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Invacare Pronto R2 Service Manual

1. 46 PROCEDURE 6 5 E p REPLACING STABILIZER WHEEL 47 CHANGING SEAT DEPTH 14 REPLACING CLUTCHHANDLE e 47 REPLACING CAPTAIN S VAN SEAT AND OR CAPTAINIS VAN SEATFFIAME 5 48 un Hane REPLACING SEAT MOUNT PLATES 49 REMOVING INSTALLING STANDARD SEAT 15 REMOVING INSTALLING CAPTAIN S REPLACING SEAT SUPPORT BRACKETS 50 REPLACING SEAT SUPPORT BRACKET VANISEAT Etats Ea Ud somes 16 T NUTS 51 REMOVING INSTALLING SEAT PAN ER 17 ae a eee ra MOUNTING PLATE SEAT ANGLE ADJUSTMENT AND INSTALLATION b LU M Merc ET ORIENTATION pec 17 PROCEDURE 12 RECLINER 53 CHANGING BACK HEIGHT 19 POSITIONING LIMIT SWITCH 53 BACK ANGLE ADJUSTMENT 21 ADJUSTING LIMIT SWITCH 53 PROCEDURE 7 ELECTRONICS TERN Ee ee A REPLACING ADJUSTING GAS CYLINDERS 55 REPOSITIONING MKIV RII JOYSTICK 22 CHANGING BACK HEIGHT 56 REMOVING INSTALLING AND OR RII CONTROLLER 22 CHANGING SEAT DE
2. 1133 4928 MDU mz mummmo p uou PROCEDURE 12 BASE FRAME 6 Repeat STEPS 4 5 for opposite side if necessary 4 Remove seat mounting plates Refer to REPLACING NOTE Forillustrations of the two 2 differentseat mounting SEAT MOUNTING PLATES in this procedure of the plates refer to MOUNTING PLATE SEAT ANGLE AD manual JUSTMENT AND INSTALLATION ORIENTATION in NOTE Note the position of the seat support brackets before PROCEDURE 6 of this manual removing to ensure proper reinstallation 7 Adjust seat mounting plates to desired angle Refer to MOUNTING PLATE SEAT ANGLE ADJUSTMENT Do not adjust the position of the seat sup AND INSTALLATION ORIENTATION in PROCEDURE port bracket in this procedure If an ad 6 of this manual justment is desired refer to ADJUSTING 8 Reassemble wheelchair by reversing STEPS 1 3 WEIGHT DISTRIBUTION in PROCEDURE 12 5 Remove the two 2 mounting screws and washers that secure the seat support bracket to the base frame REAR OF Seat Mounting CHAIR Plate Bolt Strap When installing seat support bracket en sure the mounting screws are threaded into the T Nuts located inside the channel of the base frame 6 Secure the NEW seat support bracket to the T nuts located inside the channel of the base frame with the existing two 2 mounting screws and washers Torque to 156 inch pounds SSG Base 7 Reinstall seat mountin
3. 6 BEPLACNGFORKS 30 PROCEDURE 2 TROUBLESHOOTING 7 FIELD LOAD TEST 7 PROCEDURE 10 5 5 32 EM USING HYDROMETER TO CH ECK BAT TERY REMOVING NSTALLING SHROUDS eee eee 32 T CELLS LEAD ACID iiia iisii nisa nienn 7 MOTORTESTING PROCEDURE 11 BATTERIES 5 MOTOR BRUSH INSPECTION INSTALUNG REMOVING BATTERIES T ELECTRO MECHANICAL PARKING BRAKE INTO FROM BATTERY BOXES BRRRERRRERRRRRRRRRREG 34 S TESTING es 9 CONNECTING BATTERY CABLES 35 WHEN TO CHARGE BATTERIES 39 PROCEDURE FRONT RIGGINGS 10 CHARGING BATTERIES 39 ADJUSTING THE REMOVABLE FOOTBOARD 10 REPLACING BATTERIES 41 PROCEDURE 4 ti INSTALLING REMOVING BATTERY BOXES 41 REPLACING ARMRESTPADS 11 REMOVING INSTALLING BATTERY TRAY 42 REPLACING ARMRESTPLATE 11 PROCEDURE 5 UPHOLSTERY SEAT PROCEDURE 12 BASE FRAME 44 POSITIONING 5 12 REPLACING WIRING HARNESS 44 REPLACING SEAT POSITIONING STRAP 12 ADJUSTINGSTABILIZER ASSEMBLY REPLACING BACK UPHOLSTERY 12 FOR USER PREFERENCE
4. 9 Remove the four 4 mounting screws locknuts and spacers if applicable that secure the standard seat frame to the seat mounting plates 10 Remove existing standard seat frame 11 Position NEW standard seat frame on seat mounting plates 12 Secure NEW standard seat frame onto seat mounting plates with existing four 4 mounting screws locknuts and spacers if applicable Torque to 156 inch pounds 13 Reassemble wheelchair by reversing STEPS 1 8 Mounting Screws Torque to 156 inch pounds Standard Seat Frame 21 14 Spacer 16 inch Wide Only Seat Base Frame Locknuts E HGURE 1 CHANGING SEAT DEPTH FOR SIANDARD SEAT FRAME 14 SEAT BACK REPLACING CAPTAIN S VAN SEAT AND OR CAPTAIN S VAN SEAT FRAME FIGURE 2 1 Remove footrest assemblies Refer to PROCEDURE 3ofthe Owner s Manual part number 1095602 2 Removefront and rear shrouds Referto REMOVING INSTALLING SHROUDS in PROCEDURE 10 of this manual 3 Remove battery box es Refer to INSTALLING RE MOVING BATTERY BOXES in PROCEDURE 11 of this manual 4 Cuttie wraps and disconnect joystick from controller S QR X Mounting Screws v 1 1 Torque to 156 inch pounds Captain s Van Seat Seat Mounting Plate Seat Mounting Plate Locknuts Captain s van Seat Captain s van Seat Frame Re Washer Mounting Screw Torque to 75 inch pounds FIGURE 2
5. remove the front and rear shrouds Refer to REMOVING INSTALLING SHROUDS in PROCEDURE 10 of this manual 2 Remove the battery boxes Refer to INSTALLING RE MOVING BATTERY BOXES in PROCEDURE 11 ofthis manual NOTE Before removing the tie wraps note the tie wraps po sition on the base frame and the components that they se cure 3 Remove the tie wrap A and B that secure the following components to the base frame A Theconnection between the left motor gearbox lead and left controller lead B Rightcontroller lead C The connection between the controller connector BLUE and the wiring hamess BLUE connector D Thecoil wrapped battery lead 4 Remove tie wrap that secures the following to the base frame A Theconnectionbetween the right motor gearbox lead and right controller lead B The cable extending out from the blue connector of the wiring hamess for the power take off C Powertake off cable and lead for battery charger port 5 Remove tie wrap D 10 11 12 13 14 15 BASE FRAME Remove the two 2 phillips bolts and locknuts that se cures the battery charger portto the mounting bracket Remove the battery charger port from the mounting bracket HIGH BACK CAPTAIN S SEAT MODEL WHEEL CHAIRS ONLY DETAIL A Unplug the powertake off ofthe Captain s Van Seat from the power take off of the wiring hamess Disconnect the the connection between the contro
6. 0 PROCEDURE 12 ADJ USTING STABILIZER ASSEMBLY FOR USER PREFERENCE FIGURE 2 1 Rotating the locknut that is located on top of the lower spring provides one 1 ofthe following Rotating the locknut CLOCKWISE provides more resistance of the stabilizer when stopping B Rotating the locknut COUNTER CLOCKWISE provides less resistance of the stabilizer when stop ping E Stabilizer Locknut Lower Spring FIGURE 2 ADJUSTING STABILIZER ASSEMBLY FOR USER PREFERENCE REPLACING STABILIZER CYLINDERS FIGURE 3 T Remove the top mounting screw and locknut that secures the top of the stabilizer cylinder to the wheelchair frame Note the mounting position of the existing stabi lizer cylinder for proper installation of the new sta bilizer cylinder Remove the bottom mounting screw washers and locknut that secures the bottom of the stabilizer cylinder to the swing arm Remove the existing stabilizer cylinder Secure the bottom of the NEW stabilizer cylinder to the mounting hole on the swing arm noted in STEP 2 with the mounting screw washers and locknut Loosely tighten Secure the top of the stabilizer cylinder to the wheelchair frame with the top mounting screw and locknut Loosely tighten 46 7 BASE FRAME Torque both mounting screws to 13 ft Ibs and then back off 1 8 to 1 4 turn NOTE The length of the new
7. 10 Reinstall the mounting screw through the mounting bracket of the back cane nylon washer mounting hole in the TOP of the gas cylinder nylon washer mounting bracket and washer and securely tighten with the existing locknut Torque to 75 inch pounds 11 Reinstall the recliner cable assemblies onto the back canes Refer to REPLACING RECLINER CABLES in this procedure of the manual Headrest Extension Tube N Back Cane Spreader 30 E Mounting Mounting 2 Screw 3 Washers 2 gt Locknut Push ell Mounting s Screw Seat Frame I NOTE Upholstery not shown for clarity FIGURE 5 CHANGING BACK HEIGHT 56 RECLINER NOTE There are three 3 differentcable lengths depending on back height BACKHEIGHT ninches 3812 25 224 CABLELENGTH Shot Medium Long NOTE New recliner cables will be needed if back height is changed to a height not within the length of the original cable 12 Install the NEW back upholstery onto the back canes 13 Install the ten 10 or twelve 12 mounting screws de pending on back height that secure the back upholstery to the recliner back canes 14 Reinstall headrest extension onto recliner back canes 15 Adjustthe tautness ofthe back and headrest upholstery Referto ADJUSTING BACK OR HEADREST UPHOL STERY in this procedure of the manual CHANGING SEAT DEPTH FIGURE 6 To adjust seat de
8. REAR FRONT E armrest Insert Mounting Screw Mounting Armrest Plate Screw FIGURE 1 REPLACING ARMREST PADS CAPTAIN S VAN SEATS 11 PROCEDURE 4 REPLACING CAPTAIN S VAN SEAT ARMREST PLATE FIGURE 2 1 If necessary remove the three 3 mounting screws spacers and locknuts that secure the joystick mount ing bracket to the armrest plate 2 Remove armrest pad Refer to REPLACING ARM REST PADS CAPTAIN S VAN SEATS in this proce dure of the manual 3 Removethe mounting screw washers and locknut that secure the existing armrest plate to the arm weldment 4 Position the NEW arrest plate on the armrest weldment andsecure with the mounting screw washers and lock nut Referto FIGURE 2for correct hardware orientation 5 Reinstall van style armrest pad Refer to REPLAC ING ARMREST PADS CAPTAIN S VAN SEAT in this procedure of the manual 6 Ifnecessary reinstall the three 3 mounting screws spacers and locknuts that secure the joystick mount ing bracket to the armrest plate 7 Repeat STEPS 1 6 for the opposite armrest plate if necessary Washer pe bM Locknut 2 a Mounting R pe Armrest 1 Plate Arm Weldment FIGURE 2 REPLACING CAPTAIN S VAN SEAT ARMREST PLATE Jm oroiruc 0 S T 0 N G S T R A PROCEDURE 5 This Procedure Includes the Following Replacing Seat Positioning Strap Captain
9. REPLACING CAPTAIN S VAN SEAT AND OR CAPTAIN S VAN SEAT FRAME 15 PROCEDURE 6 e Tum the lever on the adjustment lock to release the ad justment lock from the joystick mounting tube 6 Remove the joystick from the wheelchair 7 Remove the mounting screw that secures the armrest to the van seat frame Repeat for opposite side 8 Remove the four 4 mounting screws and locknuts that secure the Captain s Van Seat to sseat mounting plates 9 Remove the four 4 mounting screws two 2 wash ers and two 2 spacers that secure the Captain s van seat to the seat frame 10 Replace either Captain s van seat or Captain s van seat frame 11 Secure new existing Captain s van seat to the new ex isting Captain s van seat frame with existing four 4 mounting screws and spacers Apply Loctite on threads and torque to 75 inch pounds 12 Reassemble wheelchair by reversing STEPS 1 8 REMOVING INSTALLING STANDARD SEAT FIGURE 3 Removing 1 Remove footrest assemblies Refer to PROCEDURE 3 of the Owner s Manual part number 1095602 2 Remove front and rear shrouds Refer to REMOVING INSTALLING SHROUDS in PROCEDURE 10 of this manual Removebattery box es Referto INSTALLING REMOV ING BATTERY BOXES in PROCEDURE 11 of this manual Cut tie wraps and disconnect joystick from controller Remove the four 4 mounting screws and locknuts that secure the seat frame to the seat mounting plates 6 Rem
10. 1 battery cable and battery clamp cover are shown for clarity Both battery clamp covers install in the same manner INSTALLING BATTERY CLAMP COVERS Battery Clamp Battery Cable FIGURE 5 CONNECTING BATTERY CABLES BATIERY CLAMP METHOD When connecting the battery cable ring terminal s to the battery ies clamp s the battery cable s MUST be connected in the position shown in DEIAIL A otherwise damage may occur to the battery cable and or battery clamp covers Connect battery cable s to battery ies terminal s post s as follows DETAIL A NEGATIVE BLACK battery cable ring terminal between the mounting plate and battery clamp of NEGATIVE battery terminal post B POSITIVE RED battery cable ring terminal be tween the mounting plate and battery clamp bat tery clamp of POSITIVE battery terminal post 4 Secure the battery cable s ring terminal s to the battery damp s BLACK to NEGATIVE and RED to POSI TIVE with existing hex screws Securely Tighten 5 Verify battery cable ring terminal s are correctly installed and securely tightened 6 Slide battery clamp covers down battery cables and onto battery terminals DETAIL 7 Secure eachterminalcap in place with a tie wrap Use tie wraps 11 1 2 inches long DETAIL NOTE It will be necessary to trim excess tie wrap in order to install the battery box top s 8 _ Insta
11. Connecting Battery Cables When to Charge Batteries Charging Batteries Replacing Batteries Installing Hemoving Battery Boxes Removing Installing Battery Tray Make sure power to the wheelchair is OFF before performing this procedure The use of rubber gloves and safety glasses is recommended when working with bat teries Invacare strongly recommends that bat tery installation and battery replacement always be done by a qualified technician After ANY adjustments repair or service and BEFORE use make sure all attaching hardware is tightened securely otherwise injury or damage may result INSTALLING REMOVING BATTERIES INTO FROM BATTERY BOXES FIGURE 1 NOTE Toremove the battery ies from the battery box es reverse the following procedure NOTE Have the following tools available TOOL QTY COMMENTS Battery Lifting Strap 1 See Note 1 2 inch 6 pt Box Wrench 1 Not Supplied 7 16 inch 6pt Box Wrench 1 Not Supplied 3 8 inch 6pt Box Wrench 1 Not Supplied Diagonal Cutters 1 Not Supplied NOTE The Battery Lifting strap supplied is for Group 22 Batteries ONLY Refer to the battery manufacturer for the proper lifting strap and or battery tools for U1 battery re moval nstallation Always use a battery lifting strap when lift ing a battery It is the most convenient method and assures that the battery acid will not spill It also helps to prolong the life of the battery DO
12. Remove the armrest pad from the armrest plate 7 Remove the lug bolt washers and locknut that secure the existing armrest plate to the seat frame assembly 8 Repeat STEPS 4 7 for opposite side of wheelchair 9 Position armrest plate with joystick mounting holes on desired side of seat frame assembly and secure with lug bolt washers and locknut Refer to FIGURE 1 Armrest Plate Armrest Pad _ Lug Bolt Armrest Insert 5 5 7 9 Phillips Screw Locknuts STEPS 5 13 AN A STEPS 3 17 Locknuts oK 7 9 la uo 75 592 ks Ss Washers 824 Wa K STEPS 7 9 C mss Hex Bolts STEPS 3 16 v a j Adjustment Lock Washers STEPS 7 9 Seat Frame Assembly FIGURE 1 REPOSITIONING MKIV AND RII JOYSTICK CAPTAIN S SEATS dy ce Phillips Screw STEPS 4 14 Spacers STEPS 3 17 ELECTRONICS 10 Position armrest plate without joystick mounting holes on opposite side of seat frame assembly and secure with lug bolt washers and locknut Refer to FIGURE 1 11 Position the armrest pad on the armrest plate 12 Line up the mounting holes in the armrest insert armrest plate and armrest pad 13 Reinstall rear phillips screw through the armrest insert armrest plate and armrest pad and tighten securely 14 Reinstall the front phillips screw into the armrest plate and armrest pad and tighten securely 15 Repeat STEPS 11 14 for opposite side
13. Reposition the back canes into the correct mounting holes of the back angle plate to obtain a back angle between 80 and 1007 in 5 increments Torque mounting screws to 75 inch pounds Reinstall the armrests onto the wheelchair Refer to INSTALLING REMOVING FLIP BACK ARMRESTS in PROCEDURE 4 ofthe Owner s Manual part num ber 1095206 BACK ANGLE PLATE HOLE TOP Front BOTTOM Rear TOP Front BOTTOM Center TOP Front BOTTOM Front TOP Center BOTTOM Front TOP Rear BOTTOM Front FIGURE 8 BACK ANGLE ADJ USTMENT 21 S n B ie K PROCEDURE 7 This Procedure Includes the Following Repositioning MKIV and RII Joystick Removing Installing MKIV and RII Controller After ANY adjustments repair or service and BEFORE use make sure all attaching hardware is tightened securely other wise injury or damage may result REPOSITIONING MKIV AND RII J OYSTICK Captain s Seats FIGURE 1 1 Tum the lever on the adjustment lock to release the adjustment lock from joystick mounting tube 2 Remove the joystick from the wheelchair 3 Remove the three 3 hex bolts spacers and locknuts that secure joystick mounting bracket to armrest plate 4 Remove the phillips screw that secures the front of the armrest pad to the armrest plate 5 Remove the phillips screw that secures the rear of the armrest pad and armrest insert to the armrest plate 6
