while charging the battery.—Do Not leave the charger unattended when the breaker has tripped. Unplug and discontinue use immediately. Contact a qualified service technician or Invacare for service.—Read and follow the manufacturer's instructions for each charger (supplied or purchased). If charging instructions are not supplied, consult a qualified technician for proper procedures.

Rain Test

� CAUTIONRisk of DamageOperating the wheelchair in rain or dampness may cause the wheelchair to malfunction electrically and mechanically; may cause the wheelchair to prematurely rust or may damage the upholstery.—DO NOT leave wheelchair in a rain storm of any kind.—DO NOT use wheelchair in a shower.—DO NOT leave wheelchair in a damp area for any length of time.—Check to ensure that the battery covers are secured in place, joystick boot is NOT torn or cracked where water can enter and that all electrical connections are secure at all times. —DO NOT use if the joystick boot is torn or cracked. If the joystick boot becomes torn or cracked, replace IMMEDIATELY.

NOTE: Invacare has tested its wheelchairs in accordance with RESNA WC — 2:2009, Section 9 Part 7.3 “Rain Test”. This provides the end user or his/her attendant sufficient time to remove his/her wheelchair from a rain storm and retain wheelchair operation.



Weight Training

� WARNINGInvacare DOES NOT recommend the use of its wheelchairs as a weight training apparatus. Invacare wheelchairs have NOT been designed or tested as a seat for any kind of weight training. If occupant uses said wheelchair as a weight training apparatus, Invacare shall not be liable for bodily injury and the warranty is void.Shipping Securement Points

� WARNINGFrame end caps are only intended for manufacturer’s initial shipping securement points. They are not intended for any other use.

Front of Wheelchair

Rear of WheelchairBase

FrameFrame End Cap


SECTION 2—ELECTROMAGNETIC COMPATIBILITY (EMC) INFORMATION


� WARNINGCAUTION: IT IS VERY IMPORTANT THAT YOU READ THIS INFORMATION REGARDING THE POSSIBLE EFFECTS OF ELECTROMAGNETIC INTERFERENCE ON YOUR POWERED WHEELCHAIR.Electromagnetic Interference (EMI) From Radio Wave Sources Powered wheelchairs and motorized scooters (in this text, both will be referred to as powered wheelchairs) may be susceptible to electromagnetic interference (EMI), which is interfering electromagnetic energy (EM) emitted from sources such as radio stations, TV stations, amateur radio (HAM) transmitters, two way radios, and cellular phones. The interference (from radio wave sources) can cause the powered wheelchair to release its brakes, move by itself, or move in unintended directions. It can also permanently damage the powered wheelchair's control system. The intensity of the interfering EM energy can be measured in volts per meter (V/m). Each powered wheelchair can resist EMI up to a certain intensity. This is called its “immunity level”. The higher the immunity level, the greater the protection. At this time, current technology is capable of achieving at least a 20 V/m immunity level, which would provide useful protection from the more common sources of radiated EMI.There are a number of sources of relatively intense electromagnetic fields in the everyday environment. Some of these sources are obvious and easy to avoid. Others are not apparent and exposure is unavoidable. However, we believe that by following the warnings listed below, your risk to EMI will be minimized. The sources of radiated EMI can be broadly classified into three types:1) Hand-held Portable transceivers (transmitters-receivers with the antenna

mounted directly on the transmitting unit. Examples include: citizens band (CB) radios, “walkie talkie”, security, fire and police transceivers, cellular telephones, and other personal communication devices).

NOTE: Some cellular telephones and similar devices transmit signals while they are ON, even when not being used2) Medium-range mobile transceivers, such as those used in police cars, fire trucks,

ambulances and taxis. These usually have the antenna mounted on the outside of the vehicle; and

3) Long-range transmitters and transceivers, such as commercial broadcast transmitters (radio and TV broadcast antenna towers) and amateur (HAM) radios.

NOTE: Other types of hand-held devices, such as cordless phones, laptop computers, AM/FM radios, TV sets, CD players, cassette players, and small appliances, such as electric shavers and hair dryers, so far as we know, are not likely to cause EMI problems to your powered wheelchair.



� WARNINGPowered Wheelchair Electromagnetic Interference (EMI)

Because EM energy rapidly becomes more intense as one moves closer to the transmitting antenna (source), the EM fields from hand-held radio wave sources (transceivers) are of special concern. It is possible to unintentionally bring high levels of EM energy very close to the powered wheelchair's control system while using these devices. This can affect powered wheelchair movement and braking. Therefore, the warnings listed below are recommended to prevent possible interference with the control system of the powered wheelchair.Electromagnetic Interference (EMI) from sources such as radio and TV stations, amateur radio (HAM) transmitters, two-way radios, and cellular phones can affect powered wheelchairs and motorized scooters. FOLLOWING THE WARNINGS LISTED BELOW SHOULD REDUCE THE CHANCE OF UNINTENDED BRAKE RELEASE OR POWERED WHEELCHAIR MOVEMENT WHICH COULD RESULT IN SERIOUS INJURY.1) DO NOT operate hand-held transceivers (transmitters receivers), such as citizens band

(CB) radios, or turn ON personal communication devices, such as cellular phones, while the powered wheelchair is turned ON;

2) Be aware of nearby transmitters, such as radio or TV stations, and try to avoid coming close to them;

3) If unintended movement or brake release occurs, turn the powered wheelchair OFF as soon as it is safe;

4) Be aware that adding accessories or components, or modifying the powered wheelchair, may make it more susceptible to EMI (NOTE: There is no easy way to evaluate their effect on the overall immunity of the powered wheelchair); and

5) Report all incidents of unintended movement or brake release to the powered wheelchair manufacturer, and note whether there is a source of EMI nearby.

Important Information1) 20 volts per metre (V/m) is a generally achievable and useful immunity level against EMI

(as of May 1994) (the higher the level, the greater the protection);2) This device has been tested to a radiated immunity level of 20 volts per meter.3) The immunity level of the product is unknown.Modification of any kind to the electronics of this wheelchair as manufactured by Invacare may adversely affect the EMI immunity levels.

� CAUTIONRisk of Injury or Damage.EMC interference affecting other products may result in injury or damage.To avoid impacting the operation and function of other products:

—Products not specified by Invacare that may be used on or near the wheelchair may be impacted by emissions from this product if they have a sensitivity level that is lower than the recognized standard and provided by this wheelchair. Refer to the manufacturer specifications for any electronic device BEFORE use near this product to determine its level of immunity and potential risk.


SECTION 3—TROUBLESHOOTING


� WARNINGRisk of Serious Injury or DamageAttaching hardware that is loosely secured could cause loss of stability resulting in serious injury or damage.After ANY adjustments, repair or service and before use, make sure that all attaching hardware is tightened securely.

TroubleshootingNOTE: For additional troubleshooting information and explanation of error codes, refer to the individual electronics manual supplied with each wheelchair.

Wheels

WH

EELC

HA

IR V

EER

SLE

FT/R

IGH

T

SLU

GG

ISH

TU

RN

/PE

RFO

RM

AN

CE

CA

STER

SFL

UT

TER

SQU

EAK

S A

ND

RA

TT

LES

LOO

SEN

ESS

IN W

HEE

LCH

AIR

WH

EELC

HA

IR 3

WH

EELS

SOLUTIONS

X X X If pneumatic, check tires for correct and equal pressure.

X X X X Check for loose stem nuts/bolts.

X X Check that casters contact ground at the same time.



Troubleshooting—Wiring Harness

SYMPTOM PROBABLE CAUSE SOLUTIONS

No power to wheelchair motors.

Bad connection or blown fuse. Check Joystick connection.

Check all connections and housings for damage. Replace fuse if blown.

Loose battery connections Check battery cable connections, they may have vibrated loose when driving on rough terrain.

E28 Error code.

Charger still plugged in when user tries to drive the wheelchair.

Unplug charger to drive wheelchair.

Drive lockout condition in high back van seat, recliners, and power seating systems.

Return to proper seat and back angle. Re-calibrate mercury switch or reconnect wiring (may have come loose). Check POT calibration or mercury switch on chairs equipped with power seating.

Damaged controller connections. Repair connection, or clean contacts.

E09 and E10 Error codes.

Engage motors and check motor connections.

Check motor connectors. If damaged, repair or replace. Ohm out motors and brakes.

No LED’s on DPJ/SPJ Joystick

Tiller harness unplugged. Joystick connection to controller unplugged or damaged.

Plug connections back together, and check for damaged wiring.

Corroded battery wiring connections.

Possible water, salt, or urine damage.

Replace battery wiring harness.



Troubleshooting—Motor/Gearbox/Brake


Motor makes a clicking noise.

Bad bearings, bad brushes or bad gears.

Replace motor or separate motor and gearbox. Replace gearbox or motor/gearbox.If bearings are bad, replace motor.

Raised commutator plate inside of motor.

Remove brushes and inspect commutator.

Grinding noise or motor is locking up.

Bad gearbox. Replace gearbox.

Motors stall and starts up again.

Current rollback. Leave power on; leave chair in stopped position for 30 minutes. Turn chair off and then back on.

Chair will not drive with power on (E09 or E10).

Check motor locks. Engage motor locks to drive wheelchair.

Motor chatters or runs erratically, or only one motor turns.

Damaged connector or worn brushes. Bad bearings or gears.

Check brushes and replace brushes if necessary.

Joystick malfunction. Swap out motor leads. Check for error codes with programmer. Calibrate joystick. Look for bad wiring.

Wheelchair veers to the left or right when driving on level surface.

Uneven tire pressure. Inflate tires. Replace tires if worn.

Motors out of balance. Use programmer to balance motors (2/4-Pole only).

Joystick needs to be calibrated. Re-calibrate joystick with programmer or replace inductive if necessary.

E09/E10 error code will not go away.

Bad motor connection.Bad brake coil.

Check all connections. Ohm out each brake coil. Normal reading is 40-80 Ohms.

Brake dragging causing chair to veer.

Bad brake coil, or connection. On early 2-Pole motors if the brake lever is bent, it may be rubbing on the brake pad.

Replace brake coil.

Gearbox is leaking Fluid.

Bad seal around drive shaft orLoose hardware.

If seal is bad, replace gearbox. Remove motor brushes and inspect for grease contamination. Replace motor if contamination is found.If loose hardware is found retighten hardware.

Excessive clicking coming from motor/gearbox.

Bad bearing in motor or gearbox. Replace motor or gearbox.

Loose wheel hardware. Tighten hardware, (use removable Loctite™on hardware). Follow torque settings in this manual.

Gearbox shaft movement or bent shaft.

Rough driving. Replace gearbox.

Motor Stutters.Poor connection or worn brushes. Check Anderson connectors. Check brushes and

replace if necessary.



Motor Fails to start after initial installation.

Battery voltage is too low. Check batteries and recharge if necessary.

Motor is wired improperly. Verify wiring to motor from controller.

Switch motor leads. Check for error codes.

Motor is running then fails to restart when stopped.

Heavy load on the motors forcing controller into the current rollback mode.

Leave power on and allow controller to count down. Turn chair on and let chair sit for 30 minutes. AFter 30 minutes, turn chair off and then on.

Circuit breaker may have tripped. Reset breaker and check wiring.

Motor connector, joystick problem, battery voltage, seating system, brake lever slipped into freewheel.

Check for error code.Check brake lever.Restart wheelchair.

Worn out brushes. Replace brushes.

Controller power stage board or relays may be damaged.

Check for error code. Turn chair on and off.

Motor runs but loses power.

Controller senses heavy load and has entered the current rollback mode.

Stop driving and let electronics cool.

Wheelchair loses all power while driving.

Blown fuse; dead battery. Test for proper voltage, charge batteries.

Brake code error on joystick

Bent lever or internal damage. Replace the brake.

Bad micro switch or out of adjustment.

Repair micro switch, readjust switch or replace brake coil (motor).




Troubleshooting—Battery Charger

Troubleshooting—Battery


Batteries won’t charge.

Old batteries lose connection. Test battery with charger plugged in. Charger won’t charge if less than 12 volts combined on batteries.

Short Charge Time.

One or both batteries may be bad (if batteries charge up to soon).

Check each battery and replace if needed.

No LED’s on Charger.

Charger not plugged into outlet, or disconnected from wiring harness on wheelchair.

Make sure the charger is plugged into the outlet and check the wiring on the wheelchair.

No AC power at outlet. Check for AC power with digital volt meter.

Power cord may be damaged. Check for damage on the power cord, replace if damaged or send in for repair.

Charger may have internal fuse that is blown.

Remove charger cover and check for fuses. If fuses are present Ohm out fuses and replace if necessary.


Batteries won’t charge.

Blown battery fuse in wiring harness, or charger.

Check all fuses on the chair, and in the charger.

Charger not plugged into outlet. Make sure charger is plugged into the outlet.

No AC power at the outlet. Check for AC power with a digital volt meter.

Charger Power cord may bedamaged, or the connector may be damaged.

Check for damage and replace if necessary, or send in for repair.

Battery voltage too low to charge. Test voltage and change batteries if voltage is too low.

Batteries have short driving range during a single charge. Battery Gauge falls off faster than normal.

Consumer not charging batteries long enough.

Instruct consumer to charge for 8-10 hours minimum.

Batteries may be weak. Perform load test or check “Battery Quality Menu” with the programmer. Refer to MKIV electronics manual, part number 1043576.

Check programming settings. Torque setting and power level setting may be too high. Refer to MKIV electronics manual, part num-ber 1043576.

Heavy load on motors. Chairs weight distribution may be offset (wheelchair may be front loaded).

E28 Error code.Charger still plugged in when user tries to drive the wheelchair.