14. STEPS 3 12 e 1 Mounting 1 Screw STEPS 3 14 ed Al gt Spacers N Washer AF STEPS 5 6 STEPS3 14 7 0 Pd N Bak 1 2 s Upholster 1 1 STEPS 3 7 J A 2 Spreader Bar Ps STEPS 2 7 16 Mounting Screw Mounting pem Torque to 60 in Ibs Screw Pd STEP 2 STEP 2 P Mounting onc Screws E STEPS 5 6 Washers STEPS 5 6 Insert Washers STEPS 5 6 Mounting Screws 5 Seat Frame Torque to 75 in Ibs x 9 STEPS 5 6 AGURE 2 REPLACING BACK UPHOLSTERY 13 PROCEDURE 6 This Procedure includes the following Changing Seat Depth For Standard Seat Frame Replacing Captain s van Seat and or Captain s van Seat Frame Removing Installing Standard Seat Removing Installing Captain s Van Seat Removing Installing Seat Pan Mounting Plate Seat Angle Adjustment and Installation Orientation Changing Back Height Back Angle Adjustment After ANY adjustments repair or service and BEFORE use make sure that all attaching hardware is tightened securely otherwise injury or damage may result NOTE The procedures in this section of the manual refer to NON RECLINER seat frames only EXCEPT Seat Angle Adjustment For reclinerseatframes referto PROCEDURE 14 of this manual CHANGING SEAT DEPTH FOR STANDARD SEAT FRAME FIGURE 1 NOTE
15. BASE FRAME 5 If handling of the power wheelchair is drifting repeat this procedure moving seat up in small increments until the chair handles properly 6 Once the seat is adjusted to the point of proper han dling comfort adjustments can be made 7 Adjustthe stabilizers to the desired setting Refer to ADJUSTING STABILIZERS in this procedure of the manual Seat Support Bracket Mounting Screws Two 2 on each bracket Front of Seat Support Bracket Front of Base Frame FIGURE 11 ADJ USTING WEIGHT DISTRIBUTION RECLINER This Procedure Includes the Following Positioning Limit Switch Adjusting Limit Switch Replacing Recliner Cable Assemblies Replacing Adjusting Gas Cylinders Changing Back Height Changing Seat Depth Changing Seat Width Installing Replacing Adjustable 16 to 19 inch Deep Recliner Seat Frame onto Arrow or X Base After ANY adjustments repair or service and BEFORE use make sure that all attaching hardware is tightened securely otherwise injury or damage may result POSITIONING LIMIT SWITCH FIGURE 1 NOTE The battery charger connector as well as the limit switch are factory set on the RIGHT side of the wheelchair However they can be positioned on either side for userconve nience The limit switch MUST BE positioned on the same side as the battery charger connecior 1 Cut the two 2 tie wraps that secure the limit switch wire to the seat frame 2
16. BOXES BATTERIES CONNECTING BATTERY CABLES NEVER allow any of your tools and or bat tery cable s to contact BOTH battery terminal s post s at the same time An elec trical short may occur and serious personal injury or damage may occur The use of rubber gloves and safety glasses is recommended when working with bat teries Dual U1 or Dual 22NF Battery Boxes Perform one 1 of the following methods for connecting the battery cable s A FOR DUAL U1 BATTERIES Use direct mount method Refer to FIGURES 2 and 3 FOR DUAL 22 NF BATTERIES THAT HAVE MOUNTING HOLES IN THE BATTERY TERMINAL S POST S Use direct mount method Referto FIGURES 2 and 3 FOR DUAL 22 NF BATTERIES THAT DO NOT HAVE MOUNTING HOLES IN THE BATTERY TERMINAL S POST S Use battery clamp method Refer to FIGURES 4 5 AND 6 DIRECT MOUNT METHOD FIGURE 2 3 AND 4 1 Install battery terminal cap s onto battery cable s as follows FIGURE 2 DUAL U1 BATTERIES A ORANGE battery terminal cap onto RED battery cable B GRAY battery terminal cap onto BLACK battery cable DUAL 22 NF BATTERIES A RED battery terminal cap onto RED battery cable B BLACK battery terminal cap onto BLACK battery cable INSTALLING BATTERY TERMINAL CAPS Battery Cable Battery Terminal Cap NOTE Only one 1 battery cable and terminal cap shown for clarity Both caps install in the same manner HGURE 2 CONNECTING BATTERY CABLES DIRECT MOUNT
17. Includes the Following Adjusting Limit Switch After ANY adjustments repair or service and BEFORE use make sure all attaching hardware is tightened securely other wise injury or damage may result ADJ USTING LIMIT SMTCH FIGURE 1 NOTE The following procedure is for High Back Captain s seat model wheelchairs only NEVER operate the wheelchair while in any recline position over 114 RELATIVE TO THE SEAT FRAME If the limit switch does not stop the wheelchair from operating in a recline position greater than 114 RELATIVE TO THE SEAT FRAME DO NOT operate the wheelchair Adjust the limit switch or have the wheelchair serviced by a qualified technician otherwise injury or damage may occur Place the wheelchair on a level surface Recline the captain s seat back to a 24 to achieve the 114 angle relative to the seat frame Refer to ADJUST ING CAPTAIN S SEAT in PROCEDURE 5 of the Owner s Manual part number 1095602 NOTE The captain s seat frame is at a 5 angle relative to the ground When the back angle is adjusted to 114 rela tive to the seat it will measure 61 relative to the ground 114 24 Back Recline Angle V 584 inches NN Magnetic Protractor Will read 61 when back recline angle is at 114 relative to the seat frame 5 Seat Angle actuator NOTE To determine 114 back angle relative to the seat frame place a magnetic protr
18. PROCEDURE 6 ofthis manual REMOVING INSTALLING THE CAPTAIN S VAN SEAT in PROCEDURE 6 of this manual REMOVING INSTALLING THE RECLINER SEAT FRAME in PROCEDURE 13 of this manual 7 Plugjoystick into controller The coil wrapped battery lead B C Mounting Stud on Wheelchair Frame Washers MKIV Controller _ Locknuts Washers NOTE Base Frame shown is for reference only It is not a true representation of the Pronto Base Frame FIGURE 2 REMOVING INSIALLING CONTROLLER 23 PROCEDURE 7 ELECTRONICS Right Coil Wrapped Wiring Harness Motor Gearbox Battery Lead Connector BLUE Lead Cable for Power Take Off Right Controller Lead Controller BLUE Crossmember Right Controller Lead Nel Tie Wrap 11 LEFT HAND RIGHT HAND SIDE OF SIDE OF WHEELC HAIR WHEELC HAIR Tie Wrap j 5 A Tie Wrap 11 5 Crossmember Left Motor Gearbox Lead VIEW FROM REAR OF CHAIR Left Controller Lead FIGURE REMOVING INSIALLING MKIV CONTROLLER TIE WRAP LOCATIONS 24 ELECTRONICS RII Controller FIGURE 4 REMOVING 1 Remove the seat Refer to one 1 of the following A REMOVING INSTALLING THE STANDARD SEAT FRAME in PROCEDURE 6 ofthis manual B REMOVING INSTALLING THE CAPTAIN S VAN SEAT in PROCEDURE 6
19. Remove the two 2 mounting screws and washers that secure the actuator to the gas cylinder pivot block 3 Position actuator on opposite gas cylinder pivot block CAUTION DO NOT over tighten the mounting screws that secure the actuator to the pivot block Damage to actuator will occur 4 Secure the actuator to the pivot block with the two 2 mounting screws and washers DO NOT overtighten 5 Remove the mounting screw that secures the wire re tainer to the inside of the seat frame 6 Remove the two 2 mounting screws and washers that secure the limit switch sensor to the seat frame 7 Tumlimit switch sensor over so opposite side is facing up andthe wire is on the INSIDE ofthe seat frame 8 Position the limit switch sensor onto the opposite side of the seat frame DO NOT over tighten the mounting screws that secure the limit switch sensor the seat frame Damage to the limit switch sensor will occur PROCEDURE 13 9 Secure limit switch sensor to the seat frame with the two 2 mounting screws and washers 10 Secure the wire retainer onto the INSIDE of the seat frame with the mounting screw 11 Tie wrap the limit switch wire to the seat frame 12 Adjust the limit switch Refer to ADJUSTING LIMIT SWITCH in this procedure of the manual Mounting Screws DO NOT Over Tighten Limit Switch Sensor Washers Tie Wraps Mounting _ Screws Wire Retainer Seat F
20. The seat depth ofthe wheelchaircan be adjusted up to 71 inch from the original seat depth by simply using the correct depth seat pan without changing the seat frame Example SEATFRAME AVAILABLE SEAT DEPTHS 16 inch 16 and 17 inch 18 inch 18 and 19 inch 20 inch 20 and 21 inch 22 inch 22 inch NOTE If the desired seat depth change only requires a NEW seat pan refer to REMOVING INSTALLING SEAT PAN in this procedure If the desired seat depth change re quires a change in the seat frame perform the following 1 Remove footrest assemblies Refer to PROCEDURE 3 in the Owner s Manual part number 1095602 2 Remove front and rear shrouds Refer to REMOVING INSTALLING SHROUDS in PROCEDURE 10 of this manual 3 Remove battery box es Referto INSTALLING REMOV ING BATTERY BOX in PROCEDURE 11 ofthis manual 4 Cuttie wraps and disconnect joystick from controller 5 Tum the lever on the adjustment lock to release the ad justment lock from the joystick mounting tube 6 Remove the flip back armrests from the wheelchair Re fer to INSTALLING REMOVING FLIP BACK ARM RESTS in PROCEDURE 4 of the Owner s Manual part number 1095602 SEAT BACK 7 Remove the seat pan including seat positioning straps Referto REMOVING INSTALLING SEAT this pro cedure of the manual 8 Removethe back upholstery including back canes and spreader bar if applicable Referto REPLACING BACK UPHOLSTERY in PROCEDURE 5 of the manual
21. higher electrical rating as the device being connected In addition Invacare has placed RED ORANGE WARNING TAGS on some equipment DO NOT re move these tags Carefully read battery battery charger information prior to installing servicing or operating your wheelchair gt omz rmo co PROCEDURE 1 GENERAL GUIDELINES WARNING CAUTION LABEL LOCATION CAUTION ENGAGE SIEP 22 PUSH FORWARD G E N R A L G U D E L Bur DISENGAGE STEP 1 _ RE BO CHES ARE TROUBLESHOOTING This Procedure Includes the Following Field Load Test Using Hydrometer To Check Battery Cells Lead Acid Motor Testing Motor Brush Inspection Electro Mechanical Parking Brake Testing FIELD LOAD TEST FIGURE 1 NOTE The following test can also be performed through the controller of the wheelchair along with a remote pro grammer Refer to the individual CONTROLLER MANUAL supplied with each wheelchair Old batteries lose their ability to store and release power due to increased internal resistance This means that as you try to take power from the battery some of that power is used up in the process of passing through the battery resulting in less voltage at the posts The more power drawn the lower the voltage available When this lost volt age drops the output 1 0 volts under load 2 0 for a pair replace the batteries Testing under load is the only
22. into the 1 operator of the recliner cable assembly HOT C GAS DO cross thread the operator of the re cliner cable assembly with the gas cylinder 55 Aamz romz PROCEDURE 13 Adjusting Gas Cylinder 1 Toadjustthe LEFT gas cylinder Squeeze the handle of the RIGHT recliner cable assembly andtryto recline the back The back should not recline 2 Ifthe LEFT side of the back releases without squeez ing the handle of the LEFT recliner cable assembly perform the following steps A Finger tighten the jam nut on the rod of the gas cylinder until it bottoms out on the rod of the cylin der FIGURE 4 B Tumthe jam nutonthe LEFT gas cylinder COUN TERCLOCKWISE approximately one half 1 2 revolution NOTE The gas cylinder rod will turn C Repeat STEP 1 D Repeat STEP B until the LEFT side of the back DOES NOT 3 To adjust the RIGHT gas cylinder Repeat STEPS 1 and 2 for the LEFT handle of the cable assembly Damage to the gas cylinder rod WILL oc cur if the following steps are NOT followed when the jam nut is torqued against the pivot block 4 Using NO LARGER than 1 4 inch wide fine toothed pliers wrap masking tape around the teeth ofthe pliers two 2 or 3 revolutions 5 Using NO excessive force hold the gas cylinder rod just above the jam nut 6 While holding the gas cylinder rod and using a 17mm wrench tum the jam nut CLOCKWISE and torque the RIGHT and LEFT
23. jam nuts against the RIGHT and LEFT pivot blocks to 156 inch pounds CHANGING BACK HEIGHT FIGURE 5 1 Press the push pins on the headrest extension tubes in and remove headrest extension from back canes 2 Remove the recliner cables from the back canes Re ferto REPLACING RECLINER CABLE ASSEMBLIES in this procedure of the manual 3 Remove the mounting screws washers and locknuts that secure the TOP of the gas cylinders to the mount ing bracket on the back canes 4 Remove the mounting screws washers and locknuts that secure the back canes to the seat frame 5 Remove the existing recliner back assembly from the wheelchair RECLINER 6 Turn the spreader bar on the existing back canes CLOCKWISE toward back upholstery and remove the spreader bar from the existing back canes 7 Loosely install the spreader bar onto the NEW back cane handles by rotating the spreader bar COUN TERCLOCKWISE away from the back canes NOTE If the spreader bar does not thread onto the back canes do not force Turn the spreader bar around and repeat STEP 7 8 Line up two 2 bottom mounting holes of back canes with the two 2 mounting holes in the seat frame The back canes MUST be fastened se curely to the seat frame BEFORE using the wheelchair Torque mounting screws to 156 inch pounds 9 Reinstall the mounting screw washer and locknut through the back cane and seat frame mounting holes and torque to 156 inch pounds
24. of the base frame 4 Replace battery charger mount bracket and secure to base frame with existing mounting screw 5 Secure the battery charger connector to the mount bracket with the EXISTING two 2 mounting screws Tighten securely Battery Mounting Screw Charger Mouni N Locknuts Bracket Mounting Screws Battery Charger Connector Base Frame FIGURE 10 REPLACING BATIERY CHARGER BRACKET AND 20 0 maryn M PROCEDURE 12 USTING WEIGHT DISTRIBUTION FIGURE 11 NOTE The seat mount plates and seat support brackets allow seat frame to be repositioned along the base frame NOTE The position of the seat support brackets is factory set between 3 4 inch and 2 3 4 inch depending on seat depth Measurements are taken from the front end of the base frame Distance measured from the front of the base frame to the front of the seat support bracket Adjustment for Optimum Performance 1 Loosen the four 4 mounting screws that secure the seat support brackets to the base frame 2 Adjustseat back until one 1 of the following occurs A Theclearance ofthe front riggings and the stabiliz ers is at a minimum or B The rear stop is contacted WARNING DO NOT adjust seat beyond end of extru sion or seat stop screws if applicable 3 Retighten mounting screws securing the seat support brackets to the base frame 4 Testwheelchairfor handling 52
25. of the wheel A REMOVING INSTALLING THE STANDARD chair if necessary SEAT FRAME in PROCEDURE 6 ofthis manual 15 Install the controller Refer ot REMOVING INSTALL B REMOVING INSTALLING THE CAPTAIN S VAN ING THE CONTROLLER in PROCEDURE 7 of this SEAT in PROCEDURE 6 of this manual C REMOVING INSTALLING THE RECLINER SEAT 16 Install the battery tray and both motor gearboxes Re FRAME in PROCEDURE 13 of this manual ECCE BATTERY TRAY 4 Remove the drive wheels Refer to REMOVING N STALLING THE DRIVE WHEELS in PROCEDURE 9 of this manual DETAIL A 5 Forwheelchairs equipped with motors that have clutches perform the following Referto FIGURE 5 Motor Gearbox A Removethe pin that secures the clutch handle to the existing motor gearbox Clutch B Disconnect clutch handle from existing motor gear Handle box 6 Note mounting position of motor gearbox on the wheel chair frame for installation of the new motor gearbox Pin 7 Remove the three 3 outside and two 2 inside mount ingscrews that secure one 1 motor gearbox and battery Outside of tray to the base frame Refer to FIGURE 6 8 Removethe motor gearbox from wheelchair frame 9 Positionthe NEW motor gearboxandalign mountingholes Gearbox with the existing battery tray and wheelchair frame at the position noted previously Refer to FIGURE 6 The three 3 OUTSIDE mounting screws that secure the motory gearbox to the base frame MUST be M6