Unplug charger to drive wheelchair.

Batteries have swelled up.

Batteries have been overcharged. Check or replace batteries. Some swelling in Gel Batteries is normal.

Batteries are leaking, (wet lead acid type).

Overcharged or loose caps. Check and Replace batteries.



Troubleshooting—ElectricalNOTE: For additional troubleshooting information and explanation of error codes, refer to the individual Electronics Manual supplied with each wheelchair.

All Wheelchairs

SYMPTOM PROBABLE CAUSE SOLUTIONSBatteries draw excessive current-when charging.

Battery failure.

Electrical malfunction.

Check batteries for shorted cell.Replace if necessary (Refer to Charging Batteries on page 90).

Contact Dealer/Invacare for Service.

Battery indicator flashes the charge level is low—immediately after recharge.

Battery failure.

Malfunctioning battery charger.


Check batteries for shorted cell.Replace if necessary (Refer to Charging Batteries on page 90).

Contact Invacare for Service.

Poor connections between charger/wheelchair. Contact Dealer/Invacare.

Battery indicator flashes the charge level is low—too soon after being recharged.

Batteries not charged.Weak batteries.

Old Batteries. Batteries sat too long without charge. Replace batteries.

Have charger checked.Replace batteries if necessary.


Motor “chatters” or runs irregular. Electrical malfunction. Contact Dealer/Invacare for Service.

Only one drive wheel turns. Electrical malfunction.

Motor is locked up, stuck.


Separate motor and gearbox (Except GB).

Chair erratic or does not respond as desired.

Damaged motor coupling.


Controller programmed improperly.



Reprogram controller. (Refer to electronics manual supplied with wheelchair).

Wheelchair does not respond to commands.

Power indicator OFF—even after recharging.

Bad Joystick.

Batteries did not charge.Joystick cable is not plugged in.

Calibrate Joystick, replace if necessary.

Test for 24 volts.Plug in joystick.



Wheelchairs with Powered Seating Systems

NOTE: For additional troubleshooting information and explanation of error codes, refer to the individual Electronics Manual supplied with each wheelchair.


Wheelchair Power ON but does not drive

System tilted, reclined or elevated beyond drive lock-out angle (20°).

Return to neutral position (upright and completely lowered). Refer to Operating Powered Seating Systems in the user manual.Contact Invacare/Dealer for service if this does not solve the problem.

Seating system not functioning or working intermittently.

Low batteries.

Faulty electrical connection.

Blown fuse.

Limit switch or switches preventing seating.

Charge batteries.

Check all connections.

Have wiring harness replaced by a qualified technician.

Trouble shoot limit switches for position and connectivity.

Programmer does not work or gives “communication error”.

System tilted, reclined or elevated beyond drive lock-out angle (20°).

Return to neutral position (upright and completely lowered). Refer to Operating Powered Seating Systems in the user manual.Contact Invacare/Dealer for service if this does not solve the problem.

Wheelchair drives at reduced speed. Seating system is elevated. Completely lower the seat.



SPJ™+, SPJ+ w/PSS or SPJ+ w/ACC Joysticks

The joystick information gauge and the service indicator give indications of the type of fault or error detected by the control module. When a fault is detected, the wheelchair may stop and not drive. The LEDs on the information gauge may flash in a particular pattern or the service indicator light will flash. The number or type of flashes indicates the nature of the error. If multiple errors are found, only the first error encountered by the control module will be displayed.

Information Gauge Display Diagnostics

DISPLAY DESCRIPTION DEFINITION COMMENTS

All LEDs are off. Power is off.

All LEDs are on. Power is on. Fewer than three LEDs on implies reduced battery charge.

Left RED LED is flashing. Battery charge is low. The batteries should be charged as soon as possible.

Left to Right “chase” alter-nating with steady display.

Joystick is in program-ming, inhibit and/or charg-ing mode.

The steady LEDs indicate the current state of the battery charge.

All LEDs are flashing slowly. Joystick has detected Out-of-Neutral at Power-Up mode.

Release the joystick back to Neutral.

Information Gauge Display



Service Indicator Light Diagnostics

MPJ™+, PSR+, PSF+ Joysticks or Displays

NUMBER OF

FLASHES

ERROR CODE DESCRIPTION POSSIBLE SOLUTION

1 User Fault Release joystick to neutral and try again.

2 Battery Fault Charge the batteries. Refer to Charging Batteries on page 90.Check that battery cables are connected properly. Refer to Disconnecting/Connecting Battery Cables on page 84.If necessary, replace batteries.Refer to Replacing Batteries on page 92.

3 Left Motor Fault Contact Invacare/dealer for service.

4 Right Motor Fault Contact Invacare/dealer for service.

5 Left Park Brake Fault Contact Invacare/dealer for service.

6 Right Park Brake Fault Contact Invacare/dealer for service.

7 Remote Fault Check to make sure joystick is connected properly.Contact Invacare/dealer for service.

8 Controller Fault Contact Invacare/dealer for service.

9 Communications Fault Contact Invacare/dealer for service.

10 General Fault Contact Invacare/dealer for service.

11 Incompatible or incorrect remote

Wrong type of remote connected. Contact Invacare/Dealer for service.


� SPM L Park Brake Fault or

� SPM R Park Brake Fault displays and wheelchair does not drive.

Brake lock levers disengaged (Error code E9 or E10).

Engage brake lock levers.

CHARGER PLUGGED IN displays. Battery charger connected (Error code E28).

Unplug battery charger from the wheelchair.

� SPM Battery Fault displays and the wheelchair does not drive.

Batteries need to be charged (Error code E14).

Charge batteries. If batteries fail to charge properly, check battery charger or replace batteries.

� JOYSTICK TIMEOUT displays and the wheelchair does not drive.

Joystick or input device is disconnected (Error code 32).

Turn off power, reconnect the joystick of input device and turn power on.

� JS REV TOO LARGE

� JS FWD TOO LARGE

� JS LFT TOO LARGE or

� JS RGT TOO LARGEdisplays and the wheelchair does not drive.

The joystick or input device is sending a value outside of the reverse, forward, left or right limits (Error codes E01, E02, E03 or E04).

Replace joystick or input device.

NEUTRAL TESTING displays. The joystick neutral test has failed (Error code E18).

Release the joystick and try to get the joystick back into the center-most position.



� BAD JOYSTICK CAL VALUES displays and the wheelchair does not drive.

The joystick calibration values are outside of the expected range (Error code E19).

Re-calibrate the joystick (joystick throw procedure).

� SPM NOT CONNECTED The MPJ or Display module is not communicating with the control module (Error code E200).

Check the connections between the joystick or display and the controller. Turn the power off and then back on. Replace the controller if necessary.

� SPM Communications Fault displays and the wheelchair drives slowly.

The controller has determined a fault during a previous turn-off process (Error code E41).

Turn the wheelchair off and back on.

ATTENDANT ACTIVE

and displays.

The Proportional or Digital Attendant control is active and can be used to drive the chair (Error code W05).

This is normal behavior.

Batteries draw excessive current when charging.

Battery failure.


Have batteries checked for shorted cell. Replace if necessary.

Contact dealer/Invacare for service.

Battery indicator flashes the charge level is low—immediately after recharge.

Battery failure.

Malfunctioning battery charger.


Check batteries for shorted cell. Replace if necessary.

Contact dealer/Invacare for Service.

Contact dealer/Invacare for Service.

Battery indicator flashes the charge level is low—too soon after being recharged.

Batteries not charged.

Weak batteries.

Have charger checked.

Replace batteries if necessary. Contact Dealer/Invacare for Service.

Motor “chatters” or runs irregular. Electrical malfunction. Contact Dealer/Invacare for Service.

Wheelchair erratic or does not respond as desired.

Damaged motor coupling.


Controller programmed improperly.



Contact Dealer/Invacare to have controller reprogrammed.

Wheelchair does not respond to commands.

Bad joystick. Calibrate Joystick or replace.

Power indicator off—even after recharging.

Blown fuse or bad connection. Test battery voltage and check wiring connections.




Checking Battery Charge LevelThe following “Do’s” and “Don’ts” are provided for your convenience and safety.

Field Load TestNOTE: For this procedure, refer to FIGURE 3.1 on page 35.

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 more than 1.0 volts under load (2.0 for a pair), replace the batteries.

Testing under load is the only way to spot this problem. While special battery load testing equipment is available, it is costly and difficult to transport.

Use a digital voltmeter to check battery charge level at the charger connector. It is located on the base of the wheelchair frame.NOTE: Read the instructions carefully before using the digital voltmeter.

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

1. Ensure that power is Off.

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

3. Remove the footrests from the wheelchair and place the casters of the wheelchair against a wall, workbench or other stationary object.

DO DON’T

Read and understand this manual and any service information that accompanies a battery and charger before operating the wheelchair.

Don’t perform any installation or maintenance without first reading this manual.

Move the wheelchair to a work area before opening battery box or installing service batteries.

Don’t perform installation or maintenance of batteries in an area that could be damaged by battery spills.

Recharge as frequently as possible to maintain a high charge level and extend battery life.

Don’t make it a habit to discharge batteries to the low-est level.

Follow recommendations in this manual when select-ing a battery or charger.

Don’t use randomly chosen batteries or chargers.

Fully charge new batteries before using. Don’t put new batteries into servcie before charging.

Use a carrying strap to remove, move or install a bat-tery.

Don’t tip or tilt batteries.

Push battery clamps on the terminals. Spread clamps wider if necessary.

Don’t tap on clamps and terminals with tools.

Use ONLY a GEL charger for a GEL battery or “Sealed” battery.

Don’t mismatch your battery and chargers.



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

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

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

NOTE: If the voltage drops to less than 23.5 volts from a pair of fully charged batteries while under load, they should be replaced regardless of the unloaded voltages. FIGURE 3.1 Field Load Test

Motor TestingNOTE: For this procedure, refer to FIGURE 3.2.

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

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

2. Set the digital multi-meter to measure ohms (Ω).

3. Measure the resistance between the two 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.

FIGURE 3.2 Motor Testing

Digital Voltmeter

Battery Charger Connector

(+)

(-)

Ohmmeter

Ohmmeter

Motor Connector



Motor Brush InspectionNOTE: For this procedure, refer to FIGURE 3.3.

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

There are two contact brushes on STORM motors located under the brush caps on the motor housing. If these caps are hard to remove they are either overtightened or the motor has become very hot. Let motors cool. If caps still cannot be removed, it is recommended that the motor be sent to Invacare Technical Services for inspection/repair.NOTE: It is very important to note which way the brush comes out of the motor. The brush MUST be placed into the motor exactly the same way to ensure good contact with the commutator.

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

FIGURE 3.3 Motor Brush Inspection

Electro-Mechanical Parking Brake TestingNOTE: For this procedure, refer to FIGURE 3.4 on page 37.

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 multi-meter to read ohms (Ω).

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

4-Pin Motor Connector

CapMotor



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

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

FIGURE 3.4 Electro-Mechanical Parking Brake Testing

4-Pin Motor ConnectorOhmmeter


SECTION 4—ARMS

SECTION 4—ARMS


Installing/Removing Flip Back Armrests

� WARNINGMake sure the flip back armrest release and height adjustment levers are in the locked position before using the wheelchair.

NOTE: For this procedure, refer to FIGURE 4.1 on page 39.

NOTE: Flip back armrest release lever MUST be in the unlocked (horizontal) position when placing the armrest into the arm sockets.

Installing

1. Visually inspect to ensure flip back armrest release lever is in the unlocked (horizontal) position.

2. Slide the flip back armrest into the arm sockets on the seat frame.

3. Install the quick release pin through the rear arm socket and flip back armrest.

4. Lock the flip back armrest by pressing the flip back armrest release lever into the locked (vertical) position.

5. Repeat STEPS 1-4 for the opposite flip back armrest.

Removing

1. Unlock the flip back armrest by positioning the flip back armrest release lever into the unlocked (horizontal) position.

2. Remove the quick release pin that secures the flip back armrest to the rear arm socket.

3. Pull up on the flip back armrest and remove the armrest from the arm sockets.

4. Repeat STEPS 1-3 for the opposite flip back armrest, if necessary.


SECTION 4—ARMS

FIGURE 4.1 Installing/Removing Flip Back Armrests

Adjusting Flip Back Armrests

� WARNINGMake sure the flip back armrest release and height adjustment levers are in the locked position before using the wheelchair.


Positioning Flip Back Armrests for User Transfer

1. Unlock the flip back armrest by pulling the armrest release lever into the up (horizontal) position.

2. Pull up on the flip back armrest and remove the armrest from the front arm socket.

3. Continue to pull up on the flip back armrest until the armrest is out of the way.

4. Repeat STEPS 1-3 for opposite flip back armrest, if necessary.

Positioning Flip Back Armrests for Use

1. Make sure the flip back armrest release lever is in the up (horizontal) position.

2. Install the flip back armrest into the front arm socket.

3. Lock flip back armrest by pressing flip back armrest release lever into the down (vertical) position.

4. Lift up on flip back armrest to make sure the armrest is locked in place.

5. Repeat STEPS 1-4 for opposite flip back armrest, if necessary.

Flip Back Armrest

Rear Arm

Socket

Quick Release Pin

Front Arm Socket

Seat Frame

Unlocked (Horizontal)

Locked (Vertical)

Flip Back Armrest Release Lever


SECTION 4—ARMS

Adjusting

1. Unlock top of flip back armrest by pulling height adjustment lever into the up (horizontal) position.

2. Adjust top of the flip back armrest to the desired height.

3. Lock top of flip back armrest by pushing height adjustment lever into the down (vertical) position.

FIGURE 4.2 Adjusting Flip Back Armrests

Height Adjustment

Lever

Flip Back Armrest

Locked (Vertical)

Unlocked (Horizontal)


SECTION 5—UPHOLSTERY/ POSITIONING STRAP

SECTION 5—UPHOLSTERY/POSITIONING STRAP


Replacing Back UpholsteryNOTE: For this procedure, refer to FIGURE 5.1 on page 42.

NOTE: This procedure is for ASBA seats ONLY.

1. Remove one armrest from the wheelchair. Refer to Installing/Removing Flip Back Armrests in SECTION 4 of the User Manual, part number 1104782 or 1123757.

2. Remove the two mounting screws and locknuts that secure the spreader bar to the back canes.

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

4. Cut the tie-wraps that secure the bottom of the existing back upholstery to theback 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 of the mounting screws, washer, spacer, and locknut that secures the back cane to theseat frame.

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

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

7. Slide the back cane out of the spreader bar (if applicable) and the existingback upholstery.

8. Remove other armrest from the chair. Refer to Installing/Removing Flip Back Armrests on page 38.

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

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



11. Slide one 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 mounting screws, washers, spacers, and locknuts. Use Loctite® 242 and torque to 75 in-lbs (6.25 ft lbs) (8.47 Nm).

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 existing mounting screws.

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

NOTE: Spreader bar required on all back heights.

15. Reposition the spreader bar at the correct height for the corresponding back height and torque the mounting hardware to 60 in-lbs (5 ft-lbs) (6.78 Nm).

16. Reinstall the armrests onto the wheelchair. Refer to Installing/Removing Flip Back Armrests on page 38.

FIGURE 5.1 Replacing Back Upholstery

BACK HEIGHT SPREADER BAR HEIGHT

16 - 17 inches 5 inches

18 - 26 inches 7 inches

Washer Locknut

Mounting Screw

Washer

Mounting ScrewsTorque to 75 In-Lbs

(6.25 ft lbs) (8.47 Nm)

Mounting ScrewTorque to 60 in-lbs(5 ft-lbs) (6.78 Nm)

Locknut

Back Cane

Back Upholstery

Insert

Spreader Bar

Spacer



Removing/Installing the Back CanesNOTE: For this procedure, refer to FIGURE 5.2 on page 44.

NOTE: Existing hardware will be reused.

NOTE: Take note of position and orientation of mounting hardware for reinstallation.

Removing

1. If applicable, remove the back pan.

2. Remove armrest from the wheelchair. Refer to the wheelchair user manual.

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

3. For proper installation, note the mounting position of the upper hex screw securing the cane bracket to the back cane.

4. Remove the upper hex screw, washer and locknut securing the cane bracket to the back cane.

5. Remove the lower hex screw, washer and locknut securing the cane bracket to the back cane.

6. Remove the back cane from the wheelchair.

7. Repeat STEPS 2 - 6 for the opposite back cane.



InstallingNOTE: If replacing back canes, discard existing back canes and perform this procedure using new back canes.

1. Install the lower hex screw, washer and locknut through the slot in the cane bracket to secure the cane bracket to the back cane.

NOTE: The cane bracket should be positioned as shown in FIGURE 5.2.

2. Install the upper hex screw, washer and locknut through one of the following:

• Using the Same Back Angle - the mounting hole noted in STEP 3 of Removing on page 43.

• Changing the Back Angle - the mounting hole determined in Back Angle Adjustment on page 79.

3. Torque both locknuts to 156 in lbs (13 ft-lbs) (17.62 Nm).

4. Repeat STEPS 1 - 3 for the opposite back cane.

5. Reinstall the flip back armrest onto the wheelchair. Refer to the wheelchair user manual.

6. If applicable, install the back pan.

FIGURE 5.2 Removing/Installing the Back Canes

Lower Hex Screw

Upper Hex Screw

Washers

Cane Bracket

Back CaneLocknuts

Slot


SECTION 6—FIXED AND ASBA SEAT FRAME



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 SECTION 14 of this manual.

Preparation for Removing/Installing Seat FrameNOTE: For this procedure, refer to FIGURE 6.1 on page 46.

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

1. Remove footrest assemblies. Refer to the wheechair user manual.

2. Remove battery boxes. Refer to Removing/Installing Battery Boxes on page 93.

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 of the following:

• FIXED ASBA OR ADJASBA, - Remove the flip-back armrests from the wheelchair. Refer to Installing/Removing Flip Back Armrests on page 38.

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

7. If necessary, remove the seat pan (including seat positioning straps). Refer to Removing/Installing Seat Pan on page 56.

8. Disconnect battery and left/right motor connectors from the controller. Refer to Removing/Installing the Wiring Harness on page 101.

9. Remove tie-wraps that secure the wiring harness to the seat frame and the charger cable from its mounting bracket. Refer to Removing/Installing the Wiring Harness on page 101.

10. If necessary, remove the back upholstery (including back canes and spreader bar, if applicable). Refer to Replacing Back Upholstery on page 41.



FIGURE 6.1 Preparation for Removing/Installing Seat Frame

Replacing the Seat FrameNOTE: For this procedure, refer to FIGURE 6.2 on page 47.

NOTE: This procedure is for replacing the same size seat frame only. Refer to the procedures below to change seat size:

• Changing Seat Depth on page 48.

• Changing Seat Width (Standard and Asba) on page 52.

1. Perform the instructions outlined in Preparation for Removing/Installing Seat Frame on page 45.

Battery Boxes (Step 2)

Footrest Location (Step 1)

Joystick (Steps 3, 5)

Adjustment Lock Lever for Joystick

(Step 4)

Flip Back Armrest (Step 6A)

Seat Pan (Step 7)

Controller, Left/Right Motor Connectors (Steps 8, 9)

Seat Positioning Strap (Step 7)

Back Upholstery (Step 10)

Height Adjustment Holes

Van Seat Base

Socket Screw



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

3. Remove the existing standard seat frame.

4. Position new standard seat frame subassembly on seat mount plates.

5. Secure new standard seat frame subassembly onto seat mounting plates with the existing four mounting screws, locknuts and spacers, if applicable. Torque to 156 in-lbs (13 ft lbs) (17.62 Nm).

6. Remove the existing standard seat frame subassembly and install the new standard frame.

7. FOR 12 TO 15-INCH ASBA 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 Brackets on page 74.

8. Reinstall the components previously removed in STEP 1. Perform the instructions outlined in Preparation for Removing/Installing Seat Frame on page 45.

FIGURE 6.2 Replacing the Seat Frame

Fixed Seat Frame

Mounting Screws (Torque to 156 in-lbs)(13 ft lbs) (17.62 Nm)

Spacer (16-Inch Wide Only)

LocknutsBase Frame

Seat Mounting Plate



Changing Seat Depth

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

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.


• If the current seat depth and the desired seat depth is within the 12 to 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 on page 48.

• If the desired change only requires a new seat pan, refer to Removing/Installing Seat Pan on page 56.

• For all other seat depth changes, perform the following:

• Preparation for Removing/Installing Seat Frame on page 45.

Perform one, or both of the procedures listed below depending on the components required for the desired seat depth determined from STEPS 1-5:

• Removing/Installing CJ Back Brackets on page 74.

• Removing/Installing Seat Pan on page 56.

After completing the procedure(s) listed above, perform the steps outlined in Preparation for Removing/Installing Seat Frame on page 45.

SEAT FRAME COMPONENTS

SEAT DEPTH CJ BACK BRACKETS REQUIRED

SEAT PAN SEAT FRAME DEPTH

12-INCHES TO 15-INCHES

YES 17-INCH 16-INCH DEEP

16-INCHES NO 16-INCH 16-INCH DEEP







ASBANOTE: For this procedure, refer to FIGURE 6.3 on page 50.

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

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 to 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 on page 48.

If the desired change only requires a new seat pan, refer to Removing/Installing Seat Pan on page 56.

If the desired change requires the removal/installation of CJ back brackets, refer to Removing/Installing CJ Back Brackets on page 74.

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

A. Perform the instructions outlined in Preparation for Removing/Installing Seat Frame on page 45.

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

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

C. Remove the side frame from the center frame.

SEAT FRAME COMPONENTS

SEAT DEPTH CJ BRACKETS REQUIRED

SEAT PAN SIDE FRAME CENTER FRAME

12-inches to 15-inches YES 17-inch Short Short

16-inches NO 16-inches Short Short

17-inches NO 17-inches Short Short

18-inches NO 18-inches Medium Short

19-inches NO 19-inches Medium Short

20-inches NO 20-inches Long Long

21-inches NO 21-inches Long Long

22-inches NO 22-inches X-Long Long



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

NOTE: 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 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 mounting screws and locknuts. Torque to 156 in-lbs (13 ft-lbs) (17.62 Nm).

H. Secure new side frame to the center frame at the position noted previously. Torque to 75 in-lbs (6.25 ft-lbs) (8.47 Nm).

NOTE: If seat width adjustment is also desired, refer to Changing Seat Width (Standard and Asba) on page 52 for mounting hole locat ions and allowable seat width/seat depth combinations.

FIGURE 6.3 Changing Seat Depth - ASBA

Mounting Screws (Torque to 156 in-lbs)(13 ft-lbs) (17.62 Nm)

Support Brackets

Locknuts

Center Frame

Mounting Screws (Torque to 75 In-Lbs.)(6.25 ft-lbs) (8.47 Nm)

Covered Washers

Side Frame

Side Frame

Spacers



Changing Seat Depth Between 12 and 15 InchesNOTE: For this procedure, refer to FIGURE 6.4 on page 52.NOTE: There are two 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.

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

If the seat depth required is NOT within the seat depth range of the original CJ back brackets, the CJ back brackets must be replaced before repositioning the back canes. Refer to Removing/Installing CJ Back Brackets on page 74.

1. Remove the armrests from the wheelchair. Refer to Installing/Removing Flip Back Armrests in the User Manual, part number 1104782 or 1123757.

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 on page 79.

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 in-lbs.

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

11. Reinstall the armrests onto the wheelchair. Refer to Installing/Removing Flip Back Armrests in the User Manual, part number 1104782 or 1123757.



FIGURE 6.4 Changing Seat Depth - Changing Seat Depth Between 12 and 15 Inches

Changing Seat Width (Standard and ASBA)

Fixed Seat FrameNOTE: If changing seat width below 16-inches wide, you must convert from a fixed frame to an ASBA. Refer to Removing/Installing Seat Pan on page 56. For all changes above 16-inches wide, perform the outlined steps.


2. Remove the existing fixed seat frame subassembly and install the new fixed frame.

3. FOR 12 TO 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 Brackets on page 74.

4. Reinstall the components previously removed in STEP 1. Perform the instructions outlined in Preparation for Removing/Installing Seat Frame on page 45.

ASBANOTE: For this procedure, refer to FIGURE 6.5 on page 54.

NOTE: If changing seat width above 16-inches wide, you must convert to a standard seat frame. Removing/Installing Seat Pan on page 56. For all changes below 16-inches wide, perform the outlined steps.

Mounting Screws

Washers

Covered Washers Back Cane

Threaded Insert

Seat Frame




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

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 mounting screws, coved washers, spacers, and locknuts that secure the side frame to the center frame.

4. Adjust side frame to desired width determined from STEP 2. See DETAIL “A” for proper mounting hole position.

5. Secure side frame to center frame with existing mounting screws, coved washers, spacers, and locknuts. Torque mounting screws to 75 in-lbs (6.25 ft-lbs)(8.47 Nm).

� WARNINGBoth side frames MUST be adjusted to the same mounting hole position to main-tain 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.


• For adjusting the seat width only, perform the instructions outlined in Preparation for Removing/Installing Seat Frame on page 45.

NOTE: When performing the steps outlined in Preparation for Removing/Installing Seat Frame on page 45 the seat pan, seat cushion, back upholstery and spreader bar (if applicable), will need to be replaced. Spreader bars are only required on seat depths greater than 19-inches.

SEAT WIDTH

SEA

T D

EPT

H12 12 13 14 15 16

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 ✓ ✓ ✓



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

FIGURE 6.5 Changing Seat Width - ASBA

Replacing Components of the ASBA Seat1. Perform the instructions outlined in Preparation for Removing/Installing Seat Frame

on page 45.

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 mounting screws, coved spacers, spacers, and locknuts that secure the side frame to the center frame.


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

• If opposite side frame needs replaced, repeat STEP 2, then proceed to STEP 6. Otherwise proceed to STEP 6.

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

Locknuts

Center Frame

Mounting ScrewsCovered Washers

Side Frame

Spacers

DETAIL “A”

Steps 3-6

12 Inches

13 Inches14 Inches

15 Inches

16 Inches



5. Secure new center frame to support brackets with existing four mounting screws and locknuts. Torque to 156 in-lbs (13 ft-lbs)(17.62 Nm).

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

6. Install new/existing side frame(s) into new/existing center frame at the mounting position previously noted. Torque to 75 in-lbs (6.25 ft lb)(8.47 Nm).


FIGURE 6.6 Replacing Components of the ASBA Seat

Support Bracket

Locknuts

Base Frame

Mounting Screws (Torque to 156 In-lbs)(13 ft-lbs)(17.62 Nm)

Mounting Plate

Support Bracket

Mounting Screws (Torque to 156 In-lbs)(13 ft-lbs)(17.62 Nm)



Removing/Installing Seat PanNOTE: For this procedure, refer to FIGURE 6.7 on page 57.

Fixed Frame or ASBA

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 the user manual, part number 1104782 or 1123757.

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

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

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 6.7 for proper orientation. Repeat for other seat positioning strap.

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

3. Reinstall the remaining mounting screws, locknuts, and spacers. Torque all mounting screws to 75 in-lbs (6.25 ft-lb)(8.47 Nm).