26. specifications DO NOT use parts accessories or adapters other than those authorized by Invacare TIRE PRESSURE DO NOT use your wheelchair unless it has the proper tire pressure P S l DO NOT overin flate the tires Failure to follow these suggestions may cause the tire to explode and cause bodily harm The recommended tire pressure is listed on the side wall of the tire BATTERIES The warranty and performance specifications contained in this manual are based on the use of deep cycle gel cell or sealed lead acid batteries Invacare strongly recom mends their use as the power source for this unti The use of rubber gloves and safety glasses is recommended when working with bat teries Carefully read battery battery charger information prior to installing servicing or operat ing your wheelchair ELECTRICAL Grounding Instructions DO NOT under any circumstances cut or remove the round grounding prong from any plug used with or for Invacare products Some devices are equipped with three prong grounding plugs for protection against possible shock hazards Where a two prong wall receptacle is encountered it is the personal responsibility and obligation of the customer to contact a qualified electrician and have the two prong receptacle replaced with a propery grounded three prong wall receptacle in accordance with the National Elec trical Code If you must use an extension cord use ONLY a three wire extension cord having the same or
27. tray 42 BATTERIES PROCEDURE 11 3 Position one 1 motor gearbox undemeath battery tray DETAIL A aligning the mounting holes ofall three components NOTE This is applies to motors that have clutches Base frame battery tray and motor gearbox ONLY Pin The three 3 OUTSIDE mounting screws that Clutch Handle secure the motor gearbox to the base frame MUST be M6 x 1 x 35 millimeters long and the two 2 INSIDE mounting screws Outside of Wheelchair that secure the motor gearbox to the base frame MUST be M6 x 1 x 20 millimeters long otherwise damage to the gearbox cast ing can result Motor Gearbox om um 5 Uu 4 Install the three 3 outside and two 2 inside mounting screws that secure one 1 motor gearbox and battery tray to the battery tray and base frame Apply Loctite GJ eem 74 242 Loosely tight ti h HAN EM NOTE Battery tray not shown for clarity OUTSIDE Mounting Screws Perform STEPS 3 4 for opposite motor gearbox Torqueallten 10 mounting screwsto 160 inch pounds For wheelchairs equipped with motors that have 2 INSIDE clutches perform the following Refer to DETAIL A Mounting A Connect clutch handle existing motor gearbox Screws B Installthe pinthat secures the clutch handle to the existing motor gearbox 8 Install the drive wheels Refer to REMOVING IN STALLING THE DRIVE WHEELS PROCE DURE 9 of this
28. 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 atthe charger connector It is located on the base of the wheel chair frame NOTE READ the instructions CAREFULLY before us ing the digital voltmeter NOTE Invacare recommends that ONLY qualified tech nicians perform this test 1 Ensure that power is OFF 2 Make sure battery is fully charged An extremely dis charged battery will exhibit the same symptoms as a bad one 3 Place one 1 piece of wood taller than the axle of the drive wheels between the wheelchair and a wall work bench or other stationary object 4 Remove the footrests or footboard from the wheel chair and place the stabilizer wheels against the piece of wood 5 Place the voltmeter leads into the charger plug on the wheelchair Most digital voltmeters are not affected by polarity however analog meters meters with swing ing needles can be and should be used carefully A good meter reading should be 25 5 to 26 VDC 6 Have two 2 individuals one 1 on each arm apply as much downward pressure as possible on the arms of the wheelchair PROCEDURE 2 7 Turn the wheelchair ON and push the joystick for ward trying to drive the wheelchair through the sta tionary object This puts a heavy load on the batteries asthey try to push through the stationary object
29. 5 Install battery box es Refer to INSTALLING REMOV ING BATTERY BOXES in PROCEDURE 11 of this Spacer manual vide 6 Install front and rear shrouds Refer to REMOVING nly INSTALLING SHROUDS PROCEDURE 10 of this v 4 oN manual 7 Install footrest assemblies Refer to PROCEDURE 3 of the Owner s Manual part number 1095602 d Mounting Screws Torque to 156 Captain s inch pounds dl Van k Seat Pus e Base N Frame Locknuts 2 1 Mounting FIGURE 3 REMOVING INSTALLING Seat SIANDARD SEAT Torque to 156 Mounting inch pounds Plate REMOVING INSTALLING CAPTAIN S VAN SEAT FIGURE 4 Removing Captain s Van Seat 1 Remove footrest assemblies Refer to PROCEDURE 3 of the Owner s Manual part number 1095602 2 Remove front and rear shrouds Refer to REMOV ING INSTALLING SHROUDS in PROCEDURE 10 of this manual Removebattery box es Referto INSTALLING REMOV ING BATTERY BOXES in PROCEDURE 11 of this manual Base Frame Locknuts 4 Unplugjoystick from controller FIGURE 4 REMOVING INSTALLING CAPTAIN S VAN SEAT 16 SEAT BACK REMOVING INSTALLING SEAT PAN FIGURE 5 Removing Remove the seat cushion from the seat pan 2 Removetheflip backarmrests from the wheelchair Refer to INSTALLING REMOVING FLIP BACK ARMRESTS in PROCEDURE 4 ofthe Owner s Manual part num ber 1095602 3 Removethesix 6 mounting screws locknuts and
30. D SEAT FRAME in PROCEDURE 6 ofthis manual B REMOVING INSTALLING THE CAPTAIN S VAN SEAT in PROCEDURE 6 of this manual C REMOVING INSTALLING THE RECLINER SEAT FRAME in PROCEDURE 13 of this manual 16 Install the front and rear battery boxes Refer to RE MOVING INSTALLING THE BATTERY BOXES in PROCEDURE 11 of this manual 17 Install the front and rear shrouds Refer to REMOV ING INSTALLING SHROUDS in PROCEDURE 10 of this manual REPLACING SEAT MOUNTING PLATES FIGURE 7 1 Remove the front rear and side shrouds Refer to RE MOVING INSTALLING SHROUDS in PROCEDURE 10 of this manual 2 Remove the battery boxes Refer to INSTALLING RE 49 MOVING BATTERY BOXES in PROCEDURE 11 of this manual 3 Remove the seat Refer to one 1 of the following A REMOVING NSTALLING THE STANDARD SEAT FRAME in PROCEDURE 6 of this manual B REMOVING INSTALLING THE CAPTAIN S VAN SEAT in PROCEDURE 6 of this manual C REMOVING INSTALLING THE RECLINER SEAT FRAME in PROCEDURE 13 of this manual NOTE Before removing seat mounting plates note the po sition of the washers for proper reinstallation 4 Remove the two 2 mounting screws washers and bolt strap bracket that secure the seat mounting plate to the seat support bracket 5 Secure NEW seat mounting plate with existing two 2 mounting screws washers and bolt straps to seat sup port bracket using Loctite 242 and torque to 156 inch pounds
31. ERAF ING NOISE PARTICULARLY RELATIVE TO MOTORS AND GEARBOXES DOES NOT CONSTITUTE A FAILURE ALL SUCH DEVICES WILL EXHIBIT A CHANGE IN OPERATING NOISE DUE TO AGING THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS WARRANTIES IMPLIED WARRANTIES IF ANY INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND HTNESS FOR A PARTICULAR PURPOSE SHALL NOT EXTEND BEYOND THE DURATION OF THE EXPRESSED WARRANTY PROVIDED HEREIN AND THE REMEDY FOR VIOLATIONS OF ANY IMPLIED WARRANTY SHALL BE LIMITED TO REPAIR OR REPLAC EMENT OF THE DEFECTIVE PRODUCT PUR SUANT TO THE TERMS CONTAINED HEREIN INVACARE SHALL NOT BE LIABLE FOR ANY CONSE QUENTIAL OR INCIDENTAL DAMAGES WHATSOEVER THIS WARRANTY SHALL BE EXTENDED TO COMPLY WITH SIATE PROVINCIAL LAWS AND REQUIRE MENTS 59 lt 2 gt gt Invacare Corporation www invacare com USA One Invacare Way Elyria Ohio USA 44036 2125 Yes you 800 333 6900 Canada 5970 Chedworth Way Mississauga Ontario L5R 3T9 Canada 905 890 8838 Invacare and Yes you can are trademarks of Invacare Corporation 2000 Invacare Corporation Form No 00 85 Part No 1098315 RevA 1 04 00
32. FIGURE 4 11 Adjust the NEW gas cylinders Refer to ADJUSTING GAS CYLINDERS in this procedure of the manual Replace ONE 1 gas cylinder at a time to avoid injury Nylon Washer 7 Mounting Bracket Both gas cylinders MUST be operational Mounting and adjusted properly BEFORE using the wy x Scrow recliner DO NOT operate the recliner if Wack asher only one 1 of the gas cylinders is opera tional or adjusted properly Locknut Gas Cylinder No Slack Replacing Gas Cylinder in Cable 1 Remove the mounting screw washer nylon washers and locknut that secure the TOP of the gas cylinder to mounting bracket on back cane 2 Loosenthe jam nut on existing gas cylinder rod 3 Unscrewthe existing gas cylinder from the operator of the recliner cable assembly and the pivot block and remove the existing gas cylinder from the wheelchair Gas Cylinder Gas Rod Threads Cylinder 4 Screw cylinder rod of the NEW gas cylinder into the Pivot Block pivot block until the threads of the cylinder rod are flush with inside of pivot block FIGURE 4 Pals Operator of the Recliner Cable Assembly 5 With the operator of the recliner cable assembly on the Snapped inside of the recliner seat frame line up the mounting into Slot hole in the operator of the recliner cable assembly with Bo the new gas cylinder rod a eee Seated Properly DO NOT force the gas cylinder rod
33. GURE 1 14 inch Drive Wheel FIGURE 2 REMOVING 1 Remove the battery boxes Refer to INSTALLING REMOVING BATTERY BOXES in PROCEDURE 11 of this manual PROCEDURE 9 REMOVING INSTALLING DRIVE WHEEL HUB FIGURE 3 NOTE Drive wheel hubs are only on 14 inch drive wheels NEVER use a locking tab washer more than once ALWAYS use a NEW locking tab washer when installing the drive wheels Removing 1 Remove the drive wheels Refer to REMOVING IN STALLING THE DRIVE WHEELS in this procedure of the manual NOTE The tab of the locking washer that is bent 90 up against the head of the mounting screw MUST be flat tened before the mounting screw can be removed 2 Flatten the tab of the locking washer that is bent 90 up against the head of the mounting screw 2 Remove the four 4 beveled locknuts that secure 3 Remove the mounting screw locking tab washer and the drive wheel to the wheel hub washer that secure the existing drive wheel to the wheel 3 Remove the existing drive wheel from the wheel hub hub 4 Remove the wheel hub and keystock from drive shaft INSTALLING Install drive wheel onto wheel hub Installing 2 Secure the drive wheel onto the drive wheel hub with 1 Position the keystock on the drive shaft the existing four 4 beveled locknuts Torque lock nuts to 160 inch pounds DO NOT Y tha L inch i RE apply more than a one 1 inch in 3 Repeat STEPS 1 2 for opposite side if nec
34. INTO FROM BATTERY BOXES in this procedure of the manual Clean the new battery terminals Install the new batteries into the battery boxes Refer to INSTALLING REMOVING BATTERIES INTO FROM BATTERY BOXES in this procedure of the manual Cleaning Battery Terminals 1 2 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 bums may result Should the liquid touch your skin wash the area imme diately and thoroughly with cool water In serious cases or if eye contact is made seek medical attention IMMEDIATELY NEVER smoke or strike a match near bat teries If the caps of the battery cells are removed NEVER look directly into them while_charging batteries Examine battery clamps and terminals for corrosion over the battery cell holes 41 PROCEDURE 11 Cut the tie wraps around the terminal caps covers Slide the terminal cap cover up the wire to expose the battery terminal Clean the terminals and inside the battery clamps by using a battery cleaning tool wire brush or medium grade sand paper NOTE When done these areas should be shiny not dulll Carefully dust off all metal particles Slide the terminal cap cover back down the wire to cover the battery terminal Secure the terminal cap cover using NEW tie wraps INSTALLING REMOVING BATTERY BOXES FIGURE 9 NOTE To remove the batter
35. Installing Shrouds SHROUDS Remove rear shroud and rear storage compartment if equipped from the wheelchair Refer to REMOVING INSTALLING REAR SHROUD AND REAR STORAGE COMPARTMENT in this procedure of the manual 3 Perform one 1 of the following CAPTAIN S SEAT MODELS Remove the Captain s Seat from the wheelchair Refer to RE MOVING INSTALLING CAPTAIN S SEAT in PRO After ANY adjustments repair or service and BEFORE use make sure all attaching hardware is tightened securely other wise injury or damage may result CEDURE 5 of this manual SHROUDS FIGURE 1 4 Removethe phillips screws washer and coved wash ers that secure side shroud to wheelchair frame Refer to FIGURE 1 for phillips screw and washer locations Remove the phillips bolts washers and locknuts that secure the side shroud to the wheelchair frame Refer to FIGURE 1 for phillips bolt and locknut location 6 Repeat STEPS 4 5 for the opposite side of the wheel chair if necessary INSTALLING SIDE SHROUDS 1 Position the side shroud on the wheelchair frame 2 Line up the mounting holes in the side shroud with the mounting holes in the wheelchair frame REMOVING FRONT SHROUD 1 Tumthe two 2 1 4 turn bolts that secure front shroud to the two 2 side shrouds COUNTERCLOCKWISE 5 2 Remove the front shroud from the wheelchair INSTALLING FRONT SHROUD 1 Positionthetwo 2 1 4 tum bolts with the two 2 mount ing holes i
36. METHOD 35 PROCEDURE 11 When connecting the battery cables to the battery ies the battery cable s MUST be connected to the battery terminal s post s as shown in DETAIL A or DETAIL of FIGURE 3 depending on battery type otherwise damage to the battery cable may result when in stalling battery terminal caps 2 Connect battery cable s to battery ies terminal s post s as follows DETAIL A or DETAIL B of FIG URE 3 depending on battery type A NEGATIVE BLACK battery cable to NEGA TIVE battery terminal post B POSITIVE RED battery cable to POSITIVE battery terminal post 3 Secure the battery cable s ring terminal s to the battery terminal s post s BLACK to NEGATIVE and RED to POSITIVE with the provided 1 4 20 x 7 8 inch hex flange screw and hex flange locknut Securely tighten DETAIL or DETAIL B of FIGURE 3 depending on battery type 4 Verify all battery cable s ring terminal s are correctly installed and securely tightened 5 Slide terminal cap s down battery cable s and onto battery clamps FIGURE 3 6 Secure each terminal cap in place with a tie wrap Use tie wraps 11 1 2 inches long FIGURE 3 NOTE It will be necessary to trim excess tie wrap in order to install the battery box top s 7 Install the battery box 5 8 Install the battery box es into the wheelchair Refer to INSTALLING REMOVING BATTERY BOX ES i
37. NOT tip the batteries Keep the batter ies in an upright position 34 BATTERIES 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 rein stalling 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 terminal post and side to NEGATIVE battery ter minal post 1 Ifnecessary remove the battery boxes from the wheel chair Refer to INSTALLING REMOVING BATTERY BOXES in PROCEDURE 11 of this manual 2 Secure the battery lifting strap to battery terminal s post s FIGURE 1 Some battery manufacturers mold a car rying strap and or hold down flanges di rectly into the battery case Batteries which interfere with the battery box cannot be used for these applications Attempting to wedge a battery into a battery box may damage the box and or the battery 3 Place batteries into battery box bottom Battery Lifting Strap Molded Carrying Strap Or Hold Down Flanges 22NF ONLY Battery Terminal s Post s U1 Battery Box Bottom 22 NF Battery ND 1 eff Box Bottom S ML HGURE 1 INSIALLING REMOVING BATIERIES INTO FROM BATTERY