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


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

• Reinstall the flip-back armrests from the wheelchair. Refer to Installing/removing Flip Back Armrests in the user manual, part number 1104782 or 1123757.



FIGURE 6.7 Removing/Installing Seat Pan

Spacer

Mounting Screws

Locknut

Seat Pan

Locknut

Seat Frame

Quick Release Pin

Seat Positioning Strap

Tab



Adjusting the Seat Pan - ADJASBANOTE: For this procedure, refer to FIGURE 6.8 on page 58.

Removing

1. Remove the seat cushion.

2. Remove the two socket screws securing the seat pan to the seat frame.

3. Remove the seat pan from the seat frame.

Installing

1. Position the new seat pan onto the seat frame as shown.

2. Secure the new seat pan to the seat frame using the two socket screws.

3. Install the seat cushion.

FIGURE 6.8 Adjusting the Seat Pan - ADJASBA

Seat Angle AdjustmentNOTE: For this procedure, refer to FIGURE 6.9 on page 59.

NOTE: The angle of the seat is factory set at 5° seat dump. This angle can be changed by adjusting either the front or back of the seat mount plate to obtain any angle between 0° or 10° seat dump.

NOTE: There are three heights of seat mounting plates; low, medium, and high.

Seat Pan

Seat Frame

Socket Screw



FIGURE 6.9 Seat Angle Adjustment

1. To obtain a 0° seat dump (DETAIL “A”):

A. Loosen the two mounting screws that secures the seat mount plate to the seat support bracket.

B. Loosen the two mounting screws that secures the remaining seat mount plate to the seat support bracket.

C. Adjust the seat mount plates so that the rear mounting screws are positioned at the bottom of the rear slots.

D. Adjust the seat mount plates so that the front mounting screws are positioned at the top of the front slots.

E. Securely tighten all four mounting screws. Torque to 156 in-lbs (13 ft-lbs)(17.62 Nm).

2. To obtain a 10° seat dump (DETAIL “A”):

A. Loosen the two 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 156 in-lbs (13 ft-lbs)(17.62 Nm).

Low Height Medium Height High Height

DETAIL A

Rear of Seat Frame

Front of Seat Frame

Mounting Screw

Mounting Screw

Medium Height Mounting Plate



Checking ASBA Seating System Mounting PositionNOTE: For this procedure, refer to FIGURE 6.10.

NOTE: Applies to ASBA standard seat, power tilt only, and Formula PTO Plus.1. Determine mounting position:

• Wheelchair with manual or power center mount front rigging (Detail “A”) - i. Position center mount front rigging to the lowest setting to position the

footplate as close as possible to the front shroud.

ii. Measure the gap between the footplate and the front shroud.

iii. Perform one of the following:

• 1 to 1½ inch Gap - ASBA seating system is in the proper mounting position.• Gap is Greater Than 1½ inches - ASBA seating system is not in the proper

mounting position. Refer to Adjusting the Seating System Mounting Position on page 61.

FIGURE 6.10 Checking ASBA Seating System Mounting Position

Front Shroud

DETAIL “A” - CENTER MOUNT FRONT RIGGING

Center Mount Front Rigging

1 to 1½-inch Gap

Footplate

Front Caster



Adjusting the Seating System Mounting PositionNOTE: For this procedure, refer to FIGURE 6.11.

NOTE: Applies to ASBA standard seat, power tilt only, and Formula PTO Plus.1. Loosen, but DO NOT remove, the four hex screws and locknuts securing the seat

frame mounting bracket to the interface mounting bracket.2. Perform one of the following to ensure the ASBA seating system is in the proper

mounting position:NOTE: Some front rigging and seat depth combinations may not allow for the 1-inch gap. In this situation, slide the seat frame mounting brackets as far back as possible.

• Wheelchairs with Swing Away Front Rigging—slide the seat frame mounting brackets as far as possible towards the rear of the wheelchair. Leave 1 to 1½-inch of clearance between the front riggings and the front casters in all caster positions.

• Wheelchairs with Manual or Power Center Mount Front Rigging—slide the seat frame mounting brackets as far as possible towards the rear of the wheelchair. Leave 1 to 1½-inch of clearance between the center mount front riggings and the front shroud.

3. Ensure the interface mounting brackets and the seat frame mounting brackets are flush and square.

4. Secure the seat frame mounting brackets to the interface mounting plates. Torque the four hex bolts and locknuts to 156 in-lbs (13 ft-lbs)(17.62 Nm) ± 20%.

5. Cycle the tilt and/or recline functions to verify wiring harnesses DO NOT obstruct the path of the system. If they do, perform one of the following:• Wires were damaged during inspection - Replace damaged wires.

• Wires were not damaged during inspection - Cut tie-wraps and relocate wires to a location where they will not become damaged.



FIGURE 6.11 Adjusting the Seating System Mounting Position

Hex Screws

Locknut

Locknuts

Interface Mounting Bracket

Seat Frame Mounting Bracket

ASBA Seating System(Base Only Shown)

Rear of Wheelchair


SECTION 7—BASE FRAME



Replacing Seat Mounting PlatesNOTE: For this procedure, refer to FIGURE 7.1.

1. Remove the seat frame. Replacing the Seat Frame on page 46.

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

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

3. Secure new seat mounting plate with existing two mounting screws, washers, and bolt straps to seat support bracket using Loctite 242 and torque to 156 in-lbs.

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

5. Adjust seat mounting plates to desired angle. Refer to Seat Angle Adjustment on page 58.

6. Reverse STEP 2.



FIGURE 7.1 Replacing Seat Mounting Plates

Washer

Bolt Strap

Seat Mounting Plate

Seat Support Bracket

Washer

Mounting Screws

Mounting Screws

Low Height Medium Height High Height



Replacing Seat Support BracketsNOTE: For this procedure, refer to FIGURE 7.2.


2. Remove standard seat frame subassembly.

3. Remove seat mounting plates. Refer to Replacing Seat Mounting Plates on page 63.

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

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

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

5. Secure the new seat support bracket to base frame with the existing two mounting screws and washers. Torque to 156 in-lbs (13 ft-lbs)(17.62 Nm).

6. Reinstall seat mounting plates. Refer to Replacing Seat Mounting Plates on page 63.


8. Reverse STEP 2.

FIGURE 7.2 Replacing Seat Support Brackets

Washer


Mounting Screws

Base FrameT-Nut

Front

Back



Replacing Seat Support Bracket T-NutsNOTE: For this procedure, refer to FIGURE 7.3 on page 66.


2. Remove the seat mounting plates. Refer to Replacing Seat Mounting Plates on page 63.

FIGURE 7.3 Replacing Seat Support BracketsNOTE: Before removing seat mounting plates, note the position of the washers.

3. Remove seat support brackets. Refer to Replacing Seat Support Brackets on page 65.

4. Remove the seat stop screw that is closest to the end cap. Refer to Removing/Installing Seat Stop Screws on page 68.

5. Remove the end cap and channel cover.

6. Slide existing t-nut(s) out of channel.

7. Insert new t-nut(s) into channel in correct orientation.

8. Replace channel cover and end cap.

NOTE: The seat stop screws must be in place before operation of your power wheelchair. Ensure the t-nut(s) are positioned between both seat stop screws.

9. Use Loctite 242 and reinstall seat stop screw into base frame.

10. Reinstall seat support brackets. Refer to Replacing Seat Support Brackets on page 65.

11. Reinstall seat mounting plates. Refer to Replacing Seat Mounting Plates on page 63.


13. Install the seat frame. Replacing the Seat Frame on page 46.


Base Frame

T-Nut

End Cap

Channel Cover



Replacing Battery Charger Bracket and T-NutNOTE: For this procedure, refer to FIGURE 7.4.

NOTE: For wheelchairs equipped with MKIV electronics.


2. Remove the seat support brackets. Refer to Replacing Seat Support Brackets on page 65.

3. Remove the two mounting screws that secure the battery charger connector to the mount bracket.

4. Remove battery charger connector from mount bracket.

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

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

NOTE: To replace the Battery Charger Bracket T-Nut, perform STEPS 3-13 in Replacing Seat Support Bracket T-Nuts on page 66.

7. Secure the battery charger connector to the mount bracket with the existing two mounting screws. Tighten securely.

8. Reverse STEP 2.

FIGURE 7.4 Replacing Battery Charger Bracket and T-Nut

Battery Charger Connector

Base Frame T-Nut

Mounting Screw

Battery Charger Mount Bracket



Removing/Installing Seat Stop ScrewsNOTE: For this procedure, refer to FIGURE 7.5 on page 68.

NOTE: The rear 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 front seat stop screw should NEVER be removed.

1. Unthread seat stop screw from base frame.

NOTE: The seat stop screws MUST be in place before operation of your power wheelchair. Ensure the seat support bracket is positioned between both seat stop screws.

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

FIGURE 7.5 Removing/Installing Seat Stop Screws

Base Frame


Rear Seat Stop Screw

Front Seat Stop Screw



Adjusting Weight DistributionNOTE: For this procedure, refer to FIGURE 7.6.

NOTE: Seat mount plates and seat support brackets allow the seat frame to be repositioned along the base frame. The range is determined by position of the seat stop screws. The front seat stop screw is positioned at 4-inches and the rear seat stop screw is positioned at 10-inches. Both seat stop screw positions are measured from the front of the base frame.

NOTE: The position of the seat support brackets is factory set at 7-inches, this measured from the front of the base frame to the front of the seat support bracket. This will put about 70% of the total weight of the chair and user over the large wheels. However, this setting may not be the most desirable in terms of maneuverability, front rigging clearance and comfort for the user.

Adjustment OptionsNOTE: This section will provide the user with some knowledge of what to expect if the following adjustments are made.

1. Moving the seat forward.

• Advantage: This adjustment allows more clearance for front riggings and a more stable “feel” for the user.

• Disadvantage: More weight is put on front casters and makes turning more difficult.

NOTE: This option can also be accomplished by moving the motor backward on the suspension arm. Refer to Repositioning the Motor on page 71.

2. Moving the seat rearward.

• Advantage: Makes turning easier and provide better traction for the large wheels.

• Disadvantage: This adjustment, however, allows less clearance for front riggings and the user will experience more engagement of the anti-tippers.

NOTE: This option can also be accomplished by moving the motor forward on the suspension arm. Refer to Repositioning the Motor on page 71.



Adjusting Weight Distribution Procedure

1. Loosen the four mounting screws that secure the seat support brackets to the base frame.

� WARNINGRisk of Injury or Damage.Improper adjustment of seat may cause instability resulting in injury or damage.—DO NOT adjust seat beyond limit stops.

2. Adjust seat forward or back to the position determined from Adjustment Options on page 69.

3. Retighten the four mounting screws securing the seat support brackets to the base frame.

4. Test wheelchair maneuverability, comfort, and handling.

5. Repeat STEPS 1-4 for further adjustment, if necessary.

FIGURE 7.6 Adjusting Weight Distribution

Base Frame

Washer

Mounting Screw




Repositioning the Motor

Repositioning the 4 Pole Motor/Gearbox or SSD Motor/GearboxNOTE: For this procedure, refer to FIGURE 7.7.

NOTE: The motor/gearbox assembly can be repositioned to lengthen or shorten the wheelbase by 2-inches in 1-inch increments.

• Standard Position - Lengthens the wheelbase and gives you the most stability and standard maneuverability.

• 1-inch Forward - Centers the wheelbase and gives you standard stability and maneuverability.

• 2-inch Forward - Shortens the wheelbase and increases maneuverability and distributes additional weight on rear wheels.

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 on page 107.

3. 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 cannot be utilized.

4. Repeat STEPS 3 for opposite side of the wheelchair.

5. Reinstall the drive wheel onto the wheelchair. Refer to Removing/Installing Drive Wheels on page 107.



FIGURE 7.7 Repositioning the Motor - Repositioning the 4 Pole Motor/Gearbox or SSD Motor/Gearbox

Standard - Approximately 65% of

weight over rear wheels

1-Inch Forward- Approximately 70% of

weight over rear wheels

Middle Position (1 inch Forward)Approximately 70% of weight over drive

wheels

Front Position (2 inches Forward)Approximately 75% of weight over drive

wheels

Motor Mounting Positions Motor Mounting Positions

Rear Position (Standard)Approximately 65% of weight over

drive wheels

Motor Mounting Positions

Motor/Gearbox Mounting Position



Replacing Suspension Arm for Wheelchairs with Motor/Gearbox AssemblyNOTE: For this procedure, refer to FIGURE 7.8.

1. Remove the drive wheels from the wheelchair. Refer to Removing/Installing Drive Wheels on page 107.

2. Loosen the hex screws that secure wiring harness to sub-frame assembly.

3. Remove plug buttons from the middle of the base frame.

4. Remove the hex screws and the beveled washers that secure the suspension arm assembly to the base frame.

5. Remove existing suspension arm from the wheelchair.

NOTE: When installing the new suspension arm, the beveled washers MUST be placed on the inside and outside of the base frame, with the bevels facing each other.

6. Install the new suspension arm assembly onto the base frame.

7. Torque suspension arm hex screws (1/2 x 7-inches) to 85 ft-lbs (approximately 1,020 in-lbs) (115.24 Nm) and replace plug buttons.

8. Reinstall the gearbox onto the existing suspension arm. Refer to Removing/Installing Drive Wheels on page 107.

9. Tighten the hex screws that secure wiring harness to sub-frame assembly securely.

10. Reinstall the drive wheel onto the wheelchair. Refer to Removing/Installing Drive Wheels on page 107.

11. Repeat STEPS 1-11 for the opposite side of the wheelchair, if necessary.

FIGURE 7.8 Replacing Suspension Arm for Wheelchairs with Motor/Gearbox Assembly

Suspension Arm

Beveled Washers

Plug Button

Suspension Arm Hex Screw (1/2 x 7 Inches)


SECTION 8—BACK FRAME



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

Removing/Installing CJ Back BracketsNOTE: For this procedure, refer to FIGURE 8.1 on page 75.

NOTE: The following procedure is for Jr. size seat frames only.

Removing CJ Back Brackets

1. If necessary, perform the instructions outlined in Preparation for Removing/Installing Seat Frame on page 45.

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

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

4. Remove the existing CJ back bracket.

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

6. For replacement of CJ back brackets, proceed to Installing CJ Back Brackets on page 74.

Installing CJ Back Brackets


2. Install the threaded studs of the CJ back bracket through the back angle plates as shown in FIGURE 8.1.

NOTE: Ensure the CJ back bracket is mounted in the front holes of the back angle plates as shown in DETAIL “A” of FIGURE 8.1.

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 in-lbs (6.25 ft lb) (8.47 Nm).



5. Install washers and locknuts onto the threaded studs of the CJ back bracket. Torque to 75 in-lbs (6.25 ft lb) (8.47 Nm).


FIGURE 8.1 Removing/Installing CJ Back Brackets

Seat Pan Seat Frame

Locknuts

Washers

Back Angle Plate

Mounting Screw

Threaded Studs

CJ Back Bracket

Seat Positioning

Strap

Quick Release

Pin

Locknut

DETAIL “A”

Toward Front Of Wheelchair

CJ Bracket Mounts in Front Holes on Back Angle Plates



Changing Back Height on Fixed and ASBA Seat FramesNOTE: For this procedure, refer to FIGURE 8.2 on page 78.

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

Back upholstery height ranges are 16 to 17-inches, 18 to 19-inches, 20-inches, 21 to 22-inches, 23 to 24-inches:

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

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

NOTE: Existing hardware and inserts will be reused.

1. Remove the armrests from the wheelchair. Refer to Installing/Removing Flip Back Armrests on page 38

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

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

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

4. Remove the inserts from the existing back canes.

5. Remove the back assembly from the wheelchair.

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

7. Remove existing back canes from the back assembly.

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

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

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

10. Slide 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 mounting holes in the back canes with the mounting holes in the seat frame.

NOTE: If needing a reference for proper mounting holes for the back angle required, or if changing the original back angle, refer to Back Angle Adjustment on page 79.

NOTE: The back canes MUST be fastened securely to the seat frame BEFORE using the wheelchair. Torque to 75 in-lbs (6.25 ft-lbs)(8.47 Nm).



13. Secure the two new back canes to the seat frame with the existing four mounting screws, washers, spacers, and locknuts. Use Loctite 242 and torque to 75 in-lbs (6.25 ft-lbs) (8.47 Nm).

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

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

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

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

� WARNINGRisk of Injury, Damage or DeathExcessive moisture or cleaning may reduce the flame retardancy of the upholstery and may result in injury, damage or death.—Follow all cleaning instructions.—Avoid excessive moisture or cleaning.

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

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

NOTE: Spreader bar required on all Heavy Duty models.

17. If necessary, reposition the spreader bar at the correct height for the corresponding back height and torque the mounting hardware to 60 in-lbs (5 ft-lb) (6.78 Nm).

18. Reinstall the armrest onto the wheelchair. Installing/Removing Flip Back Armrests on page 38.



FIGURE 8.2 Changing Back Height on Fixed and ASBA Seat Frames

Adjusting the Back Height on ADJASBA Seat FramesContoura Backs - There is no height adjustment available for wheelchairs with Contoura backs.

Upholstered Backs - The back canes MUST be replaced to adjust the back height for upholstered backs.

Locknut

Washer

Mounting Screw

Locknuts Spacers

Spreader Bar

Mounting ScrewTorque to 60 in-lbs(5 ft-lbs) (6.78 Nm)

Washers

Mounting ScrewTorque to 75 in-lbs

(6.25 ft-lbs) (8.47 Nm).

Insert

Back Upholstery

Back Cane



Back Angle AdjustmentNOTE: For this procedure, refer to FIGURE 8.3.

1. Remove armrests from the wheelchair. Refer to Installing/Removing Flip Back Armrests on page 38.

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

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

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

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

5. Torque mounting screws to 75 in-lbs (6.25 ft -lbs)*8.47 Nm).

6. Reinstall the armrests onto the wheelchair. Refer to Adjusting Flip Back Armrests on page 39.

FIGURE 8.3 Back Angle Adjustment

80°Top

Bottom

Bottom Rear

Top Front

85°Top

2nd From Bottom

Bottom Center

Top Front

90°Top

Bottom

Top Front

95°Top

2nd From Bottom

Bottom Front

Top Center

Bottom Front

100°Top

Bottom

Top Rear

Bottom Front


SECTION 9—BATTERIES


Warnings for Handling and Replacing Batteries

� WARNINGRisk of Injury.Exposure to battery acid may result in injury.—The use of rubber gloves is recommended when working with batteries. —DO NOT allow the liquid in the battery to come in contact with skin, clothes or other possessions. It is a form of acid and harmful or damaging burns may result. Should the liquid touch your skin, wash the area IMMEDIATELY and thoroughly with cool water. In serious cases or if eye contact is made, seek medical attention IMMEDIATELY.—DO NOT install/reinstall a battery with a cracked or otherwise damaged case.

� WARNINGRisk of Injury or DamageImproper lifting technique may cause injury or damage.—Use proper lifting techniques, assistance and gear such as straps when available when lifting heavy loads.

—Invacare strongly recommends battery installation and replacement be performed by a qualified technician.

—Read the installation instructions noted on the battery and in the manual.

—Ensure there is no battery acid in the bottom or around the battery box or on the sides of the battery(ies). Neutralize battery acid with baking soda if found.

—Clean battery tray and batteries prior to installation.

Using the Proper BatteriesNOTE: Failure to use the correct battery size and/or voltage may cause damage to your wheelchair and give you unsatisfactory performance. The warranty and performance specifications contained in this manual are based on the use of deep cycle gel cell batteries. Invacare strongly recommends their use as the power source for this unit.

1. Place battery on ground/flat surface.

2. Visually draw a horizontal and vertical centerline through the middle of battery.

3. Position the battery so that the terminals are above the horizontal centerline.

4. Visually inspect the battery to ensure the correct position of the positive and negative terminals, as shown in FIGURE 9.1 on page 81.



� WARNINGFOR 3G STORM WHEELCHAIRS THAT USE GP24 BATTERIES: Batteries with terminal configuration (positive on the right and negative on the left) as shown below MUST be used. Batteries that have the reverse terminal configuration MUST not be used - otherwise injury and damage may occur.

Terminals MUST have a cross hole in them as shown in DETAIL “A” below.

FIGURE 9.1 Using the Proper Batteries.

DETAIL A: TERMINAL CROSS HOLES

DO NOT USE

GP24

NEGATIVE (–) Battery

Terminal/Post

POSITIVE (+) Battery

Terminal/Post


Terminal/Post


Terminal/Post

PROPER Battery to Use

Terminal Cross Holes

GP24



Installing/Removing Batteries into/from Battery Boxes

CAUTIONRisk of Damage.Use of wrong battery type or size may cause damage.—DO NOT force a battery into place.—Batteries with molded straps or flanges that interfere with proper battery placement should not be used.

—Use batteries called out in this manual for proper replacement.


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

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

1. If necessary, remove the battery boxes from the wheelchair. Refer to Removing/Installing Battery Boxes on page 93.

2. Disconnect battery cables. Refer to Disconnecting/Connecting Battery Cables on page 84 for one of the following:

• Group 24 Batteries

3. Secure battery lifting strap to battery terminal(s)/post(s) (FIGURE 9.2).

4. Remove batteries from battery box(es).



FIGURE 9.2 Installing/Removing Batteries into/from Battery Boxes

Battery Lifting Strap

Molded Carrying Straps (These batteries must NOT be used)

22NF Battery Box

Bottom

Group 24 Battery Box

Bottom



Disconnecting/Connecting Battery Cables

� DANGERRisk of Death or Serious InjuryFailure to observe these warnings can cause an electrical short resulting in death, serious injury, or damage to the electrical system.The POSITIVE (+) RED battery cable MUST connect to the POSITIVE (+) battery terminal(s)/post(s). The NEGATIVE (-) BLACK battery cable MUST connect to the NEGATIVE (-) battery terminal(s)/post(s). NEVER allow any of your tools and/or battery cable(s) to contact BOTH battery post(s) at the same time. An electrical short may occur and serious injury or damage may occur.Install protective caps on positive and negative battery terminals.Replace cable(s) immediately if cable(s) insulation becomes damaged. DO NOT remove fuse or mounting hardware from POSITIVE (+) red battery cable mounting screw.

NOTE: Use box wrench when tightening clamps. Do Not wiggle the battery terminals/posts when tightening.



Group 24 Batteries on Wheelchairs Manufactured Before 1/26/04NOTE: For this procedure, refer to FIGURE 9.3 on page 86.

DisconnectingNOTE: Perform this procedure on one battery and battery box at a time. Repeat procedure for other battery box.

1. Lift up on battery box lid to expose underlying cables.

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. Disconnect NEGATIVE battery cable clamp from NEGATIVE(-) battery post

4. Disconnect POSITIVE battery cable clamp from POSITIVE (+) battery post (FIGURE 9.3).

ConnectingNOTE: Perform this procedure on one battery and battery box at a time. Repeat procedure for other battery box.

1. Position battery box top next to battery box bottom as shown in FIGURE 9.3.

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 battery cable clamp to NEGATIVE(-) battery post and connect

POSITIVE battery cable clamp to POSITIVE (+) battery post (FIGURE 9.3).

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).

8. Install the battery box(es) into the wheelchair. Refer to Removing/Installing Battery Boxes on page 93.

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

9. If necessary, charge the battery(ies). Refer to Charging Batteries on page 90.

N

P

N

P



FIGURE 9.3 Disconnecting/Connecting Battery Cables - Group 24 Batteries on Wheelchairs Manufactured Before 1/26/04

P

N

BLACK Battery Clamp Cover


Terminal/Post

Battery Box Bottom Battery

BLACK Battery Clamp Cover


Terminal/Post

RED POSITIVE (+) Battery

Cable

BLACK NEGATIVE (–) Battery

Cable

Two Connector

Battery Box Top

One Connector

Battery Box Top


Cable


Cable


Cable Clamp

RED Battery Clamp Cover

RED Battery Clamp Cover


Cable Clamp


Terminal/PostPOSITIVE (+)

Battery Terminal/Post POSITIVE (+)

Battery Terminal/Post


Terminal/Post

Battery Box

Botttom


Cable Clamp

Two Connector Battery Box One Connector Battery Box

Battery Box

Botttom


Cable Clamp



Group 24 Batteries on Wheelchairs Built AFTER 1/25/04NOTE: For this procedure, refer to FIGURE 9.4 on page 88.

DisconnectingNOTE: Perform this section on one battery and battery box at a time. Repeat section for other battery box.

1. Lift up on battery box lid to expose underlying cables.

2. Peel back battery terminal caps to expose battery cable ends as follows:

A. RED battery terminal cap from RED battery cable.

B. BLACK battery terminal cap from BLACK battery cable.

3. Remove the locknut and mounting screw to disconnect BLACK battery cable from the NEGATIVE(-) battery terminal/post (DETAIL “A” of FIGURE 9.4)

4. Remove the locknut and fuse mounting screw to disconnect RED battery cable from the POSITIVE (+) battery post (DETAIL “A” of FIGURE 9.4).

ConnectingNOTE: Perform this section on one battery and battery box at a time. Repeat section for other battery box.

1. Position battery box top above battery as shown in FIGURE 9.4.

2. Peel back battery terminal caps to expose battery cable ends as follows:

A. RED battery terminal cap from RED battery cable.

B. BLACK battery terminal cap from BLACK battery cable.

3. Install the locknut and mounting screw to connect the BLACK battery cable to the NEGATIVE(-) battery terminal/post (DETAIL “A” of FIGURE 9.4).

4. Install the locknut and fuse mounting screw to connect the RED battery cable to the POSITIVE (+) battery post (DETAIL “A” of FIGURE 9.4).

5. Verify battery cables are correctly installed and securely tightened.

NOTE: Cables will be crossed on one (1) connector battery box top.

6. Reposition terminal caps over battery post(s).

7. Install the battery box top(s).

8. Install the battery boxes into the wheelchair. Refer to Removing/Installing Battery Boxes on page 93.

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

9. If necessary, charge the battery(ies). Refer to Removing/Installing Battery Boxes on page 93.



FIGURE 9.4 Disconnecting/Connecting Battery Cables - Group 24 Batteries on Wheelchairs Built After 1/25/04

BLACK NEGATIVE (–) Battery Cable

Two Connector Battery Box Top

BLACK Battery

Terminal Cap

RED Battery

Terminal Cap


One Connector Battery Box Top

RED POSITIVE (+) Battery Cable

BLACK Battery

Terminal Cap

RED Battery

Terminal Cap


Terminal/Post


Terminal/Post


Terminal/Post


Terminal/Post

DETAIL A: CONNECTING CABLES TO TERMINALS

Two Connector Battery Box One Connector Battery Box

Top View of Battery

Locknut

NEGATIVE (–) Battery Terminal/Post

POSITIVE (+) Battery Terminal/Post

Locknut




Top View of Battery

Top View of Battery

Mounting Screw

Fuse Mounting Screw



When to Charge Batteries

SPJ+ JoysticksNOTE: For this procedure, refer to FIGURE 9.5.