38. PTH 57 22 9 CHANGING SEAT WIDTH 57 PROCEDURE 8 LIMIT SWITCH 27 INSTALLING REPLACING ADJUSTABLE ADJUSTING LIMIT SWITCH 27 16 TO 19 INCH DEEP RECLINER SEAT FRAME 58 LIMITED WARRANTY 59 S ie T 0 N S SPECIFICATIONS Seat Width Range Seat Depth Range Back Height Range Std W Optional Headrest W Optional Backrest Ext Back Angle Range Seat to Floor Overall Height Weight W O Batteries W Batteries Gel Cell Shipping Armrests Upholstery Overall Width No joystick SPECIFICATIONS ADJUSTABLE SEAT CAPTAIN S SEAT BACK TYPE LOW LOWSOLIDSEAT HIGH LOB LOBSS HIB 19 5 in 19 5 in 19 5 in 17 5 in 17 5 in 17 5 in 16 in 16 in 20 in N A N A 29 0 in 23 5 in 23 5 in N A 857 1142 98 85 170 23 in 20 in 23 in 25 5 in 25 5 in 25 5 in 37 in 37 in 41 5 in 142 lbs 216 165 266 165 Removable Flip Back Fixed Adjustable Height Desk and Full Length Gray Cloth Grey Vinyl Tan Vinyl BACK ANGLE 16 24 inches 16 22 inches in 1 inch increments 16 24 inches In 1 inch increments N A N A 80 to 100 in 5 increments 18 5 inches 24 75 inches 34 50 in 42 50 in Back Height 143 Ibs 217 165 267 lbs Remov
39. R CHAIR CHAIR CHAIR v REAR OF FRONT OF REAR OF CHAIR CHAIR SEAT MOUNT PLATE FRONT OF LOW CHAIR HEIGHT FRONT OF CHAIR HIGH HEIGHT AGURE 6 MOUNTING PLATE SEAT ANGLE ADJ USTMENT AND INSIALLATION ORIENTATION 18 SEAT BACK CHANGING BACK HEIGHT FIGURE 7 NOTE If changing the back height new back upholstery may be neededas well Hefer to the following chart to deter mine if new back upholstery is needed BACK UPHOLSTERY HEIGHT RANGES 16 17 INCHES 18 19 INCHES 20 INCHES 21 22 INCHES 23 24 INCHES If back height required is within the range of the origi nal back height only new back canes will be needed If the back height required is NOT within the range of the original back height new back upholstery as well as new back canes will be needed NOTE Existing hardware and inserts will be reused 1 Remove the armrests from the wheelchair Refer to IN STALLING REMOVING FLIP BACK ARMRESTS in PROCEDURE 4 of the Owner s Manual part number 1095602 NOTE Note the correct mounting screw mounting positions to ensure the proper back angle for reinstallation 2 Removethetwo 2 mounting screws and washers that secure the existing back upholstery to the back canes 3 Remove the four 4 mounting screws washers spac ers and locknuts that secure the existing back canes to the seat frame 4 Remove the inserts from the existing back canes 5 Remove the back assembly from the wheel
40. 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 pairoffully charged batteries while under load they should be replaced regardless of the unloaded voltages Battery Charger Connector Digital Voltmeter FIGURE 1 HELD LOAD TEST USING HYDROMETER TO CHECK BATTERY CELLS LEAD ACID FIGURE 2 NOTE Perform this procedure when a digital voltmeter is not available NEVER smoke or stike a match near the batteries If the caps of the battery cells are removed NEVER look directly into them when charging the battery The use of rubber gloves and safety glasses is recommended when testing the battery cells When reading a hydrometer DO NOT al low any liquid to come in contact with your eyes or skin It is a form of acid and can cause serious bums and in some cases blindness If you do get battery acid on you flush the exposed areas with cool water IMMEDIATELY If the acid comes into contact with eyes or causes serious bums get medical help IMMEDIATELY The battery acid can damage your wheel chair clothing and household items Therefore take readings cautiously and only in designated areas R 0 U B L E S H 0 0 T l N G R 0 U B L E S H 0 0 T l N G PROCEDURE 2 ONLY use distilled water when topping off the battery cells Most batteries are not sold
41. Removing Installing Drive Wheel Hub Replacing Casters Replacing Forks After ANY adjustments repair or service and BEFORE use make sure all attaching hardware is tightened securely otherwise injury or damage may result CAUTION As with any vehicle the wheels and tires should be checked periodically for cracks and wear and should be replaced REPLACING PNEUMATIC TIRES TUBES DRIVE WHEELS CASTERS DO NOT use your wheelchair unless it has the proper tire pressure p s i DO overinflate the tires Failure to follow these suggestions may cause the tire to explode and cause bodily harm If tires are pneumatic replacement of tire or tube MUST be performed by a qualified technician NOTE If drive wheels or casters are pneumatic under inflation causes excessive wear which results in poor per formance of the tires REMOVING INSTALLING DRIVE WHEELS NEVER use a locking tab washer more than once ALWAYS use a NEW locking tab washer when installing the drive wheels 12 inch Drive Wheel FIGURE 1 REMOVING 1 The tab ofthe locking washer thatis bent 90 up against the head of the mounting screw MUST be flattened before the mounting screw can be removed 2 Remove the hexscrew locking tab washer and washer that secure the existing front wheel to the wheel hub WHEELS INSTALLING NOTE The keystock in the wheel hub MUST lineup with the cutout in the gearbox drive shaft 1 Instal
42. Service Manual Pronto r Pronto DEALER KEEP THIS MANUAL THE PROCEDURES IN THIS MANUAL MUST BE PERFORMED BY A QUALIFIED TECHNICIAN Yes you can WARNING SPECIAL NOTES THE PROCEDURES IN THIS MANUAL SHOULD ONLY BE PERFORMED BY A QUALIFED TECHNICIAN DO NOT SERVICE OR OPERATE THIS EQUIPMENT WTHOUT ARST READING AND UNDERSIANDING THIS MANUAL AND THE OWNER S MANUAL SUPPLIED WITH THE WHEELCHAIR IF YOU ARE UNABLE TO UNDERSIAND THE WARNINGS CAUTIONS AND INSTRUCTIONS CONTACT INVACARE TECHNICAL SUPPORT BEFORE ATIEMPTING TO SERVICE OR OPERATE THIS EQUIPMENT OTHERMSSE URY OR DAMAGE MAY RESULT SPECIAL NOTES WARNING CAUTION notices as used in this manual apply to hazards or unsafe practices which could result in personal injury or property damage NOTICE THE INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJ ECT TO CHANGE WITHOUT NO TIC E r om uo WHEELCHAIR USER As a manufacturer of wheelchairs Invacare endeavors to supply a wide variety of wheelchairs to meet many needs of the end user However final selection of the type of wheelchair to be used by an individual rests solely with the user and his her healthcare professional capable of making such a selection omaoz WHEELC HAIR TIE DOWN RESTRAINTS AND SEAT POSITIONING STRAPS Invacare recommends that wheelchair users NOT be transported in vehicles of any kind while in wheelchairs As of this date the Department of Transportat
43. Set the digital multimeter to measure ohms Measure the resistance between the two 2 motor contacts NOTE A normal reading is between 1 and 5 ohms A reading of 0 ohms or in excess of 15 ohms indicates a problem High readings are generally caused by bad connections and or damaged brushes Contact Invacare Dealer Motor Connector HGURE 3 MOTOR TESTING TROUBLESHOOTING PROCEDURE 2 MOTOR BRUSH INSPECTION ELECTROMECHANICAL PARKING FIGURE 4 BRAKE TESTING FIGURE 5 There are two 2 contact brushes on the motors located 1 On the four pin motor connector locate the side by under the brush caps on the motor housing If these caps side connectors in the black housings are hard to remove they are either overtightened or the motor has become very hot Let motors cool If caps still cannot be removed itis recommended that the motorbe 3 Measure the resistance between the two 2 brake sent to Invacare Technical Services for inspection repair contacts A normal reading is 100 ohms Q A read ing of O ohms or a very high reading i e MEG ohms or O L out of limit indicates a shorted brake or an open connection respectively If either condition exists send the motor to Invacare Technical Service forinspection repair Set the digital multimeter to read ohms 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 w
44. TAIL A Adjusting the Removable Footboard Height Height Adjustment Flat Nut Bracket Washer After ANY adjustments repair or service Caplug and BEFORE use make sure that all attach 52045 Washer ing hardware is tightened securely oth erwise injury or damage may result Two 2 Large Washers ADJ USTING THE REMOVABLE FOOTBOARD HEIGHT FIGURE 1 5 P 9 1 Remove the removable footboard plate Refer to 9 REMOVING INSTALLING THE REMOVABLE FOOTBOARD ONTO FROM THE WHEELCHAIR R N T R G G N G 5 in PROCEDURE 3 ofthe Owner s Manual part num ber 1096502 Mounting 2 Remove the caplug cap Screw 3 Remove the mounting screw caplug washer flat Caplug washer and nut that secures the two 2 large wash Cap ers and supporttube to the height adjustment bracket and footboard bracket Refer to DETAIL Bracket Support Tube 4 Remove thenutand flatwasher that secure the threaded arm on the height adjustment bracket to the footboard bracket Refer to DETAIL DETAIL 5 Movethe height adjustment bracket to one 1 of seven 7 height positions Footboard Bracket Flat Nut 6 Reinstallthe flat washer and nutthat secures the threaded Washer arm on the height adjustment bracket to the footboard bracket Refer to DETAIL B 7 Reinstall the mounting screw caplug washer flat washer and nut that secures the two 2 large wash ers and support t
45. TANDARD SEAT FRAME in PROCEDURE 6 ofthis manual B REMOVING INSTALLING THE CAPTAIN S VAN SEAT in PROCEDURE 6 of this manual C REMOVING INSTALLING THE RECLINER SEAT FRAME in PROCEDURE 13 of this manual 4 Remove the drive wheels Refer to REMOVING IN STALLING THE DRIVE WHEELS in PROCEDURE 9 of this manual 5 For wheelchairs equipped with motors that have clutches perform the following Refer to DETAIL A A Removethe pin that secures the clutch handle to the existing motor gearbox B Disconnect clutch handle from existing motor gearbox 6 Removethethree 3 outside and two 2 inside mount ing screws that secure one 1 motor gearbox and bat tery tray to the base frame Remove the motor gearbox from wheelchair frame Perform STEPS 6 and 7 for opposite motor gearbox Remove battery tray from wheelchair frame Installing NOTE Battery Tray Installation Summary The bat tery tray will need to be positioned on some type of sup port The base frame will then be positioned on top of the battery tray The motor gearboxes are then held in posi tion underneath the battery tray with mounting holes of all three 3 components in alignment Perform the following steps to install the battery tray 1 Position the new existing battery tray on a support 2 Position the base frame on the new existing battery tray so that the mounting holes on the base frame align with the mounting holes on the battery
46. URE 5 otherwise the bat tery box top cannot be installed properly 1 Perform one 1 of the following Ifthe battery clamp ofthe POSITIVE battery ter minal post is NOT mountedin the orientation shown in FIGURE 4 perform the following Loosen the hex nut that secures the battery clamp tothe POSITIVE battery terminal post When tightening the clamps always use a box wrench Pliers will round off the nuts NEVER wiggle the bat tery terminal s post s when tightening The battery may become damaged Removethe battery clamp from the POSITIVE battery terminal post Reposition the battery clamp on the POSITIVE battery terminal post as shown in FIGURE 4 Securely tighten the hex nut that secures the battery clamp to the positive battery termi nal post B the battery clamp on the POSITIVE battery terminal post is positioned as shown in FIGURE 4 proceed to STEP 2 CORRECT ORIENTATION OF THE POSITIVE BATTERY TERMINAL POST BATTERY CLAMP POSITIVE Battery Terminal Post Note position of battery clamp NEGATIVE Battery Terminal Post and Battery Clamp Group 22NF Battery FIGURE 4 CONNECTING BATTERY CABLES BATIERY CLAMP METHOD 37 PROCEDURE 11 2 Install battery clamp covers onto battery cables as follows FIGURE 5 A RED battery clamp cover onto RED battery cable B BLACK battery clamp cover onto BLACK battery cable NOTE Only one
47. able Flip Back Fixed or Adjustable Height Desk and Full Length Black Nylon RECLINER SEAT 16 24 inches 16 22 inches in 1 inch increments 18 26 inches In 2 inch increments 29 37 inches in 1 inch increments 90 to 170 continuous 18 5 inches 24 75 inches 36 50 in 44 50 in Back Height 151 Ibs 225 Ibs 275 lbs Removable Flip Back Fixed or Adjustable Height Desk and Full Length Black Nylon Overall Length Refer to PERCENT AGE OF WEIGHT DISTRIBUTION in PROCEDURE 1 of this manual Front Stabilizers Drive Wheels Tires Casters w Precision Sealed Bearings Footrest Legrest Battery Size Not Supplied PERFORMANCE Speed M P H Turning Radius Range variable Weight Limitation Footnotes 1 Range will vary with battery conditions surface ter CAPTAIN S SEAT ADJUSTABLE SEAT BACK ANGLE RECLINER 47 5 inches 7 inch Urethane With 8 in rear casters and 93 front riggings 34 0 inches With 8 in rear casters and no front riggings 12 1 2 x 2 1 4 in Std 14 in x 3 in Opt Flat Free or Pneumatic 6 x 2 in Semi Pneumatic Opt Swingaway Removable Footboard uses 22NF Gel Cell Pronto R2 250 Series 8 x 1 3 4 in Semi Pneumatic Std 8 x 2 in Pneumatic Opt uses U1 Gel Cell CAPTAIN S SEAT ADJUSTABLE SEAT BACK ANGLE RECLINER 0 to 3 6 250 Ib Limit O to 5 5 300 Ib Limit O 3 8 400 Ib Lim
48. actor available at any hard ware store on the back as shown in FIGURE 3 and adjust the back until the magnetic protractor reads 61 3 Tumthe wheelchair power switch on the joystickto the ON position NOTE The wheelchair should not operate 4 IF wheelchair operates proceed to the following steps to adjustthe actuator on the upper limit switch bracket A Fully recline the back Refer to ADJUSTING CAPTAIN S SEAT in PROCEDURE 5 of the Owner s Manual part number 1095602 NOTE This will make access to the limit switch easier B Loosen but do not remove the two 2 phillips screws washers and locknuts that secure the ac tuator to the upper limit switch bracket C Slidethe actuator UP towards the top of the wheel chair DO NOT over tighten the phillips screws that secure the actuator to the upper limit switch bracket Damage to the actuator may occur D Only tighten the two 2 phillips screws washers and locknuts that secure the actuator to the upper limit switch bracketuntilthe actuator does not move Repeat STEPS 1 3 until the wheelchair does not operate when the captain s seat back is at a 24 angle Upper Limit Switch Bracket Phillips Screws Washers and d Locknuts FIGURE 1 ADJUSTING LIMIT SWITCH 27 ormmrz PROCEDURE 9 This Procedure Includes the Following Replacing Pneumatic Tires Tubes Drive Wheels Casters Removing Installing Drive Wheels
49. and torque to 75 in Ibs 13 Repeat STEPS 11 12 for opposite back cane 14 Secure the top of the NEW back upholstery to the back canes with the two 2 existing mounting screws Loctite Registered trademark of Loctite Corporation 12 UPHOLSTERY POSITIONING STRAP PROCEDURE 5 NOTE When replacing the back upholstery back as HEAVY DUTY MODELS sembly or changing back height follow these guidelines NOTE Spreader bar required on all back heights for spreader bar height BACK HEIGHT SPREADER BAR STANDARD MODELS HEIGHT BACK HEIGHT SPREADER BAR 16 17 inches 5 inches HEIGHT 18 24 inches 7 inches 16 inches 5 inches 17 inches 5 inches Height of Spreader Bar from Bottom of Back 18 19 inches 7 inches Canes to Top of Spreader Bar Clamp 20 24 inches 7 inches 15 If applicable reposition the spreader bar at the correct height for the corresponding back height and torque the mounting hardware to 60 in Ibs NOTE Spreader Bar required on ALL back heights between 20 24 inches Spreader bar required on back heights 16 17 18 or 19 ONLY if the width or depth of the chair exceeds 19 inches 16 Reinstall the armrest onto the wheelchair Refer to IN STALLING REMOVING FLIP BACK ARMRESTS Height of Spreader Bar from Bottom of Back PROCEDURE 4 ofthe Owner s Manual part number em STEP 2 Canes to Top of Spreader Bar Clamp 1095602 2 Locknuts 1 Back Cane n STEPS 5 6 P
50. are some basic concepts which will help you understand this automatic process The amount of electrical current drawn within a given time to charge a battery is called charge rate If due to usage the charge stored in the battery is low the charge rate is high For PRONTO Models this is indicated by the green light on the charger Initially the green light will stay illuminated for a short period of time followed by a longer period of off time 39 21 4 0 om um u PROCEDURE 11 Asa charge builds up the charge rate is reduced and the following will occur A For PRONTO series Models the green light will stay illuminated for a longer period of time followed by a shorter off time B For Models the battery charger rate decreases to a trickle charge NOTE If performing the charging procedures indepen dently READ and CAREFULLY follow the individual in structions for each charger supplied or purchased NOTE If charging instructions are not supplied consult a qualified service technician for proper procedures Required Items TOOL QUANTITY COMMENTS Battery Charger 1 Supplied Q Extension Cord 1 Not Supplied 3 prong plug 15 ampere current rating industrial type Wheelchairs Equipped With MCC Mark IV J oystick Detail A of FIGURE 8 1 Attach the battery charger connector to the charger cable battery harness 2 Plugthe cha
51. assembly exploded away for clarity It is not necessary to remove the stabilizer assembly from the wheelchair frame FIGURE REPLACING SIABILIZER CYLINDERS 47 PROCEDURE 12 REPLACING STABILIZER WHEEL FIGURE 4 1 Remove the mounting screw washers and locknut that secure the stabilizer wheel to the fork Remove the existing stabilizer wheel Secure the new stabilizer wheel to the fork with exist ing mounting screw washer and locknut Torque to 120 in lbs 4 Loosenthe locknut 1 8 of aturn by tuming the locknut COUNTERCLOCKWISE 5 Move the caster side to side NOTE If the caster moves side to side tighten the lock nut slightly Repeat STEP 3 until there is no side to side movement 6 Repeat STEP 1 for other caster and fork Locknut Mounting N Screw Washer Caster FIGURE 4 REPLACING STABILIZER WHEEL REPLACING CLUTCH HANDLES FIGURE 5 1 Remove the front rear and side shrouds Referto RE MOVING INSTALLING SHROUDS in PROCEDURE 10 of this manual 2 Removethe battery boxes Refer to INSTALLING RE MOVING BATTERY BOXES in PROCEDURE 11 of this manual 3 Remove the seat Refer to one 1 of the following A REMOVING NSTALLING THE STANDARD SEAT FRAME in PROCEDURE 6 of this manual B REMOVING INSTALLING THE CAPTAIN S VAN SEAT in PROCEDURE 6 of this manual C REMOVING INSTALLING THE RECLINER SEAT FRAME in PROCEDURE 13 of this manual Remove the pin that secures the clu
52. ay to ensure good contact With the commutator 1 Once the motor brush caps have been removed pull the brushes out of the motor The end of the brushes should be smooth and shiny and the spring should not be damaged or discolored If one or both of the brushes are damaged only the damaged or worn R 0 U B L E S H 0 0 T l N G A shorted electomechanical brake will damage the brake output section in the con troller DO NOT connect a shorted electro brushes need be replaced It is very important that ginis iem ls any time a brush is replaced it must be burned in ted brake MUST be replaced This is accomplished by running the motor for one NOTE A bad motor can damage the controller module hour in each direction with a half hour break in be bad controller should NOT damage a motor tween This should also be done with little or no load on the motor i e put the wheelchair up on blocks so the drive large wheels do not contact the ground Cap Motor 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 Motor 4 Pin Motor Connector AS 4 Pin Motor Connector lt FIGURE 4 MOTOR BRUSH INSPECTION FIGURE 5 ELEC TROMECHANICAL PARKING BRAKE TESTING PROCEDURE 3 FRONT RIGGINGS This Procedure Includes the Following DE
53. chair 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 Slidethe inserts into the bottom ofthe NEW back canes 9 Lineupthe mounting holes ofthe inserts with the mount ing holes in the back canes NOTE To keep the inserts lined up for reinstallation onto the wheelchair start one 1 of the mounting screws through the back cane from inside of the wheelchair to hold the insert in place 10 Slide the NEW back canes through the existing NEW back upholstery and spreader bar 11 If applicable loosely tighten the mounting screws that secure the spreader bar to the NEW back canes 12 Line up the mounting holes in the back canes with the mounting holes in the seat frame 19 PROCEDURE 6 NOTE If needing a reference for proper mounting holes forthe back angle required or if changing the original back angle refer to BACK ANGLE ADJUSTMENT in this pro cedure of the manual The back canes MUST be fastened se curely to the seat frame BEFORE using the wheelchair Torque to 75 inch pounds 13 Secure the two 2 NEW back canes to the seat frame with the existing four 4 mounting screws washers spacers and locknuts Use Loctite 242 and torque to 75 inch pounds 14 Secure the top of the existing new back upholstery to the back canes with the two 2 existing mounting screws a
54. charge than normal they may need to be replaced Contact an authorized dealer for service DETAIL A Battery Charger Connector Ch arger Cable From Battery Charger Three 3 Pronged Plug N Top View of Wheelchair Battery Boxes Battery Charger Battery Charger Mount Bracket From Battery Charger Base Frame DETAIL Battery Charger Three 3 Pronged Plug From Battery Charger Front View of Joystick Charger Port FIGURE 8 CHARGING BATTERIES 40 BATTERIES REPLACING BATTERIES Most batteries are not sold with instructions However wamings are frequently noted on the cell caps Read them carefully oth erwise injury or damage can occur NOTE Invacare recommends that both batteries be re placed if one 1 battery is defective Recommended Battery Types wananty and performance specifications contained in this manual are based on the use of deep cycle gel cell or sealed lead acid batteries Invacare strongly recommends their use as the power source for this unit Failure to use the correct battery sze and or voltage may cause damage to your wheel chair and give you unsatisfactory perfor mance NOTE The recommended battery type is 22NF deep cycle 1 Remove the battery boxes from the wheelchair Refer to REMOVING INSTALLING BATTERY BOXES in this procedure of the manual Remove existing batteries from the battery boxes Refer to INSTALLING REMOVING BATTERIES
55. cliner cable assembly 11 Reinstall the mounting screw through the mounting 6 Screw the NEW gas cylinder into the operator of the bracket of the back cane nylon washer gas cylinder cable assembly until the jam nut sits on the pivot block nylon washer mounting bracket and washer and se there is slack in recliner cable andthereisnomove IET curely tighten with the existing locknut Torque to 75 inch ment in the operator of the recliner cable assembly E pounds 7 Visually inspect the handle to make sure thatthe cable 12 Line up the mounting hole in the handle of the recliner is snapped completely into slot in handle and cable 8 cable assembly with the mounting hole in the back cane fitting is seat properly in the handle 13 Insert the pan screw through the handle of the recliner 8 Press the operator of the recliner cable assembly M cable assembly and the back cane and torque to 9 inch extend the NEW gas cylinder E pounds 9 Line up the mounting holes of the NEW gas cylinder R 14 Tie wrap the recliner cable assembly to the recliner back and the bracket of the back cane cane 10 Reinstall the mounting screw through the mounting 15 Adjustthe gas cylinder Referto ADJUSTING GAS CYL bracket of the back cane nylon washer NEW gas INDERS in this procedure of the manual cylinder nylon washer mounting bracket and washer and securely tighten with the existing locknut Torque REPLACING ADJ USTING GAS to 75 inch pounds CYLINDERS
56. d to make this dis connection The connection between the left motor gearbox lead and left controller lead The connection between the controller connec tor BLUE and the wiring harness BLUE con nector Remove the two 2 locknuts and washers that se cure the existing MKIV controller to the wheelchair FIGURE 2 6 Remove existing controller from the wheelchair INSTALLING 1 Install washer s onto mounting stud on wheelchair 2 Install new existing controller onto wheelchair frame Secure the new existing MKIV controller to the wheel chair with NEW locknuts Torque to 156 in lbs Connect the following 3 A connection between the right motor gearbox lead and right controller lead NOTE Tie wrap C does not need to be removed to make this con nection PROCEDURE 7 The connection between the left motor gearbox lead and left controller lead The connection between the controller connec tor BLUE and the wiring harness BLUE con nector 5 Install NEW tie wraps A and B to secure the following to the base frame A The connection between the left motor gearbox lead and left controller lead B C Right controller lead The connection between the controller connec tor BLUE and the wiring harness BLUE con nector Install the seat Refer to one 1 of the following A REMOVING INSTALLING THE STANDARD SEAT FRAME in
57. der bar to the back canes 3 Remove the two 2 mounting screws and washers that secure the existing back upholstery to the back canes 4 Cut the tie wraps that secure the bottom of the exist ing back upholstery to the back canes NOTE Note the back angle before disassembly for proper reinstallation 5 On the side of the wheelchair that the armrest was removed remove one 1 of the mounting screws washer spacer and locknut that secures the back cane to the seat frame NOTE To avoid losing the insert in each back cane thread the mounting screw just removed through the cane from the inside of the wheelchair to hold the insert in place 6 Remove the other mounting screw washer spacer and locknut that secures the back cane to the seat frame 7 Slide the back cane out of the spreader bar If appli cable and the existing back upholstery 8 Remove other armrest from the chair Refer to IN STALLING REMOVING FLIP BACK ARMRESTS in PROCEDURE 4 of the Owner s Manual part num ber 1095602 9 RepeatSTEPS 5 7 for the opposite side of the wheel chair 10 Slide the other back cane out of the spreader bar if applicable and the existing back upholstery 11 Slide one 1 back cane into NEW back upholstery and through spreader bar if applicable 12 Secure back cane to the seat frame from the outside of the wheelchair with the existing two 2 mounting Screws washers spacers and locknuts Use Loctite 242
58. dth required is NOT within the range of the original back canes spreader bar and headrest pillow the original components can not be used INSTALLING REPLACING USTABLE 16 TO 19 INCH DEEP RECLINER SEAT FRAME FIGURE 7 1 Perform one 1 of the following in PROCEDURE 7 of this manual A Remove standard seat Refer to REMOVING INSTALLING STANDARD SEAT in PROCE DURE 6 of this manual B Remove Captain s van seat Refer to INSTALL ING REMOVING CAPTAIN S VAN SEAT in PROCEDURE 6 of this manual 2 Remove seat pan on recliner 3 Install new recliner seat assembly onto seat mount ing plates 4 Secure recliner seat assembly to seat mounting plates with the mounting screws spacers 16 inch wide only and locknuts Torque the mounting screws to 156 inch pounds NOTE There are two 2 types of seat mounting plates lowand high heights The seat mount plate shown in this illustration represents the medium height Refer to MOUNTING PLATE SEAT ANGLE ADJUSTMENT AND INSTALLATION ORIENTATION in PROCEDURE 6 of this manual for illustrations of the low and high heights 5 Position limit switch onto wheelchair Refer to PO SITIONING LIMIT SWITCH in this procedure of the manual 6 Reinstall recliner seat pan with existing six 6 mount ing screws 7 Install battery box es Refer to INSTALLING RE MOVING BATTERY BOXES in PROCEDURE 11 of this manual 8 Install shrouds Refer to INSTALLING SHROUDS in PROCEDURE 10 of
59. e between 10 seat dump NOTE There are two 2 heights of seat mounting plates lowand high See chart below for proper settings 1 To obtain 0 seat dump DETAIL A A Loosen the mounting screws that secure the front and rear of the seat mount plate to the seat sup port bracket Repeat for opposite side of wheel chair B Position the mounting screws at the bottom of the rear slot and the top of the front slot C Securely tighten all four 4 mounting screws Torque to 15 in lbs 2 To obtain a 10 seat dump DETAIL A Loosen the mounting screws that secure the front and rear of the seat mount plate to the seat sup port bracket Repeat for opposite side of wheel chair B Position the mounting screws at the bottom of the front slot and top of the rear slot C Securely tighten all four 4 mounting screws Torque to 15 in lbs Installation Orientation 1 High Seat Mounting Plates Install with the angled end toward the rear of the wheelchair 2 Low Seat Mounting Plates Install with the thicker end toward the front of the wheelchair 17 S B PROCEDURE 6 DETAIL High Height Seat E A Mount Angled End of Seat Rear L Plate T Thicker End Mounting Plate Mounting Y Screw B Yo Seat Support 3 Bracket Front K Mounting Screw SEAT DUMP REAR OF FRONT OF REAROF FRONT OF REAR OF CHAI
60. er Washer Caster FIGURE 4 REPLACING CASTERS REPLACING FORKS FIGURE 5 1 Remove the hex screw washers and locknut that secure the caster to the existing fork Remove the caster from the existing fork Remove the dust cover Remove the locknut and nylon washer Drop the existing fork out of the caster head tube Slide the new fork into the caster head tube oar wD NOTE Check bearing assemblies and replace if nec essary 7 Ensure that new fork slides completely into the caster head tube 8 Install nylon washer and secure with locknut Improper positioning of the washer will prohibit the free movement of the forks 9 Install Loctite 242 onto the hex screw 30 WHEELS 10 Position the caster into the new fork 11 Reinstall the hex screw washers and locknut that secure the caster to the new fork 12 Torque the locknut to 120 inch pounds 13 Loosen the locknut 1 8 of a turn 14 Move the caster side to side NOTE If the caster moves side to side tighten the locknut slightly Repeat STEP 14 until there is no side to side movement of the caster 15 Adjust the fork Refer to ADJUSTING FORKS in PROCEDURE 8 of the Owner s Manual part num ber 1095602 31 PROCEDURE 9 Caster Headtube Dust Cover 4 Nylon Washer Locknut Fork Washer Hex Screw Washer Caster FIGURE 5 REPLACING FORKS PROCEDURE 10 This Procedure Includes the Following 2 Removing
61. er to INSTALL ING REMOVING CAPTAIN S VAN SEAT ASSEM BLY in PROCEDURE 6 of this manual 2 Removethe seat mounting plates Referto REPLAC ING SEAT MOUNTING PLATES in this procedure of the manual NOTE Before removing seat support brackets note the position of the seat support brackets relative to the base frame 3 Remove the two 2 mounting screws and washers that secure the seat support bracketto the base frame 4 Remove the seat support bracket 5 Remove the end 6 Remove the end bolt that secures the channel to the base frame Slide existing T Nut s out of channel Insert NEW T Nut s into channel 9 Use Loctite 242and reinstall end boltthat secures chan nel to base frame Seat Support Bracket Mounting Screw Channel T Washer End Bolt T Nut End Cap FIGURE 9 REPLACING SEAT SUPPORT BRACKET T NUTS 51 PROCEDURE 12 10 Replace end cap 11 Secure seat support bracket in orientation noted above to NEW T nuts with existing mounting screws and washers Torque to 13 ft lbs 12 Reassemble wheelchair by reversing STEPS 1 2 REPLACING BATTERY CHARGER BRACKET AND T NUT FIGURE 10 1 Remove the two 2 mounting screws that secure the battery charger connector to the mount bracket 2 Removebattery charger connector from mount bracket Remove the mounting screw which secures the battery charger mount bracket to the T nut located in the chan nel