The Information Gauge Display located on the front of the joystick housing, it provides the state-of-battery charge, including notification of when the battery requires charging. It also provides the following information to the user on the status of the wheelchair:

A. GREEN LEDs are lit, indicating well charged batteries.

B. AMBER LEDs are lit, indicating batteries are moderately charged. Recharge batteries before taking a long trip.

C. RED LEDs are lit, indicating batteries are running out of charge. Recharge batteries as soon as possible.

FIGURE 9.5 SPJ+ Joysticks

MPJ+ Joystick.

The far right side of the screen is the Battery Gauge Display (BGD). It provides information on the remaining charge in the batteries. At full charge, solid blocks fill in all ten segments between E (Empty) and F (Full). As the battery becomes discharged, the top most segments will progressively disappear until no segments appear between E and F. At this level, the user should charge the batteries as soon as possible.

Battery Charger/Programming

Batteries Full

Batteries Empty

Information Gauge Display



Charging BatteriesNOTE: For this procedure, refer to FIGURE 9.6 on page 92.

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

� WARNINGRisk of Injury, Damage or DeathImproper charging may cause injury or damage.—Charge battery in a cool, dry and well-ventilated area. —DO NOT attempt to charge the battery by attaching cables directly to the battery terminals.—DO NOT attempt to charge the battery and operate the wheelchair at the same time.—DO NOT attempt to charge the battery when the wheelchair has been exposed to any type of moisture.—DO NOT sit in the wheelchair while charging the battery.—DO NOT leave the charger unattended when the breaker has tripped. Unplug and discontinue use immediately. Contact a qualified service technician or Invacare for service.—Read and follow the manufacturer's instructions for each charger (supplied or purchased). If charging instructions are not supplied, consult a qualified technician for proper procedures.

—New batteries MUST be fully charged prior to initial use to avoid reduced battery life.

—Recharge daily and frequently to extend battery life and reduce charge time.

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

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



Description of Battery Chargers

The charger automatically reduces the charge from an initially high rate to a zero reading at a fully charged condition. If left unattended, the charger should automatically shut-off when full charge is obtained.

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

The amount of electrical current drawn within a given time to charge a battery is called the “charge rate”. If, due to usage, the charge stored in the battery is low, the charge rate is high, as indicated by the green light on the charger. Initially, the green light will stay illuminated for a short period of time followed by a longer period of off time. As a charge builds up, the charge rate is reduced, and the green light will stay illuminated for a longer period of time followed by a shorter off time.

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.

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

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

1. Plug the charger’s AC power cord, or extension, into the grounded 120 VAC wall outlet.

2. Wait until charging is complete.

NOTE: 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.

NOTE: If the batteries need to be charged more often or take longer to charge than normal, they may need to be replaced. Contact an Invacare dealer for service.



FIGURE 9.6 Charging Batteries

Replacing BatteriesNOTE: Invacare recommends that both batteries be replaced if one battery is defective.

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

1. Remove the battery boxes from the wheelchair. Refer to Removing/Installing Battery Boxes on page 93.

2. Remove existing batteries from the battery box(es). Refer to Installing/Removing Batteries into/from Battery Boxes on page 82.

3. Clean the new battery terminals. Refer to Cleaning Battery Terminals on page 92.

4. Install the new batteries into the battery box(es). Refer to Installing/Removing Batteries into/from Battery Boxes on page 82.

5. Install the battery boxes into the wheelchair. Refer to Removing/Installing Battery Boxes on page 93.

Cleaning Battery Terminals

1. Examine battery clamps and terminals for corrosion.

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

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

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

4. Carefully dust off all metal particles.

From Battery Charger

Battery Charger Mount Bracket

Base Frame

Battery Charger Port

Support Plate



Removing/Installing Battery Boxes

Group 24 Battery Boxes for Wheelchairs Without Vent TrayNOTE: For this procedure, refer to FIGURE 9.6 on page 92.

Removing

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

2. Verify the joystick On/Off switch is in the Off position.

3. Rotate the levers of the battery retainer assembly to the unlocked position.

4. Lift battery retainer assembly up off the mounting screws that secure the shocks to the base frame.

5. Slide one connector battery box along the sub-frame and remove from the wheelchair.

6. Slide two connector battery box along the sub-frame and remove from the wheelchair.

Installing



3. Secure the battery box carrying strap to the lid of the two connector battery box.

4. Place two connector battery box onto the battery sub-frame assembly with guide pins facing the inside of the wheelchair.

5. Slide the two connector battery box along the sub-frame until its guide pins are engaged in the sub-frame connector.

NOTE: Visually inspect for properly made connection.Connectors MUST be fully engaged.

NOTE: Make certain that battery box carrying strap is positioned on top of battery box and will not interfere with one battery box guide pins when engaging connector on the one battery box lid.

6. Secure the battery box carrying strap to the lid of the one connector battery box.

7. Place one connector battery box onto battery sub-frame.

8. Slide one connector battery box along the sub-frame until its guide pins are engaged in the connector of the two connector battery box.

NOTE: Visually inspect for properly made connection.Connectors MUST be fully engaged.

9. Place the battery retainer assembly on head portion of the mounting screws that secure the shocks to the base frame.

10. Rotate the levers of the battery retainer assembly to the locked position.



� WARNINGRisk of Injury, Damage or DeathLoose or missing retainer resulting in disconnection of wiring may cause injury, damage or death resulting from erratic wheelchair operation.—Ensure battery retainer is in locked position.—DO NOT use wheelchair if erratic operation occurs.

FIGURE 9.7 Removing/Installing Battery Boxes - Group 24 Battery Boxes for Wheelchairs Without Vent Tray

Front of Base Frame

Battery Retainer Assembly

Lever in Locked Position

Lever in Unlocked Position

Rearof Base Frame



Group 24 Battery Boxes for Wheelchairs Equipped With Vent TrayNOTE: For this procedure, refer to FIGURE 9.7 on page 94.

Removing



3. Pull the battery box retainer up over the end of the one connector battery box.

4. Slide one connector battery box along the sub-frame and remove from the wheelchair.

5. Slide the two connector battery box along the sub-frame and remove from the wheelchair.

Installing



3. Secure the battery box carrying strap to the lid of the two connector battery box.

4. Place two connector battery box onto the battery sub-frame assembly with guide pins facing the inside of the wheelchair.

5. Slide the two connector battery box along the sub-frame until its guide pins are engaged in the sub-frame connector.

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

NOTE: Make certain that the battery box carrying strap is positioned on top of the battery box and will not interfere with the one battery box guide pins when engaging the connector on the one (1) battery box lid.

6. Secure the battery box carrying strap to the lid of the one connector battery box.

7. Place one connector battery box onto battery sub-frame.

8. Slide one connector battery box along the sub-frame until its guide pins are engaged in the connector of the two connector battery box.

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

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



� WARNINGRisk of Injury, Damage or DeathLoose or missing retainer resulting in disconnection of wiring may cause injury, damage or death resulting from erratic wheelchair operation.—Ensure battery retainer is in locked position.—DO NOT use wheelchair if erratic operation occurs.

FIGURE 9.8 Removing/Installing Battery Boxes - Group 24 Battery Boxes for Wheelchairs Equipped With Vent Tray

Battery Box Sub-Frame

Base Frame

Battery Box Retainer Bar

Two Connector Battery Box


Base Frame

One Connector Battery Box


One Connector Battery Box


Two Connector Battery Box



Removing/Installing Group 24 Battery Box Sub-FrameNOTE: For this procedure, refer to FIGURE 9.9 on page 98.

Removing

1. Remove the battery boxes. Refer to Removing/Installing Battery Boxes on page 93.

2. Remove the two mounting screws and locknuts that secure the wiring harness w/bracket and the sub-frame to the base frame.


• Wheelchairs Equipped with Vent Tray - Remove the four mounting screws that secure the shocks, retainer bar, spacers and retainer clips to the base frame.

• Wheelchairs without Vent Tray - Remove the four mounting screws that secure the shocks and spacers to the base frame.

4. Remove the existing sub-frame assembly.

Installing

1. Install the two mounting screws and locknuts that secure the wiring harness with bracket and the new sub-frame to the base frame. Use Loctite 242 and torque mounting screws to 160 in-lbs (13.36 ft-lbs)(18.03 Nm).


• Wheelchairs Equipped with Vent Tray - Reinstall the four mounting screws that secure the shocks, retainer bar, spacers and retainer clips to the base frame. Use Loctite 242 and torque mounting screws to 160 in-lbs (13.36 ft-lbs)(18.03 Nm).

• Wheelchairs without Vent Tray - Reinstall the four mounting screws that secure the shocks and spacers to the base frame.

3. Reinstall the battery boxes. Refer to Removing/Installing Battery Boxes on page 93. Use Loctite 242 and torque mounting screws to 160 in-lbs (13.36 ft-lbs)(18.03 Nm).



FIGURE 9.9 Removing/Installing Group 24 Battery Box Sub-Frame

Rear of ChairMounting Screws

Sub-Frame

Wiring Harness w/Bracket

Locknuts

Front of Chair

Wheelchairs Equipped With Vent Tray

Front of Chair


Retainer Bar

Retainer Clip Spacer

Shock Base Frame

Mounting Screws Spacer Battery

Box Sub-Frame

Base Frame

Shock

Wheelchairs Equipped Without Vent Tray

Front of Chair

Rear of Chair

Spacer Battery Box

Sub-Frame



Installing Group 24 ComponentsNOTE: For this procedure, refer to FIGURE 9.10 on page 100.

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.

2. Install the two mounting screws through the wiring harness w/bracket, battery box sub-frame, and base frame.

3. Install the locknuts onto mounting screws. Torque to 160 in-lbs (13.36 ft-lbs)(18.03 Nm).


• Wheelchairs Equipped with Vent Tray -

i. 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.

NOTE: Make sure the closed end of the battery box retainer clip is pointing up.

ii. Install the mounting screw that secures the retainer clip to the battery box sub-frame. Use Loctite® 242 and torque to 160 in-lbs (13.36 ft-lbs)(18.03 Nm).

iii. Line up the new battery box retainer bar and spacers with mounting holes in the base frame.

iv. Reinstall the mounting screws that secure the battery box retainer bar to the base frame. Use Loctite 242 and torque to 160 in-lbs (13.36 ft-lbs)(18.03 Nm).

• Wheelchairs Equipped without Vent Tray - Reinstall the four mounting screws that secure the shocks and spacers to the base frame.

5. Perform STEPS 2-7 of Removing/Installing the Wiring Harness on page 101 to complete the wiring harness installation.

6. Install the group 24 battery boxes. Refer to Removing/Installing Battery Boxes on page 93.



FIGURE 9.10 Installing Group 24 Components

Rear of Chair Mounting Screws


Wiring Harness w/Bracket

Locknuts

Front of Chair

Wheelchairs Equipped With Vent Tray

Front of Chair


Retainer Bar

Retainer Clip Spacer

ShockBase

Frame

Mounting Screws

Spacer Battery Box

Sub-Frame

Base Frame

Shock

Wheelchairs Equipped Without Vent Tray

Front of Chair

Rear of Chair

Spacer

Battery Box

Sub-Frame

Steps 1-3

Steps 4-7


SECTION 10—WIRING HARNESS


Removing/Installing the Wiring Harness

Group 24 BatteriesNOTE: For this procedure, refer to FIGURE 10.1.

Removing


2. Remove the two mounting screws and locknuts that secure the wiring harness bracket to the base frame (DETAIL “A” of FIGURE 10.1).

3. Perform one of the following sections:

• Wheelchairs with motor/gearbox assembly

i. Cut TIE-WRAPS A and B that secure the two motor/controller connections and the controller/wiring harness connection (BLUE connectors) together (DETAIL “B” of FIGURE 10.1).

ii. Cut TIE-WRAP C that secures the battery charger cable, motor connector cable, controller connector cable, and wiring harness cable to the base frame (DETAIL “B” of FIGURE 10.1).

• Wheelchairs with gearless/brushless motor

i. Cut TIE-WRAP A that secures the battery charger cable to the base frame (DETAIL “C” of FIGURE 10.1).

NOTE: For STEPS 4-6 refer to DETAIL “B” or “C” of FIGURE 10.1.

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. Install new wiring harness w/bracket to the rear of the sub-frame and torque mounting screws to 160 in-lbs (DETAIL “A” of FIGURE 10.1).

2. Secure the charger cable to the mounting bracket with the two mounting screws. Securely tighten (DETAIL “B” OR “C” of FIGURE 10.1).

3. Connect the battery harness/charger cable (BLUE) to the controller connector (BLUE) (DETAIL “B” or “C” of FIGURE 10.1).


• Wheelchairs with motor/gearbox assembly

i. Group the two motor/controller connections together along with the controller/wiring harness connection (BLUE) and secure with TIE-WRAPS A and B (DETAIL “B” of FIGURE 10.1).

ii. Secure the Wiring Harness Cable, Battery Charger Cable, Controller Connector Cable, and Motor Connector Cable to the suspension arm with TIE-WRAP C (DETAIL “B” of FIGURE 10.1).

• Wheelchairs with gearless/brushless motor option:

i. Secures the battery charger cable to the base frame with TIE-WRAP A(DETAIL “C”).