62. essary length thin film of anti seize compound to 4 Installthe battery boxes Refer to INSTALLING RE the drive shaft Applying more than one MOVING BATTERY BOXES in PROCEDURE 11 1 inch in length can cause the anti seize of this manual Hub compound to leak resulting in damage to eel ru floorin ul Js Drive Wheel Assembly Assembly 900g campe Four 4 Beveled Hex Nuts FIGURE 2 REMOVING INSTALLING 14 INCH DRIVE WHEELS 29 2 Apply a thin film of anti seize compound one 1 inch in length to the end of the drive shaft 3 Reinstall drive wheel hub onto the gearbox drive shaft NOTE While installing the drive wheel hub onto the drive shaft spin the drive wheel hub to evenly distribute the anti seize compound over the entire drive shaft 4 Install the washer and NEW locking tab washer onto the wheel hub Make sure the locking tab is in line with the keyway of the wheel hub Apply Loctite 242 to the mounting screw Install the mounting screw Use a torque wrench only and torque to 90 inch pounds ormmrz PROCEDURE 9 7 Examine the head ofthe hex screw and the locking tab washer Make sure one 1 of the tabs on the locking tab washer is parallel with one 1 of the flats on the head of the hex screw 8 Ifone 1 of the tabs on the locking tab washer is NOT parallel with one 1 of the flats on the head of the hex screw FIGURE 1 TIGHTEN the hex screw until the closest flat and lock
63. ever attempt to recharge the batteries by attaching cables directly to the bat tery terminals or clamps Always use the recharging plug located on the control ler OR the side rear of the wheelchair frame DO NOT attempt to recharge the batter ies and operate the power wheelchair at the same time During use and charging unsealed bat teries will vent hydrogen gas which is ex plosive in the right concentration with air CAUTION Always charge new batteries fully BEFORE initial use or battery life will be reduced NOTE As a general rule batteries should be recharged daily to assure the longest possible life and minimize the required charging time Plan to recharge the batteries when itis anticipated the wheelchair will not be used for several days The range per battery charge using recommended bat teries should be approximately 5 to 9 hours of typical op eration Extensive use on inclines or age of batteries may substantially reduce per charge mileage Description and Use of Battery Chargers The charger automatically reduces the amount of charge from an initially high rate to a zero reading at a fully charged condition SHUTOFF PROCEDURE For PRONTO Models If left unattended the charger will automatically shut off when full charge is obtained B For PRONTO series Models The Charger output and green light will stay ON until the power Switch on the battery charger is moved to the OFF position There
64. fthe Owner s Manual part num ber 1095206 Spacers STEPS 3 13 Locknuts STEPS 3 13 Back Cane STEPS 3 10 S E T B ee Screw M STEPS 2 1 Washer STEPS 2 14 p Upholst 7 6 p dd Locknut d __ es 6 11 pcs Spreader Bar p STEPS 6 17 Locknut ___ a 2s Mounting Screw STEPS 6 11 Torque to 60 in Ibs Pd STEPS 6 11 o Mounting p Screw Mounting Screws STEPS 6 11 STEPS 3 13 Insert Washers STEPS 4 8 P 7 STEPS 3 13 Mounting Screws Torque to 75 in Ibs STEPS 3 13 Washers STEPS 3 13 Seat Frame HGURE 7 CHANGING BACK HEIGHT 20 SEAT BACK BACK ANGLE ADJ USTMENT FIGURE 8 1 Remove armrests from the wheelchair Refer to IN STALLING REMOVING FLIP BACK ARMRESTS in PROCEDURE 4 of the Owner s Manual part num ber 1095206 Remove the mounting screw and washer from the top mounting hole of back angle plate and back cane NOTE To avoid losing the insert in each back cane thread the mounting screw through the cane from the inside of wheelchair to hold the insert in place TO ACHIEVE A BACK ANGLE OF BACK CANE MOUNTING HOLE Top 2nd from Bottom Top Bottom Top 2nd from Bottom Top Bottom PROCEDURE 6 Remove the mounting screw and washer from the bottom mounting hole of the back angle plate and back cane
65. g plates Refer to REPLACING X D Frame SEAT MOUNTING PLATES in this procedure of the Seat manual Support 8 Adjust seat mounting plates to desired angle Refer to MOUNTING PLATE SEAT ANGLE ADJUSTMENT Mounting AND INSTALLATION ORIENTATION in PROCEDURE 25 Washer FRONT OF 6 ofthis manual CHAIR 9 Reassemble wheelchair by reversing STEPS 1 3 FRONT OF HGURE 7 REPLACING SEAT MOUNTING CHAIR Mounting PLATES Screws REPLACING SEAT SUPPORT Channel 5 BRACKETS FIGURE 8 1 Removethefront rear and side shrouds Referto RE MOVING INSTALLING SHROUDS in PROCEDURE 10 of this manual 2 Removethe battery boxes Refer to INSTALLING RE MOVING BATTERY BOXES in PROCEDURE 11 of this manual Seat Support 3 Remove the seat Refer to one 1 of the following Bracket REMOVING NSTALLINGTHE STANDARD SEAT FRAME in PROCEDURE 6 of this manual B BEMOVING INSTALLING THE CAPTAIN S VAN SEAT in PROCEDURE 6 of this manual NOTE Left side of base frame shown Right and Left C REMOVING INSTALLINGTHERECLINERSEAT 270 determined by sitting in the wheelchair FRAME in PROCEDURE 13 of this manual FIGURE 8 REPLACING SEAT SUPPORT BRACKETS Channel of Base Frame 50 BASE FRAME REPLACING SEAT SUPPORT BRACKET T NUTS FIGURE 9 1 Perform one 1 of the following A Remove standard seat frame Refer to REMOV ING INSTALLING STANDARD SEAT FRAME in PROCEDURE 6 of this manual B Remove Captain s van seat Ref
66. ing tab are parallel NOTE Tighten hex screw only DO NOT loosen hex screw to make one of the tabs on the locking washer parallel 9 Bend the parallel tab of locking tab washer up tight against flat of the hex screw FIGURE 1 10 Reinstall the drive wheel onto the wheel hub Refer to REMOVING INSTALLING DRIVE WHEELS inthis pro cedure of the manual 11 Repeat procedure for the opposite side of the wheel chair if necessary Keystock _ Locking Washer Mounting Screw Keyway Washer Mounting Screw Apply Loctite 242 and use a Torque Wrench only to Torque to 90 inch pounds TIGHTEN Hex Screw if Locking Tab is not Parallel with Flat on Head STEP 9 Locking Tab Parallel with Flat on Head of Hex Screw STEP 9 Flat on Head of Hex Screw Bend Tab up tight against Flat on Neq Head of Hex Screw STEP 10 FIGURE REMOVING INSIALLING DRIVE WHEEL HUB WHEELS REPLACING CASTERS FIGURE 4 1 Remove the hex screw washers and locknut that secure the caster to the fork Remove the caster from the fork Install Loctite 242 onto the hex screw Replace caster and reverse STEPS 1 3 Torque the locknut to 120 inch pounds Loosen the locknut 1 8 of a turn Move the caster side to side NOTE If the caster moves side to side tighten the locknut slightly Repeat STEP 7 until there is no side to side movement of the caster NOOR Fork Locknut Hex Screw UN Wash
67. ion 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 trans portation systems AS REGARDS RESTRAINTS SEAT POSITIONING STRAPS IT IS THE OBLIGATION OF THE DME DEALER THERAPISTS AND OTHER HEALTHC ARE PROFESSIONALS TO DETERMINE IF A SEATING POSITIONING STRAP IS REQUIRED TO ENSURE THE SAFE OPERATION OF THIS EQUIPMENT BY THE USER SERIOUS INJ URY MAY OCCUR IN THE EVENT OF A FALL FROM A WHEELCHAIR SAVE THESE INSTRUCTIONS 2 TABLE CONTENTS TABLE OF CONTENTS NOTE The following procedures refer to the Pronto and the Pronto SPECIAL 2 9 1 4 REPLACING PNEUMATIC TIRES TUBES DRIVE WHEELS CASTERS 28 PROCEDURE 1 GENERAL GUIDELINES 5 PEPAIRORSEPVICE INF OPMIATON 5 REMOVING NSTALLINGDRIVEWHEELS 28 a OPERATING iG 5 REMOVING INSTALLING DRIVE WHEEL HUB 29 REPLACING CASTERS 30 WARNING CAUTIONLABELLOCATION
68. it gt 23 inches With Removable Footboard 17 miles 250 Ibs 300 Ibs or 400 rain and operators weight 2 Includes seating systems and accessories lbs See FOOTNOTE 3 Weight limitation varies with motor Refer to WEIGHT LIMITATION GENERAL WARNINGS in PROCE DURE 1 of this manual GENERAL GUIDELINES PROCEDURE 1 This Procedure Includes the Following Repair or Service Information Operating Information REPAIR OR SERVICE INFORMATION Set up of the Electronic Control Unit is to be performed ONLY by Invacare dealers The final tuning adjustments of the controller may affect other activities of the wheelchair Damage to the equipment could occur under these circumstances If any individual other than a qualified technician performs any work on these units the warranty is void OPERATING INFORMATION GENERAL WARNINGS Performance adjustments should only be made by professionals of the healthcare field or persons fully conversant with this process and the drivers capabilities Incorrect set tings could cause injury to the driver bystanders damage to the chair and to sunounding property After the wheelchair has been set up check to make sure that the wheelchair performs to the specifications entered during the set up procedure If the wheelchair does perform to specifications tum the wheelchair OFF immediately and reenter set up speci fications Repeat this procedure until the wheelchair performs to
69. l new existing front wheel onto the motor drive shaft Make sure the chamfered angled in side of the wheel hub is pointing away from the wheelchair Install washer onto motor drive shaft Install the NEW locking tab washer onto the motor drive shaft Make sure the locking tab is in line with the keyway of the front wheel Apply Loctite 242 to the hex screw 5 Install the hex screw Use a torque wrench only and torque to 90 inch pounds Hex Screw Apply Loctite 242 and use a Torque Wrench only to Torque to 90 inch pounds TIGHTEN Hex Screw if Locking Tab is not Parallel with Flat on Head STEP 9 Locking Tab Parallel 5 d with Flat on Head of Hex Screw STEP 9 Locking Tab Bend Tab up tight against Flat on Head of Hex Screw STEP 10 A FIGURE 1 REMOVING INSIALLING 12 INCH DRIVE WHEELS 28 WHEELS Examine the head of the hex screw and the locking tab washer Make sure one 1 of the tabs on the locking tab washer is parallel with one 1 of the flats on the head of the hex screw If one 1 ofthe tabs on the locking tab washer is NOT parallel with one 1 of the flats on the head of the hex screw FIGURE 1 TIGHTEN the hex screw until the closest flat and locking tab are parallel NOTE Tighten hex screw only DO NOT loosen hex screw to make one of the tabs on the locking washer parallel 8 Bend the parallel tab of locking tab washer up tight against flat of the hex screw FI
70. level is maintained well above a low condition MKIV RII J oystick BATTERY DISCHARGE INDICATOR BDI is located at the frontofthe joystick housing and provides information on the remaining charge in the batteries At FULL charge the BDI will be GREEN As the battery becomes discharged the BDI indicator will tum AMBER YELLOW then RED and finally FLASHING RED Ifthe BDI is FLASHING RED the user should charge the batteries as soon as possible NOTE Accurate readings are displayed when in neutral MCC MKIV X A or A J oystick BATTERY GAUGE DISPLAY BGD is the bar graph dis play located on the MKIV X A or A joystick It will keep you informed as to power availability A visual waming is given be fore the power becomes too low to operate the wheelchair At full charge the two 2 LEFT segments and the farthest RIGHT segment of the bar graph will be illuminated As the battery becomes discharged the farthest RIGHT segment will pro gressively move to the LEFT until only the last two 2 bars LEFT are illuminated At this level the last two 2 bars LEFT will start to Flash ON and OFF to indicate that the end user should charge the batteries as soon as possible NOTE Accurate readings are displayed when in neutral Battery Discharge Indicator BDI Battery Gauge Display BGD MKIV X A OR A JOYSTICK NOTE MKIV X Shown FIGURE 7 WHEN TO CHARGE BATTERIES PROCEDURE 11 CHARGING BATTERIES FIGURE 8 N
71. ller connector BLUE and the wiring hamess BLUE con nector Remove the existing wiring hamess from wheelchair Connect the controller connector BLUE and the new wiring hamess BLUE connector Install the battery charger port into the mounting bracket Secure the battery charger port to the mounting bracket with the existing two 2 phillips bolts and locknuts Se curely tighten HIGH BACK CAPTAIN S SEAT MODEL WHEEL CHAIRS ONLY Plug the power take off of the captain s van seat into the power take off of the wiring hamess Perform the following steps for tie wrap installation A Position the connection between left controller lead and the left motor gearbox lead below the crossmember with the left controller lead furthest out on the crossmember and then fold cable lead back in the opposite direction B Position the connection between the controller con nector BLUE and the wiring hamess BLUE con nector on top of the crossmember with the coil wrapped battery lead extending outtoward the right hand side of the chair then fold back in opposite direction and positioned on top of the two 2 blue connectors The cable for the PTO extending from the BLUE connector is to run along crossmember to the right hand side of the chair C Position the connection of the right controller lead and the right motor gearbox lead on top of the crossmembersothatthe rightcontroller lead is routed on top of the blue connectors D Ins
72. llthe battery box top s om zum 2m u om um u PROCEDURE 11 BATTERIES 9 Install the battery box es into the wheelchair Referto 10 If necessary charge the battery ies Referto CHARG INSTALLING REMOVING BATTERY BOX ES in ING BATTERIES in the PROCEDURE 11 of this PROCEDURE 11 of this manual manual NOTE New Battery ies MUST be fully charged BEFORE using otherwise the life of the battery ies will be reduced CONNECTING BATTERY CABLE S TO BATIERY IES TERMINAL S POSI S POSITIVE Battery Terminal NEGATIVE Battery Terminal Post and Battery Clamp Post and Battery Clamp Positive RED Negative BLACK Battery Cable Battery Cable TOP VIEW Group 22NF Battery ETIL A Positive RED QU Battery Cable J Pex sow 5 Mounting Plate 7 Battery Clamp EXPLODED Negative BLACK S VIEW Battery Cabe Gu POSITIVE 4 Battery Terminal Post 22NF Battery 1 NEGATIVE Battery Terminal Post NOTE Battery clamps exploded away for clarification purposes only DETAIL B RED Battery Clamp Cover POSITIVE Battery Terminal Post NEGATIVE Batter Terminal Post Tie Wrap 22NF Battery BLACK Battery Clamp Cover FIGURE 6 CONNECTING BATTERY CABLES BATIERY CLAMP METHOD 38 BATTERIES WHEN TO CHARGE BATTERIES FIGURE 7 Itis advantageous to recharge daily rather than only when necessary In fact a battery s life is extended if the charge
73. manual 9 Installthe seat Refer to one 1 of the following Battery REMOVING INSTALLING THE STANDARD Way SEAT FRAME in PROCEDURE 6 ofthis manual B REMOVING INSTALLING THE CAPTAIN S VAN SEAT in PROCEDURE 6 of this manual C REMOVING INSTALLING THE RECLINER SEAT Motor FRAME in PROCEDURE 13 of this manual Gearbox 10 Install the front and rear battery boxes Refer to RE MOVING INSTALLING THE BATTERY BOXES in PROCEDURE 11 of this manual 11 Install the front and rear shrouds Refer to REMOV ING INSTALLING SHROUDS in PROCEDURE 10 of this manual Motor Gearbox Support Not provided FIGURE 10 REMOVING INSTALLING THE BATIERY TRAY 43 mz zm 0 PROCEDURE 12 This Procedure includes the following Replacing the Wiring Harness MKIV Controller Only Adjusting Stabilizer Assembly for User Preference Replacing Stabilizer Cylinders Replacing Stabilizer Wheel Replacing Clutch Handles Replacing Motor Gearbox Basic Motors Replacing Motor Gearbox Standard Motors Replacing Seat Mounting Plates Replacing Seat Support Brackets Replacing Seat Support Bracket T Nuts Replacing Battery Charger Bracket and T Nut Adjusting Weight Distribution After ANY adjustments repair or service and BEFORE use make sure all attaching hardware is tightened securely other wise injury or damage may result REPLACING THE WIRING HARNESS MKIV CONTROLLER ONLY FIGURE 1 1
74. n PROCEDURE 11 of this manual NOTE New Battery ies MUST be fully charged BE FORE using otherwise the life of the battery ies will be reduced 9 Ifnecessary charge the battery ies Referto CHARG ING BATTERIES in the PROCEDURE 11 of this manual om zum Dm u om zum u PROCEDURE 11 BATTERIES DETAIL A DETAIL B DUAL U1 BATTERIES DUAL 22NF BATTERIES POSITIVE Battery Terminal Post 1 4 20 x 7 8 Inch i Negative 1 4 20 x 7 8 Inch Hex Flange Screw Battery Terminal POSITIVE Red Hex Flange Screw Post Battery Cable 1 4 20 Hex Flange Locknut Positive Battery 22NF Battery NEGATIVE Terminal Post Black Battery Cable NEGATIVE Battery Terminal Post CONNECT BATTERY CABLE TO BATTERY TERMINAL AS SHOWN CONNECT BATTERY N CABLE S RING TERMINAL S TO THIS SIDE OF BATTERY TERMINAL S POST S DUAL U1 BATTERIES DUAL 22NF BATTERIES Gray NEGATIVE RED POSITIVE POSITIVE Battery Battery VE Battery 9 Battery Battery Terminal Terminal Battery Terminal Terminal Cap Post Terminal Post Cap Wrap 1 Battery Orange Battery 22NF Battery BLACK BatteryTerminal Terminal Cap Cap HGURE 3 CONNECTING BATTERY CABLES DIRECT MOUNT METHOD 36 BATTERIES BATTERY CLAMP METHOD FIGURES 4 5 AND 6 The battery clamp of the POSITIVE battery terminal post MUST be mounted in the posi tion shown in AG