5. Reinstall the battery boxes. Refer to Removing/Installing Battery Boxes on page 93.



FIGURE 10.1 Removing/Installing the Wiring Harness - Group 24 Batteries

DETAIL A: GROUP 24 BATTERIES

Mounting Screws

Rear of Chair

Wire Harness Bracket


Base Frame

Locknuts

DETAIL B: WHEELCHAIRS WITH MOTOR/GEARBOX ASSEMBLY

Mounting Screws (Not Shown)

Wiring Harness Cable

Tie Wrap C

Battery Charger Cable

Controller Connector

Motor Connector



(BLUE)

Tie Wraps A and B

Wiring Harness

Connector (BLUE)

Motor Connector

Cable

Motor Connector


(BLUE)

Wiring Harness

Connector (BLUE)

Mounting Screws

Charger Cable

Tie Wrap ANOTE: There is no need to cut this tie wrap.

DETAIL C: WHEELCHAIRS WITH GEARLESS/BRUSHLESS MOTOR



Adjusting Limit SwitchNOTE: For this procedure, refer to FIGURE 10.2.

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

1. Place the wheelchair on a level surface.

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

2. Turn the wheelchair power switch on the joystick to the On position.

NOTE: The wheelchair should not operate.

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

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

A. Loosen, but DO NOT remove, the two phillips screws, washers and locknuts that secure the actuator to the upper limit switch bracket.

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

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

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

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



.

FIGURE 10.2 Adjusting Limit Switch

Upper Limit

Switch Bracket

Phillips Screws, Washers

and Locknuts

5-3/4 Inches

24° Back Recline Angle

114°

61°

5° Seat AngleMagnetic Protractor (Will read 61° when back

recline angle is at 114° relative to the seat frame.


SECTION 11—WHEELS/MOTORS



� DANGERRisk of Injury, Damage or DeathOverinflation of tires may cause tires to explode.—Inflate tire to the proper tire pressure (P.S.I./ kilopascals) listed on the side wall of the tire.—Only use wheelchair with tires at proper tire pressure.—The wheels and tires should be checked periodically for cracks and wear and should be replaced if necessary.



Replacing Pneumatic Tires/Tubes - Drive Wheels/CastersNOTE: If drive wheels or casters are pneumatic, under-inflation causes excessive wear which results in poor performance of the tires.

Removing/Installing Drive WheelsNOTE: For this procedure, refer to FIGURE 11.1 on page 107.

Removing


2. Remove the four beveled hex nuts that secures the drive wheel assembly to one of the following: drive wheel hub or adapter plate with studs.

3. Remove existing drive wheel assembly from wheel hub.

Installing

1. Reinstall new/existing drive wheel assembly to one of the following: drive wheel hub, or adapter plate with studs and torque the four beveled hex nuts to 160-inch pounds.

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

3. Reinstall the battery boxes. Refer to Removing/Installing Battery Boxes on page 93.

FIGURE 11.1 Removing/Installing Drive Wheels

14 X 3 Inch Wheel 14 X 4 Inch WheelConventional Motor with Gearbox

Drive Wheel Assembly Motor/Gearbox Assembly

Drive Wheel Hub

Four Beveled Hex Nuts

Drive Wheel Assembly

Motor/Gearbox Assembly

Four Beveled Hex Nuts

Drive Wheel Hub



Removing/Installing Drive Wheel HubNOTE: For this procedure, refer to FIGURE 11.2.

Removing

1. Remove the drive wheel from the wheelchair. Refer to Removing/Installing Drive Wheels on page 107.

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

Installing

1. Position the keystock on the drive shaft of the motor/gearbox assembly.

NOTE: DO NOT apply more than a 1-inch (in length) thin film of Super Lube® to the drive shaft. Applying more than 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 Super Lube, one inch in length, to the end of the drive shaft.

3. Reinstall drive wheel hub onto the drive shaft of the motor/gearbox assembly.

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 ft-lbs (540 in-lbs).

5. Reinstall the drive wheel assembly to the wheelchair. Refer to Removing/Installing Drive Wheels on page 107.

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

9F

FIGURE 11.2 Removing/Installing Drive Wheel Hub

14 X 4 Inch Wheel 14 X 3 Inch WheelMotor/Gearbox

Assembly

Drive Wheel Hub

Washer

Locknut

Motor/GearboxKeystock

Drive Wheel Hub

Washer

Locknut



Removing/Installing the SSD Motor Drive Wheel/Wheel Hub

RemovingNOTE: For this procedure, refer to FIGURE 11.3 on page 110.




4. Place two 5-inch blocks under battery frame to lift frame off the ground for ease in performing this procedure.


• To remove the drive wheel only -

i. Remove the five mounting screws securing the drive wheel to the wheel hub.

ii. Remove the drive wheel from the wheel hub.

• To remove the drive wheel and the wheel hub -

i. Remove the five mounting screws securing the drive wheel to the wheel hub.

ii. Remove the drive wheel from the wheel hub.

iii. Remove the locknut, washer, and 8mm hub spacer that secures the wheel hub to the drive shaft.



InstallingNOTE: For this procedure, refer to FIGURE 11.3 on page 110.


• To install the drive wheel -

i. Secure the drive wheel to the wheel hub with the five 5/16-18 X .88 cap screws. Torque to 160 in-lbs.

• To Install the Drive Wheel and Wheel Hub -

i. Apply a thin film of Super Lube®, one inch in length, to the end of the drive shaft.

NOTE: DO NOT apply more than a 1-inch (in length) thin film of Super Lube to the drive shaft. Applying more than 1-inch (in length) can cause the anti-seize compound to leak resulting in damage to flooring (carpet, tile, etc.).

ii. Place the 8mm hub spacer on to the drive shaft.

iii. Place the wheel hub onto the drive shaft, spin the wheel hub to evenly distribute the Super Lube over the entire drive shaft. Remove the wheel hub from the drive shaft.

iv. Insert the 3/16 X 1 1/4 inch key into the keyway of the drive shaft.

v. Place the wheel hub onto the drive shaft.

NOTE: Align the slot in the wheel hub with the key on the drive shaft.

vi. Secure the wheel hub to the drive shaft with washer and locknut.

FIGURE 11.3 Removing/Installing the SSD Motor Drive Wheel/Wheel Hub

Drive Wheel

Wheel HubLocknut

Washer

8mm Hub Spacer

Motor/Gearbox Assembly

Drive Shaft

Mounting Screws

3/16 X 1 1/4 Inch Key



Installing Wheel Lock Bracket onto WheelchairNOTE: For this procedure, refer to FIGURE 11.4.

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

1. Remove the two 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 mounting screws.

4. Reinstall the two mounting screws into the mounting holes of the wheel lock mounting bracket and gear box and torque to 75 in-lbs (6.25 ft-lbs)(8.47 Nm).

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

6. Adjust the wheel locks. Refer to Adjusting Wheel Locks in the User Manual, part number 1104782 or 1123757.

FIGURE 11.4 Installing Wheel Lock Bracket onto Wheelchair

7. Reinstall battery boxes. Refer to Removing/Installing Battery Boxes on page 93.

8. If wheelchair is equipped with pneumatic tires, inflate tire to proper tire pressure located on the side wall of the tire.

Mounting Screws

Gearbox

Wheel Lock Mounting Bracket

Suspension Arm



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

6 inch Casters and 8 inch CastersNOTE: For this procedure, refer to FIGURE 11.5 on page 112.

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

2. Remove the existing caster from the fork.

FIGURE 11.5 Removing Casters - 6 inch Casters and 8 inch Casters

Shock Fork

8 Inch Fork

Hardware Orientation8 Inch Caster Mounting

Hole

Spacer

Washer

Mounting Screw

Washer

Spacer

Locknut

WasherWasher

Locknut

Spacer

Mounting Screw

Spacer

Fork (Reference)



9 inch CastersNOTE: For this procedure, refer to FIGURE 11.6.

1. Remove the mounting screw and locknut that secures the spacer, wave washer, axle reducer, 9 inch caster, and spacer to the 9 inch fork.

FIGURE 11.6 Removing Casters - 9 inch Casters

Mounting Screw

Fork

Locknut

SpacerSpacer

Axle ReducerWave Washer(If equipped)



Installing Casters

6 Inch Casters and 8 Inch CastersNOTE: For this procedure, refer to FIGURE 11.7.

1. Position the caster into the fork.

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

3. Torque locknut to 13 ft-lbs (156 in-lbs) (17.6 Nm). All values are ± 20%.

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.

FIGURE 11.7 Installing Casters - 6 inch Casters and 8 inch Casters

Shock Fork

8 Inch Fork

Hardware Orientation

8 Inch Caster Mounting

Hole

Spacer

Washer

Mounting Screw

Washer

Spacer

LocknutWasher

Washer

Locknut

Spacer

Mounting Screw

Spacer

Fork (Reference)



9 inch CastersNOTE: For this procedure, refer to Refer to FIGURE 11.8.

1. Position axle reducer into 9 inch wheel.

2. Position wave washer onto axle reducer.

3. Position one spacer onto each side of axle reducer.

4. Position 9 inch caster assembly with hardware into fork.

5. Secure 9 inch caster assembly with mounting screw and locknut.

6. Torque locknut to 13 ft-lbs (156 in-lbs) (17.6 Nm). All values are ± 20%.

FIGURE 11.8 Installing Casters - 9 inch Casters

Mounting Screw Fork

Locknut

Spacer

Spacer

Axle ReducerWave Washer(If equipped)



Replacing ForksNOTE: For this procedure, refer to FIGURE 11.9 on page 116.

1. Remove the caster from the existing fork. Refer to Removing Casters on page 112.

2. Remove the dust cover.

3. Remove the locknut, nylon washer, and spacer.

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

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

NOTE: Check bearing assemblies. Replace if necessary.

6. Ensure new fork slides completely into caster headtube.

7. Install spacer, nylon washer and secure with locknut.

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

8. Install the caster onto the new fork. Refer to Removing Casters on page 112.

9. Adjust the forks. Refer to Adjusting Forks in the User Manual.

FIGURE 11.9 Replacing Forks

Washer

Locknut

Spacer

Dust Cover

Caster Headtube

Fork

Spacer



Removing/Installing the SSD Motor/Gearbox AssemblyNOTE: For this procedure, refer to FIGURE 11.10 on page 118.

Removing the SSD Motor/Gearbox Assembly




4. Place two 5-inch blocks under battery frame to lift frame off the ground for ease in performing this procedure.

5. Remove the drive wheel. Refer to Removing/Installing the SSD Motor Drive Wheel/Wheel Hub on page 109.

NOTE: Take note of position and orientation of tie-wraps securing wiring to the wheelchair before cutting tie-wraps that secure the motor wiring to the wheelchair base frame. Wiring must be reinstalled and secured in the same position and orientation as it was removed from.

6. Cut and remove any tie-wrap securing the motor cable to the wheelchair base frame and other cables.

7. Disconnect the motor cable from the controller.

8. Remove the two upper hex head screws securing the fender assembly and the motor/gearbox assembly to the suspension arm.

9. Remove the two lower hex head screws securing the motor/gearbox assembly to the suspension arm.

Installing the SSD Motor/Gearbox Assembly

1. Perform one of the following -

• If replacing the entire motor/gearbox assembly perform the following:

i. Ensure the new motor is properly indexed to gearbox. Refer to Aligning the SSD Motor to the Gearbox on page 119.

ii. Install the brake lever. Refer to Installing the SSD Brake Lever on page 120.

iii. Install the brake lever push/drive label. Refer to Installing the SSD Motor Push/Drive Label on page 120.

iv. Reverse STEPS 3-9 to reinstall motor/gearbox of Removing the SSD Motor/Gearbox Assembly on page 117.

• If replacing the motor or gearbox perform the following:i. Replace the motor or gear box. Refer to Replacing the SSD Motor or Gearbox

Only on page 118.ii. Reverse STEPS 3-9 to reinstall motor/gearbox of Removing the SSD

Motor/Gearbox Assembly on page 117.



NOTE: When installing the motor/gearbox torque the hex head screws to 13 ft-lbs (156 in-lbs) (17.6 Nm).

FIGURE 11.10 Removing/Installing the SSD Motor/Gearbox Assembly

Replacing the SSD Motor or Gearbox OnlyNOTE: For this procedure, refer to FIGURE 11.10 on page 118.

NOTE: Take note of the position and orientation of the motor in relation to the gearbox before separating the motor from the gearbox.

1. Remove the square neck bolt, spacer, washer and locknut securing the band clamp to the motor/gearbox assembly.

2. Pulling the band clamp open, remove the existing band clamp from the motor/gearbox assembly. Discard existing band clamp.

3. Firmly gripping the motor and the gearbox, pull to separate the motor from the gearbox.

4. Remove the existing coupling from between the motor and the gearbox.

5. Discard the existing coupling and either the existing motor or gearbox depending on which is being replaced.

6. Insert the new coupling onto the motor drive shaft.

7. Align the gearbox drive shaft with the new coupling.

8. Twist the motor to the proper alignment to the gearbox. Refer to Aligning the SSD Motor to the Gearbox on page 119.

9. Push the motor into the gearbox.

Motor Cable

Upper Hex Head Screws

Motor/Gearbox AssemblySuspension Arm

Middle Position (1 inch Forward)Approximately 70% of weight over drive

wheels

Front Position (2 inches Forward)Approximately 75% of weight over drive

wheels

Motor Mounting Positions Motor Mounting Positions

Rear Position (Standard)Approximately 65% of weight over

drive wheels


Lower Hex Head Screws





NOTE: When installing the new band clamp, it may be necessary to pull the band clamp open to slide the new band clamp around the motor/gearbox.

10. Use the new band clamp, and the existing square neck bolt, spacer, washer and locknut to secure the motor to the gearbox. Torque locknut to 75 in-lbs ± 10% (6.25 ft-lbs)(8.47 Nm).

11. If replacing the motor, install the brake lever. Refer to Installing the SSD Brake Lever on page 120.

FIGURE 11.11 Replacing the SSD Motor or Gearbox Only

Aligning the SSD Motor to the Gearbox1. If adjusting an assembled motor/gearbox, loosen the square neck bolt, spacer, washer

and locknut securing the band clamp to the motor/gearbox assembly.