75. n the right motor gearbox lead and right controller lead B The connection between the left motor gearbox lead and left controller lead C If necessary connect the power take off lead to the Captain s Van Seat or manual recliner Install NEW tie wraps A and B to secure the following to the base frame A The connection between the left motor gearbox lead and left controller lead B Rightcontroller lead C The power take off lead Install the seat Refer to one 1 of the following A REMOVING INSTALLING THE STANDARD SEAT FRAME in PROCEDURE 6 ofthis manual B REMOVING INSTALLING THE CAPTAIN S VAN SEAT in PROCEDURE 6 of this manual C REMOVING INSTALLING THE RECLINER SEAT FRAME in PROCEDURE 13 of this manual PROCEDURE 7 ELECTRONICS Left Motor Gearbox Lead and Left Controller Lead Power Take off Lead L If present E Right Motor Gearbox Lead and Right Controller S Lead Hf Controller Lead Tie Wrap Tie Wrap Tie Wrap Mounting Stud on Wheelchair Frame Washer Three 3 required per side RII Controller Washer Three 3 required per side Locknuts NOTE Base Frame shown is for reference only It is not a true representation of the Pronto Base Frame FIGURE 4 REMOVING INSIALLING RII CONTROLLER 26 LIMIT SWITCH PROCEDURE 8 This Procedure
76. n the side shrouds 2 Install the front shroud onto the two 2 side shrouds 3 Tum the two 2 1 4 tum bolts that secure the front shroud to the two 2 side shrouds CLOCKWISE REMOVING REAR SHROUD AND REAR STORAGE COMPARTMENT NOTE The rear storage compartment is available on wheelchairs NOT equipped with weight shift basic tilt only 1 Liftup on rear shroud and remove from wheelchair DO NOT overtighten the phillips screws and phillips bolt that secure the side shroud to the wheelchair frame otherwise damage to the side shroud can occur 2 Tumthe two 2 1 4 turn bolts that secure the rear stor compartmentto the wheelchair frame COUNTER Install the phillips bolt washers and locknut that secure CLOCKWISE the side shroud to the wheelchair frame and tighten se curely DO NOT OVERTIGHTEN Referto FIGURE 1 3 Remove rear storage compartment from wheelchair for phillips bolt and locknut location INSTALLING REAR SHROUD AND REAR 4 Install the phillips screws washers and coved washers COMPARTMENT that secure the side shroudto the wheelchairframe and Position the two 2 1 4 tum bolts with the two 2 mount tighten securely DO NOT OVERTIGHTEN Refer to ing holes in the wheelchair frame FIGURE 1 for phillips screw and washer locations 2 Install rear storage compartment onto chair frame 5 Repeat STEPS 1 4 for the opposite side of the wheel 3 Tumtwo 2 1 4 tum bolts that secure
77. nd washers 15 Secure bottom of the existing NEW back upholstery to rear of the seat pan 16 Secure the bottom of the existing NEW back uphol stery to the back canes with new tie wraps NOTE Clean upholstery with warm DAMP cloth and mild detergent to remove superficial soil WARNING Laundering or moisture will reduce flame retardancy of the upholstery NOTE When replacing the back upholstery back as sembly or changing back height follow these guidelines for spreader bar height where applicable BACK HEIGHT SPREADER BAR HEIGHT 16 inches 5 inches 17 inches 5 inches 18 19 inches 7 inches 20 24 inches 7 inches NOTE Spreader Bar required on back heights 20 24 inches Spreader bar ONLY required on these back heights if the width or depth of the chair exceeds 19 inches Height of Spreader Bar from Bottom of Back Canes to Top of Spreader Bar Clamp HEAVY DUTY MODELS NOTE Spreader bar required on all Heavy Duty models BACK HEIGHT SPREADER BAR HEIGHT 16 17 inches 5 inches 18 24 inches 7 inches Height of Spreader Bar from Bottom of Back Canes to Top of Spreader Bar Clamp S n B Cc K PROCEDURE 6 SEAT BACK 17 If necessary reposition the spreader bar at the cor 18 Reinstall the armrest onto the wheelchair Refer to rect height for the corresponding back height and INSTALLING REMOVING FLIP BACK ARMRESTS torque the mounting hardware to 60 inch pounds in PROCEDURE 4 o
78. nstall new 1 inch deeper shorter seat pan onto seat frame 4 Reinstall the mounting screws spacers and locknuts and torque to 75 inch pounds 5 Remove the protective strips on the seat pan and rein stall the seat cushion onto the seat pan NOTE Clean upholstery with a warm damp cloth and mild detergent to remove superficial soil WARNING Laundering or moisture will reduce the flame retardation of the upholstery Seat Seat Pan Positioning Strap Seat Frame Locknuts FIGURE 6 CHANGING SEAT DEPTH CHANGING SEAT WIDTH To change seat width the seat frame must be changed to the desired width Referto INSTALLING REPLACING AD JUSTABLE 16 TO 19 INCH DEEP RECLINER SEAT FRAME ONTO PRONTO BASE FRAME in this proce dure of the manual 5 NOTE If changing the seat wiath of the wheelchair the back and headrest upholstery seat pan and cushion also need to be changed NOTE If changing the seat width of the wheelchair the back canes spreader bar and headrest pillow may also need to be changed Heferto the following charts BACK CANES AND SPREADER BAR SEAT WIDTH RANGES 14H 7NCHES OR 18 244NCHES HEADREST PILLOWS SEAT WIDTH RANGES IN INC HES 14 15 16 18 19 20 OR 21 24 Jmumz romz RECLINER If the seat width required is within the range of the origi nal back canes spreader bar and headrest pillow the original components can still be used If the seat wi
79. oes not include any labor or shipping charges incumed in replacement part installation or repair of any such product Invacare s sole obligation and your exclusive remedy under this warranty shall be limited to such repair and or replacement For warranty service please contact the dealer from whom you purchased your Invacare product In the event you do not receive satisfactory warranty service please write directly to Invacare at the address on the bottom of the back cover Provide dealers name ad dress date of purchase indicate nature of the defect and if the product is serialized indicate the serial number Do not retum products to our factory without our prior consent LIMITATIONS AND EXCLUSIONS THE FOREGOING WARRANTY SHALL NOT APPLY TO SERIAL NUM BERED PRODUCTS IF THE SERIAL NUMBER HAS BEEN REMOVED OR DEFACED PRODUCTS SUB JECT TO NEGLIGENCE ACCIDENT IMPROPER OPERATION MAINTENANCE OR STORAGE COM MERCIAL OR INSTITUTIONAL USE PRODUCTS MODIHED WITHOUT INVACARES EXPRESS WRIT TEN CONSENT INCLUDING BUT NOT LIMITED TO MODIHCATION THROUGH THE USE OF UNAU THORIZED PARTS OR ATIAC HMENTS PRODUCTS DAMAGED BY REASON OF REPAIRS MADE TO ANY COMPONENT WITHOUT THE 5 CONSENT OF INVACARE OR TO A PRODUCT DAM AGED BY CIRCUMSTANCES BEYOND INVACARES CONTROL AND SUCH EVALUATION WILL BE SOLELY DETERMINED BY INVACARE THE WARRANTY SHALL NOT APPLY TO PROBLEMS ARISING FROM NORMAL WEAR OR FAILURE TO ADHERE TO THESE INSTRUCTIONS A CHANGE IN OP
80. of the recliner seat frame line up the mounting hole in the operator of the new recliner cable assembly with the gas cylinder rod DO NOT force the gas cylinder rod into the operator of the recliner cable assembly DO NOT cross thread the operator of the re cliner cable assembly with the gas cylinder If dack in the recliner cable or movement in the operator of the cable assembly can not be eliminated DO NOT use the recliner cable assembly 9 Screw the NEW gas cylinder into the operator of the cable assembly until the jam nut sits on the pivot block there is no slack in the recliner cable and there is no movement in the operator of the recliner cable as sembly Mounting Bracket Pan Screw Handle 5 2 Screw TOME 145 Washer Washers Locknut gt 3 Tm Gas Oylinder Tie f M D it Cane Cable N Operator Rod b No Slack Jam in Cable Nut Li Cable T Snapped into Slot Pivot 54 Handle NO Movement in Operator of the Recliner Cable Assembly Cable Fitting Seated Properly HGURE 3 REPLACING RECLINER CABLE ASSEMBLIES RECLINER PROCEDURE 13 10 Visually inspectthe handle to make sure thatthe cableis If slack in the recliner cable or movement in the operator of snapped completely into slotin handle and cable fitingis the cable assembly can not be eliminated DO NOT use seat properly inthe handle the re
81. of this manual C REMOVING INSTALLING THE RECLINER SEAT FRAME in PROCEDURE 13 of this manual 2 Remove tie wrap A and B that secure the following to the base frame The connection between the left motor gearbox lead and left controller lead B Rightcontroller lead C The power take off PTO lead NOTE The PTO is present if wheelchair is equipped with Captain s Van Seat or manual recliner Removetie wrap C that secures the following to the base frame A Theconnection betweenthe right motor gearbox lead and right controller lead B The power take off lead NOTE The PTO is present if wheelchair is equipped with Captain s Van Seat or manual recliner 4 Disconnect the following A connection between the right motor gearbox lead and right controller lead B The connection between the left motor gearbox lead and left controller lead C If necessary the power take off lead from Captain s Van Seat or manual recliner 25 5 6 PROCEDURE 7 Remove the two 2 locknuts and washers that se cure the existing RII controller to the wheelchair Remove existing RII controller from the wheelchair INSTALLING 1 2 3 Install washer s onto mounting stud on wheelchair Install new existing RII controller onto wheelchair frame Securethe new existing RII controllerto the wheelchair with NEW locknuts Torque to 156 in lbs Connect the following A connection betwee
82. of wheelchair 16 Install Loctite 242 onto the three 3 hex bolts 17 Install the three 3 hex bolts spacers and locknuts that secure joystick mounting bracket to armrest plate 18 Slide the joystick mounting tube through the joystick mount ing bracket to the desired position 19 Secure adjustmentlock to joystick mounting tube by tum ing lever on adjustment lock REMOVING INSTALLING THE MKIV CONTROLLER OR RII CONTROLLER WARNING Replacement controller MUST be same part number as factory installed controller Oth erwise injury or damage may result MKIV Controller FIGURES 2 AND 3 REMOVING 1 Removethe seat Referto one 1 of the following A REMOVING NSTALLING THE STANDARD SEAT FRAME in PROCEDURE 6 of this manual B REMOVING INSTALLING THE CAPTAIN S VAN SEAT in PROCEDURE 6 of this manual C REMOVING INSTALLING THE RECLINER SEAT FRAME in PROCEDURE 13 of this manual Unplug joystick from controller Removetie wrap A and B that secure the following to the base frame Refer to FIGURE 3 A Theconnection between the left motor gearbox lead andleftcontroller lead B Rightcontrollerlead C The connection between the controller connector BLUE and the wiring hamess BLUE connector D Thecoil wrapped battery lead 22 ELECTRONICS Disconnect the following A connection between the right motor gearbox lead and right controller lead NOTE Tie wrap C does not need to be remove
83. ove the standard seat frame from the base frame Installing Position standard seat frame on seat mounting plates 2 Secure standard seat frame onto seat mounting plates with the existing four 4 mounting screws locknuts and spacers if applicable Torque to 156 inch pounds Plug joystick into controller and secure with new tie wraps 4 Install battery box es Refer to INSTALLING REMOV ING BATTERY BOXES in PROCEDURE 11 of this manual 5 Install front and rear shrouds Refer to REMOVING IN STALLING SHROUDS in PROCEDURE 10 of this manual S T B PROCEDURE 6 SEAT BACK 6 Install footrest assemblies Refer to PROCEDURE 5 Remove the four 4 mounting screws and locknuts that the Owner s Manual part number 1095602 secure the Captain s van seat to the seat mounting plates Mounting Screws 6 Remove captain s van seat from seat mounting plates Torque to 156 S inch pounds Installing Captain s Van Seat 1 Position the Captain s van seat on the seat mounting 2 plates at the position shown in FIGURE 4 2 Lineupmounting holes in the Captain s van seatframe B and the mounting holes in the seat mounting plates A 3 Secure the Captain s van seat to the seat mounting plates with four 4 mounting screws and locknuts Torque to 156 inch pounds Standard 4 Plug joystick into controller and secure with new tie Seat D Seat wraps f Mounting Plate
84. pth of wheelchair use following guidelines If the current seat depth is an ODD number i e 17 inches 19 inches or 21 inches the seat depth CANNOT be IN CREASED without changing the seat frame Refer to IN STALLING REPLACING ADJUSTABLE 16 TO 19 INCH DEEP RECLINER SEAT FRAME ONTO in this procedure of the manual If the current seat depth is an ODD number i e 17 inches 19 inchesor21 inches the seat depth be DECREASED by 1 inch by installing a 1 inch shorter seat pan Referto the following procedures If the current seat depth is an EVEN number i e 16 inches 18 inches 20 inches or 22 inches the seatdepth CANNOT be DECREASED without changing the seat frame Refer to INSTALLING REPLACING ADJUSTABLE 16 TO 19 INCH DEEP RECLINER SEAT FRAME ONTO PRONTO BASE FRAME in this procedure of the manual n NOTE 16 inch seat depth is the smallest seat depth avail able on recliner seat frames If the current seat depth is an EVEN number i e 16 inches 18 inches 20 inches or 22 inches the seat depth can be INCREASED by 1 inch by installing a 1 inch deeper seat pan Refer to the following procedures NOTE 22 inch seat depth is the deepest seat depth avail able on recliner seat frames 57 PROCEDURE 13 Seat Pan Removal Replacement Procedures Remove the seat cushion from the wheelchair 2 Removethe six 6 mounting screws and locknuts that secure seat pan seat positioning strap to the seat frame 3 I
85. r does not move D Repeat STEPS 1 and 2 until the wheelchair does not operate when the gas cylinder rod is 3 21 32 inch long POSITION OVER 105 RELATIVE Gas Cylinder Rod Measures 3 21 32 inches Mounting Screws and Washers DO NOT Over Tighten Actuator Gas Cylinder Pivot Block FIGURE 2 ADJUSTING LIMIT SWITCH REPLACING RECLINER CABLE ASSEMBLIES FIGURE 3 NOTE There are three 3 different cable lengths depend ing on back height CABLELENGTH BACKHEIGHT Short 18 1 2 and 20 inches Medium 22 and 24 inches Long 26 inches WARNING Replace ONE 1 recliner cable assembly ata time to avoid injury 1 Cut the tie wraps that secure the existing recliner cable assembly to the back cane Remove the pan screw that secures the handle of the existing recliner cable assembly to the back cane Loosen the jam nut on the gas cylinder rod Remove the mounting screw washer nylon wash ers and locknut that secure the TOP of the gas cylin der to the mounting bracket on the back cane Unscrew the gas cylinder from the operator of the existing recliner cable assembly but do not remove the gas cylinder from the pivot block 6 Gas Cylinder RECLINER Remove the operator of the existing recliner cable as sembly from the pivot block Make sure the threads of the gas cylinder rod are flush with the inside of the pivot block With the operator of the NEW recliner cable assem bly on the inside
86. rame Actuator Gas Mounting Screws Limit Cylinger Switch Pivot Block PO NOT Sensor Washers Actuator Overtighten FIGURE 1 POSITIONING LIMIT SWITCH ADJ USTING LIMIT SMTCH FIGURE 2 NEVER operate the wheelchair while in any recline position over 105 RELATIVE TO THE SEAT FRAME If the limit switch does not stop the wheelchair from operating in a recline position greater than 105 RELATIVE TO THE SEAT FRAME do not oper ate the wheelchair Adjust the limit switch BEFORE using the wheelchair otherwise injury or damage can occur 1 Redlinethe back of the wheelchair until the gas cylinder rod measures 3 21 32 of an inch 2 Turn the power of the joystick to the ON position NOTE ALL segments of the bar graph on the joystick should start to flash on and off and the wheelchair should not oper ate IF the wheelchair operates proceed to the following steps to adjust the actuator on the gas cylinder pivot block A Loosen but do not remove the two 2 mounting screws and washers that secure the actuator to the gas cylinder pivot block JAmzz r omz Jaumz romz PROCEDURE 13 B Slide actuator UP towards top ofthe wheelchair CAUTION DO NOT over tighten the mounting screws that secure the actuator to the pivot block Damage to the actuator will occur C Only tighten the two 2 mounting screws and washers that secure the actuator to the gas cylin der pivot block until the actuato