2. Align the motor to the gearbox according to the table below:

3. If adjusting an assembled motor/gearbox, securely tighten the square neck bolt, spacer, washer and locknut. Torque locknut to 75 in-lbs ± 10% (6.25 ft-lbs)(8.47 Nm).

WHEELCHAIR LEFT SIDE RIGHT SIDE

TDX SP - 4 POLE

Square Neck Bolt

Spacer

Washer

Locknut

Band ClampMotor

Gearbox

Coupling

Gearbox Drive Shaft

Motor Drive Shaft

3G Storm Series Wheelchairs

180° Indicator Mark (Motor)

Indicator Mark (Gearbox) Indicator Mark (Gearbox)

0° Indicator Mark

(Motor)



Installing the SSD Brake LeverNOTE: For this procedure, refer to FIGURE 11.12.

NOTE: Brake levers are right and left side specific. Brake levers MUST mount to the brake lever post as described in STEP 2 and shown in FIGURE 11.12 to ensure the proper brake lever has been mounted to the correct motor.

1. Locate the brake lever post on the end of the motor opposite the gearbox.

2. Align the brake lever with the brake lever post so that:

• The brake lever handle will be positioned towards the outside of the wheelchair.

• The set screw will tighten against the flat space of the brake lever post.

• The cut out on the bottom edge of the brake lever will fit around the brake lever stop.

3. Securely tighten the set screw securing the brake lever to the brake lever post.

4. If necessary, perform STEPS 1-3 to install the remaining brake lever.

FIGURE 11.12 Installing the SSD Brake Lever

Installing the SSD Motor Push/Drive LabelNOTE: For this procedure, refer to FIGURE 11.13.

1. Peel the label from the adhesive backing.

2. Position the label on the motor near the brake lever as shown.

3. If necessary, repeat STEPS 1-2 for opposite motor to install the remaining push/drive label.

FIGURE 11.13 Installing the SSD Motor Push/Drive Label

Outside of Wheelchair

Brake Lock Lever (Handle)Cutout

Set Screw

Brake Lever PostBrake

Lever Stop

Outside of Wheelchair

Brake Lock Lever (Handle)Cutout

Set Screw

Brake Lever Post

Brake Lock Lever Stop

Right Side Motor Left Side Motor

NOTE: Right side motor shown, use same location for left side motor. Position Push/Drive

Label HERE



Installing/Removing Fenders

4 Pole MotorsNOTE: For this procedure, refer to FIGURE 11.14 on page 122.

Installing

1. Remove the drive wheel. Refer to Removing/Installing Drive Wheels on page 107.

NOTE: When performing STEPS 2 and 3, only the two mounting screws on the side of the suspension arm where the drive wheel mounts need to be removed in order to install the fender.

2. Remove the longer mounting screw that secures the rear of motor/gearbox to the suspension arm.

3. Remove the SHORTER mounting screw and lock washer (if applicable) that secures the rear of motor/gearbox to the suspension arm.

NOTE: The longer mounting screws MUST be used to secure the rear of the gearbox to the suspension arm and the SHORTER mounting screws MUST be used to secure the FRONT of the gearbox to the suspension arm - otherwise, damage to the gearbox casting can result.

4. Secure the rear of 4 pole fender bracket to the suspension arm and motor/gearbox, in the orientation shown, using the LONGER mounting screw removed in STEP 2. Torque mounting screw to 160 in-lbs (13.3 ft-lbs)(18.03 Nm).

5. Secure the front of 4 pole fender bracket to the suspension arm and motor/gearbox, in the orientation shown, using the SHORTER mounting screw and lock washer (if applicable) removed in STEP 3. Torque mounting screw to 160 in-lbs (13.3 ft-lbs)(18.03 Nm).

6. Secure the fender and spacer to the 4 pole fender bracket, in the orientation shown, with two pan head tap screws provided. Securely tighten.

7. Reinstall the drive wheel. Refer to Removing/Installing Drive Wheels on page 107.



FIGURE 11.14 Installing/Removing Fenders - 4 Pole Motors

Removing

1. Remove the drive wheel. Refer to Removing/Installing Drive Wheels on page 107.

NOTE: When performing STEPS 2 and 3, only the two mounting screws on the side of the suspension arm where the drive wheel mounts need to be removed in order to remove the fender.

2. Remove the longer mounting screw that secures the rear of motor/gearbox to the suspension arm.

3. Remove the shorter mounting screw and lock washer (if applicable) that secures the rear of motor/gearbox to the suspension arm.

NOTE: The longer mounting screws MUST be used to secure the rear of the gearbox to the suspension arm and the SHORTER mounting screws MUST be used to secure the FRONT of the gearbox to the suspension arm - otherwise, damage to the gearbox casting can result.

4. Secure the rear of the suspension arm to the motor/gearbox using the LONGER mounting screw removed in STEP 2. Torque mounting screw to 160 in-lbs (13.3 ft-lbs)(18.03 Nm).

5. Secure the front of the suspension arm to the motor/gearbox using the SHORTER mounting screw and lock washer (if applicable) removed in STEP 3. Torque mounting screw to 160 in-lbs (13.3 ft-lbs)(18.03 Nm).

6. Reinstall the drive wheel. Refer to Removing/Installing Drive Wheels on page 107.

Lock Washer (If Applicable)

Suspension Arm

LONGER Mounting Screw

Spacer

SHORTER Mounting Screw

Fender

4 Pole Fender Bracket

Pan Head Tap Screws


SECTION 12—ANTI-TIPPERS/SHOCKS


� WARNINGRisk of Serious Injury or DamageAttaching hardware that is loosely secured could cause loss of stability resulting in serious injury or damage.After ANY adjustments, repair or service and before use, make sure that all attach-ing hardware is tightened securely.

Shock or Rubber Element Replacement

Group 24 BatteriesNOTE: For this procedure, refer to FIGURE 12.1 on page 125 and FIGURE 12.2 on page 126.

1. Remove the group 24 battery boxes. Refer to Removing/Installing Battery Boxes on page 93.

2. Remove the drive wheel from the wheel hub. Refer to Removing/Installing Drive Wheels on page 107.


• Wheelchairs Equipped with Vent Tray - Loosen the hex screw that secures the battery box retainer bar to the base frame.

• Wheelchairs without Vent Tray - Loosen the rearmost hex screw that secures the battery box sub-frame and spacer to the base frame.


• Wheelchairs Equipped with Vent Tray - Remove the mounting screw that secures the top of the shock and retainer clip to the base frame.

• Wheelchairs without Vent Tray - Remove the mounting screw that secures the top of the shock to the base frame.


• For Shocks - Remove the mounting screw, two short spacers, two large washers and locknut that secure the shock to the anti-tip bracket and suspension arm.

• For Rubber Elements - Remove the mounting screw, two short spacers, two large washers, two small washers, one 2-inch spacer and locknut that secure the rubber element to the anti-tip bracket and suspension arm.

6. Remove the shock or rubber element.




• Wheelchairs Equipped with Vent Tray -

i. Position retainer clip between shock and battery box sub-frame making sure the retainer clip mounting hole is towards the bottom and the closed end of clip is against battery box retainer bar.

ii. Secure the top of shock and retainer clip to base frame. Apply Loctite 242 and torque to 160 in-lbs (13.3 ft-lbs)(18.03 Nm).

iii. Apply Loctite 242 and torque the hex screw that secures the battery box retainer bar to the base frame to 160 in-lbs (13.3 ft-lbs)(18.03 Nm).

• Wheelchairs without Vent Tray - Secure the top of shock to base frame. Apply Loctite 242 and torque to 160 in-lbs (13.3 ft-lbs)(18.03 Nm).


• For Shocks - Secure the new shock to the anti-tip bracket and suspension arm with the existing mounting screw, two large washers, two short spacers, and locknut. Torque to 13 ft-lbs.

• For Rubber Elements - Secure the new rubber element to the anti-tip bracket and suspension arm with the existing mounting screw, two large washers, two small washers, two short spacers, one 2-inch spacer and locknut. Torque to 13 ft-lbs.

9. Reinstall the drive wheel from the wheel hub. Refer to Removing/Installing Drive Wheels on page 107.

10. Reinstall the group 24 battery boxes. Refer to Removing/Installing Battery Boxes on page 93.



� WARNINGRisk of Injury, Damage or DeathLoose or missing retainer resulting in disconnection of wiring may cause injury, damage or death resulting from erratic wheelchair operation.—Ensure battery retainer is in locked position.—DO NOT use wheelchair if erratic operation occurs. Contact qualified service technician or Invacare for assistance.

FIGURE 12.1 Shock or Rubber Element Replacement - Group 24 Batteries

Wheelchairs Equipped With Vent Tray Wheelchairs Equipped Without Vent TrayTop of Shock or Rubber Element

Rear of Chair

Front of Chair

Mounting Screws(Loosen)


Retainer Clip (Closed End)

Spacer


Top of Shock

Spacer

Base Frame

Battery Box

Sub-Frame

Rearmost Mounting Screws

(Loosen)



FIGURE 12.2 Shock or Rubber Element Replacement—Group 24 Batteries

Shock Spring ReplacementNOTE: For this procedure, refer to FIGURE 12.3 on page 127.

1. Remove the group 24 battery box. Refer to Removing/Installing Battery Boxes on page 93.

2. Group 24 Batteries Only - Loosen the mounting screw that secures the battery box retainer bar to the base frame.

3. Remove the mounting screw that secures the top of the shock to the suspension arm.

4. Swing the top of the shock rearward.

5. Hold the spring retainer and turn the shock eyelet assembly counterclockwise to unthread it from the shock.

6. Remove the spring retainer and spring.

7. Place the new spring onto the shock.

8. Reinstall the shock eyelet assembly and the spring retainer onto the new spring.

9. While holding the spring retainer, torque the shock eyelet assembly to 245 in-lbs.

10. Position the retainer clip between the shock and the battery box sub-frame making sure the retainer clip mounting hole is towards the bottom and the closed end of the clip is against the battery box retainer.

NOTE: Hardware is mounted inside of the anti-tip bracket

Washers

2 Inch Spacers

Shock or Rubber ElementAnti-Tip Bracket

Large Washer

Small Washer 5-16 - 18 x 3-1/2 Inch

Hex Head Cap Screw

Suspension Arm for 4 Pole Motors

Locknut

Long Spacer

Short Spacer

Bottom of Shock or Rubber Element



11. Secure top of shock and retainer clip to base frame. Apply Loctite 242 and torque to 160 in-lbs.

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 in-lbs (13.3 ft-lbs)(18.03 Nm).

13. Reinstall the group 24 battery boxes. Refer to Removing/Installing Battery Boxes on page 93.

FIGURE 12.3 Shock Spring Replacement

Group 22 Batteries Group 24 Batteries

NOTE: Shock exploded away for clarity. There is no need to remove shock from suspension arm.

Shock

Suspension Arm

Mounting Screw

Spacer

Retainer Clip


Shock Eyelet Assembly

Hex Screws

Shock Eyelet Assembly Spring Retainer

Shock Spring

Spring Base

Shock



Anti-Tipper Wheel ReplacementNOTE: For this procedure, refer to FIGURE 12.4 on page 128.

1. Remove the locknuts, hex screws and spacers that secure the anti-tipper wheels to the anti-tip bracket.

2. Replace anti-tipper wheel(s) and torque existing hardware to 156 in-lbs (13 ft-lbs)(17.62 Nm). DO NOT overtighten.

FIGURE 12.4 Anti-Tipper Wheel Replacement

Removing/Installing the 3-inch Anti-Tip AssemblyNOTE: For this procedure, refer to FIGURE 12.5.

1. Remove the 5/16-18 x 3-1/2-inch hex head cap screw, two short spacers, two large washers, and locknut that secure the rear of the anti-tip bracket and shock (or rubber element) to the suspension arm. Save hex head mounting screw, two small spacers, and locknut for installation of the 4-inch active anti-tip assemblies.

2. Remove the 5/16-18 x 3-1/4-inch hex head cap screw, two small washers, long spacer and locknut that secure the front of the anti-tip bracket to the the suspension arm. Save hex head mounting screw and locknut for installation of 4-inch active anti-tip assemblies.

Anti-Tipper Wheel

Spacer

Locknut

Spacer



FIGURE 12.5 Removing/Installing the 3-inch Anti-Tip Assembly

Shock or Rubber ElementAnti-Tip Bracket

Large Washer

Small Washer

5-16 - 18 x 3-1/2 Inch Hex Head Cap Screw

Suspension Arm for 4 Pole Motors

Locknuts

Long Spacer

Short Spacer

5-16 - 18 x 3-1/4 Inch Hex Head Cap Screw


Invacare Corporation www.invacare.com

USAOne Invacare WayElyria, Ohio USA44035800-333-6900

Canada570 Matheson Blvd E Unit 8Mississauga OntarioL4Z 4G4 Canada800-668-5324

© 2016 Invacare Corporation. All rights reserved. Republication, duplication or modification in whole or in part is prohibited without prior written permission from Invacare. Trademarks are identified by ™ and ®. Making Life's Experiences Possible is a registered trademark in the U.S.A. All trademarks are owned by or licensed to Invacare Corporation or its subsidiaries unless otherwise noted.

Loctitie is a registered trademark of Loctite Corporation.Super Lube is a registerd trademark of SYNCO Chemical Corporation.

Part No. 1104849 Rev G~02 - 12/16

LIMITED WARRANTYFor warranty information, please refer to the original user manual which came with this product or contact Invacare for more information.

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