87. re fac ing the REAR of the chair B ONE 1 connector battery box in REAR so that the flying lead is on the RIGHT side of the wheelchair NOTE Make sure the leads that connect the REAR battery box to the FRONT battery box are on the same side 4 Position retaining straps around each battery box as shown in DETAIL B of FIGURE 7 and clip re taining strap together 5 Connectthe REAR battery box lead to the FRONT battery box lead 6 Connect the FRONT battery box lead to the wiring harness 7 f necessary reinstall the removable footboard Refer to REMOVING THE REMOVABLE FOOTBOARD ASSEMBLY FROM THE WHEEL CHAIR in PROCEDURE 3 of this manual REAR OF CHAIR Retaining Rear Battery Box Strap Clip Front One 1 Connector Battery Box Lead To Retaining Strap Wiring pta Harness Rear Battery 4 Box Lead Flying Lead Open Ends of Connector Face Front Battery Hear of Chair Box Lead Front Battery Box Two 2 Connector FRONT OF CHAIR FIGURE 9 INSIALLING REMOVING BATTERY BOXES BATTERIES REMOVING INSTALLING THE BATTERY TRAY FIGURE 10 Removing 1 Remove the front and rear shrouds Refer to RE MOVING INSTALLING SHROUDS in PROCEDURE 10 of this manual 2 Remove the front and rear battery boxes Refer to REMOVING INSTALLING THE BATTERY BOXES in PROCEDURE 11 of this manual 3 Remove the seat Refer to 1 of the following A REMOVING INSTALLING THE S
88. rger s AC power cord or extension into the grounded 120 VAC wall outlet 3 Waituntil charging is complete NOTE Allow eight 8 hours for normal charging Larger batteries greater than 55 ampere hours or severely dis charged batteries may require up to sixteen 16 hours to be properly charged and equalized NOTE PRONTO ONLY If the charger operates for sixteen 16 hours and is unable to fully charge the batter ies an internal timer tums the charger off and begins to fast blink the green light NOTE If the batteries need to be charged more often or take longer to charge than normal they may need to be replaced Contact an Invacare dealer for service Wheelchairs Equipped With Mark IV RII J oystick Detail B of FIGURE 8 1 Attach the battery charger connector to the charger port on the FRONT of the joystick 2 Plugthe charger s AC power cord or extension into the grounded 120 VAC wall outlet 3 Waituntil charging is complete NOTE Allow eight 8 hours for normal charging Larger batteries greater than 55 ampere hours or severely dis charged batteries may require up to sixteen 16 hours to be properly charged and equalized BATTERIES NOTE PRONTO ONLY If the charger operates for sixteen 16 hours and is unable to fully charge the batter ies an internal timer turns the charger off and begins to fast blink the green light NOTE If the batteries need to be charged more often or take longer to
89. s Van Seats Replacing Back Upholstery After ANY adjustments repair or service and BEFORE use make sure that all attach ing hardware is tightened securely oth erwise injury or damage may result REPLACING SEAT POSITIONING STRAP CAPTAIN S VAN SEATS FIGURE 1 1 Remove the van style seat from the van seat frame Referto INSTALLING REMOVING CAPTAIN S VAN SEAT ASSEMBLY in PROCEDURE 6 ofthis manual 2 Removethe two 2 rear mounting screws washers and locknuts that secure the seat positioning straps to the van seat frame NOTE The washer is positioned between the seat posi tioning strap and the mounting screw 3 Secure the NEW seat positioning strap halves with the mounting screws washers and locknuts to the van seat frame and torque to 75 inch pounds 4 Reinstall the van style seat to the van seat frame Referto INSTALLING REMOVING CAPTAIN S VAN SEAT ASSEMBLY in PROCEDURE 6 ofthis manual Van Seat Frame ru Seat Positioning Strap 4 a REAROFSEAT 2 Mounting Screw Washer FIGURE 1 REPLACING SEAT POSITIONING STRAP CAPTAIN S VAN SEATS UPHOLSTERY POSITIONING STRAP REPLACING BACK UPHOLSTERY FIGURE 2 1 Remove one 1 armrest from the wheelchair Refer to INSTALLING REMOVING FLIP BACK ARMRESTS in PROCEDURE 4 of the Owner s Manual part number 1095602 2 If applicable remove the two 2 mounting screws and locknuts that secure the sprea
90. spac ers that secure the seat pan seat positioning strap and quick release pin to the seat frame NOTE When removing seat pan note tab position of quick release pin to the seat positioning strap Installing 1 Position the NEW seat pan on the seat frame aligning the mounting holes of the seat pan and the mounting holes of the seat frame 2 Position the seat positioning strap and quick release pin tab onto the seat frame and secure with mounting screw and locknut See FIGURE 9 for proper orientation Re peat for other seat positioning strap NOTE Check seat positioning strap for proper length The width range for the two 2 seat positioning straps are 16 through 19 inches wide and 20 through 22 inches wide Mounting Screws Seat Positioning Strap Spacer Seat Frame Es D Tab Locknut Locknut Quick Release Pin FIGURE 5 REMOVING INSTALLING SEAT PAN PROCEDURE 6 go Reinstall the remaining mounting screws locknuts and spacers Torque all mounting screws to 75 inch pounds 4 Remove the protective strips from new seat pan and reinstall the seat cushion onto the seat pan MOUNTING PLATE SEAT ANGLE ADJ USTMENT AND INSTALLATION ORIENTATION FIGURE 6 Seat Angle Adjustment NOTE The angle of the seat is factory set providing the user With a 5 seat dump This angle can be changed by adjusting either the front or back of the seat mount plate to obtain any angl
91. stabilizer cylinder must be adjusted to match the length of the stabilizer cylin der just removed 8 10 11 12 13 Measure the distance between the top mounting hole and the bottom mounting hole on the existing stabilizer cylinder Note this distance as distance Refer to DETAIL A Place the wheelchair on a flat surface so that the sta bilizer wheels can hang freely Loosen the jam nut located underneath the hex nut adjuster by turning CLOCKWISE as viewed from the top Rotate the hex nut adjuster in one 1 of the following directions Rotating the hex nut adjuster CLOCKWISE as viewed from the top will move the stabilizer wheel up B Rotating the hex nut adjuster COUNTER CLOCKWISE as viewed from the top will move the stabilizer wheel down When distance is achieved noted from STEP 8 retighten the jam nut by rotating COUNTER CLOCKWISE as viewed from the top to lock the hex nut adjuster in position Place the wheelchair on a flat surface with all six wheels in contact with the surface BASE FRAME DETAIL A Top of Stabilizer Cylinder Stabilizer Cylinder 7 Hex Nut Adjuster Measure this distance and note as DISTANCE Jam Nut Top Mounting Screw Top of Stabilizer Cylinder Bottom of Stabilizer Cylinder Locknut Washer Locknuts Swing Arm Bottom Mounting Screw NOTE Stabilizer
92. tall tie wrap A and B to secure all components and cables noted in STEPS 1 3 to the base frame E With the connection of the right controller lead and the right motor gearbox lead on top of the crossmember fold the power take off leads under neath crossmember and secure with tie wrap Install tie wrap 16 Reassemble wheelchair by reversing STEPS 1 2 44 BASE FRAME PROCEDURE 12 Right Coil Wrapped Wiring Harness Cable for Motor Gearbox Battery Lead Connector BLUE Power Take Off Lead A Le 5 gt Tie Wrap 11 NY Tie Wrap 1 66 55 7 JA ff Controller Connector Cable for Power Take Off Tie Wrap Right Controller Lead Right Controller 2 gt 20 BLUE Crossmember Lead Pon Power Cable Tie Wrap Take Off RIGHT HAND SIDE OF WHEELC HAIR R Tie Wrap Tie Wrap Tie Wrap B Port S d 7 Cable for Tie Wrap Battery Charger Port Tie Wrap A Crossmember Mounting Charger Port Left Mounting Motor Gearbox Left Bracket Lead NOTE View of base frame is from the rear of the wheel chair HGURE 1 REPLACING WIRING HARNESS MKIV CONTROLLER ONLY 45 mz zm
93. tch handle to the existing motor gearbox 5 Disconnectclutch handle from existing motor gearbox 6 Repeat STEPS 4 5 for other clutch handle gt 2 gt 20 0 2 gt PROCEDURE 12 BASE FRAME 7 Remove the battery tray and both motor gearboxes 17 Connect clutch handles to existing motor gearboxes Refer to REMOVING INSTALLING THE BATTERY 18 Install the pins that secure the clutch handles to the TRAY in PROCEDURE 11 in this manual existing motor gearboxes 8 Removethecontroller Referot REMOVING INSTALL 19 Reassemble wheelchair by reversing STEPS 1 3 ING THE CONTROLLER in PROCEDURE of this manual REPLACING THE MOTOR 9 Remove the tip from the existing clutch handle GEARBOX FIGURES 5 AND 6 10 Feed the existing clutch handle through the wheelchair frame 1 Remove the front and rear shrouds Refer to RE 11 Remove the rubber tip from the new clutch handle MOVING INSTALLING SHROUDS in PROCEDURE 10 of this manual 12 Install the NEW clutch handle onto the wheelchair 2 Remove the front and rear battery boxes Refer to NOTE Make sure the NEW clutch handle is pointing to REMOVING INSTALLING THE BATTERY BOXES in wards the outside of the wheelchair PROCEDURE 11 of this manual 13 Install the rubber tip onto the new clutch handle 3 Remove the seat Refer to one 1 of the following 14 Repeat STEPS 9 13 forthe opposite side
94. the rear storage chair if necessary compartment to the wheelchair frame CLOCKWISE 6 Reinstall the Captain s Seat onto the wheelchair Refer 4 Position rear shroud on the two 2 side shrouds and to REMOVING INSTALLING CAPTAIN S SEAT in PRO slide towards the front of the wheelchair until it stops CEDURE 5 of this manual or WEIGHT SHIFT TILT MODELS Proceed to STEP 7 5 Press down on the rear shroud until the two 2 clips secure the rear shroud to the two 2 side shrouds 7 Reinstall the rear shroud and rear storage compartment if equipped onto the wheelchair Referto REMOVING REMOVING SIDE SHROUDS INSTALLING REAR SHROUD AND REAR STORAGE 1 Remove the front shroud from the wheelchair Refer to COMPARTMENT in this procedure of the manual REMOVING INSTALLING FRONT SHROUD in this 8 Reinstall the front shroud onto the wheelchair Refer to procedure of the manual 32 REMOVING INSTALLING FRONT SHROUD inthis pro cedure of the manual SHROUDS PROCEDURE 10 Rear Shroud Phillips Bolt H Side Shroud td x Washers y X Phillips Screws Rear Trunk im Optional Wheelchair Frame Side Shroud 1 4 Turn Bolts Washer Coved Washer d Locknut oe Locknut 21 Phillips Bolts Front Shroud FIGURE 1 REMOVING INSTALLING SHROUDS 33 om um 2 Uu PROCEDURE 11 This Procedure includes the following Installing Hemoving Batteries into From Battery Boxes
95. this manual 58 PROCEDURE 13 Recliner Mounting Seat Assembly Screws 9 Spacers 16 inch wide only Base _ Frame Seat Mount Plate Locknuts FIGURE 7 INSTALLING REPLACING ADJUSTABLE 16 TO 19 INCH DEEP RECLINER SEAT FRAME WARRANTY LIMITED WARRANTY PLEASE NOTE THE WARRANTY BELOW HAS BEEN DRAFTED TO COMPLY WITH FEDERAL LAW APPLICABLE TO PRODUCTS MANUFACTURED AFTER J ULY 4 1975 This warranty is extended only to the original purc haser user of our products This waranty gives you specific legal rights and you may also have other legal rights which vary from state to state With regards to the original purchaser user only Invacare warrants the side frames to be free from defects in materials and workmanship for a period of five 5 years from date of purchase electronics for a period of one 1 year from the date of purchase motors and gearboxes for a period of eighteen 18 months for Pronto models with motors that have motor locks and a period of twelve 12 months for Pronto models with motors that have clutc hes from the date of purchase all remaining components including gas cylinders for recliners for one 1 year from the date of purchase except upholstered materials padded materials and tires wheels If within such warranty period any product shall be proven to be defective such product shall be repaired or replaced at Invacare s option This warranty d
96. ube to the height adjustment bracket and footboard bracket Refer to DETAIL A 8 Reinstall the caplug caps 9 Repeat STEPS 2 8 for the opposite footboard bracket 10 Reinstall the removable footboard plate Refer to Height REMOVING INSTALLING THE REMOVABLE Adjustment FOOTBOARD ONTO FROM THE WHEELCHAIR Bracket in PROCEDURE 3 of the Owner s Manual _ Mounting Positions Threaded Arm FIGURE 1 ADJUSTING THE REMOVABLE FOOTBOARD HEIGHT 10 ARMS This Procedure Includes the Following Replacing Armrest Pads Captain s van Seats Replacing Captain s van Seat Armrest Plate After ANY adjustments repair or service and BEFORE use make sure that all attach ing hardware is tightened securely oth erwise injury or damage may result REPLACING ARMREST PADS CAPTAIN S VAN SEATS FIGURE 1 1 Remove the mounting screw that secures the front of the armrest pad to the armrest plate 2 Remove the mounting screw that secures the rear of the armrest pad and armrest insert to the armrest plate 3 Remove the existing armrest pad and position the NEW armrest pad on the armrest plate 4 Lineupthe mounting holes in the armrest insert arm rest plate and NEW armrest pad 5 Reinstall the rear mounting screw through the arm rest insert armrest plate and armrest pad and tighten securely 6 Reinstall the front mounting screw into the armrest plate and NEW armrest pad and tighten securely
97. with instructions However wamings are frequently noted on the cell caps Read them carefully Remove the battery box es Refer to INSTALLING RE MOVING BATTERY BOXES in PROCEDURE 11 of this manual Remove the battery caps from the battery Squeeze the air from the hydrometer Place the hydrometer into a battery cell NOTE DO NOT fill hydrometer more than 3 4 full 5 Drawup sufficient acid to cover float balls 6 Taplightly to remove air bubbles 7 Number of floating balls indicates charge Number of Floating Balls Discharged 25 Charged 50 Charged 75 Charged 100 Charged Overcharged Check charging system 8 Flush the liquid back into the same cell after reading the float Repeat this step until all cells have been properly read A shorted or dead cell can be detected when it is the only cell that does not charge Number of Floating Balls Will Vary According to Charge FIGURE 2 USING A HYDROMETER TO CHECK BATTERY CELLS LEAD ACID TROUBLESHOOTING 9 Flush hydrometer in cold running water by allowing the water to rise into hydrometer as far as possible Do this several times to guard against burn damage 10 Replace the battery caps 11 Reinstall battery boxes Referto INSTALLING REMOV ING BATTERY BOXES in PROCEDURE 11 of this manual MOTOR TESTING FIGURE 3 1 Onthe 4 pin motor connector locate the two 2 con tacts in the red and black housings
98. x 1 x 35 millimeters long and the two 2 INSIDE mounting screws that secure the motor gearbox to the base frame MUST be M6 x 1 x 20 millimeters long otherwise NOTE Battery tray not shown for clarity FIGURE 5 REPLACING CLUTCH HANDLES g can result damage to the gearbox casti BASE FRAME 10 Install apply loctite to mounting screws the three 3 outside and two 2 inside mounting screws to secure motor gearbox and battery tray to the base frame Refer to FIGURE 6 11 Torque mounting screws to 160 inch pounds 12 Forwheelchairs equipped with motors that have clutches perform the following Referto FIGURE 5 Connectclutch handle existing motor gearbox B Install the pin that secures the clutch handle to the existing motor gearbox NOTE Make sure the detent ball on the pin is fully visible 13 Perform STEPS 5 12 for other motor gearbox if nec essary 14 Install the drive wheels Refer to REMOVING ANSTALL ING THE DRIVE WHEELS in PROCEDURE 9 of this manual OUTSIDE Mounting Screws M6 x 1 x 35 millimeters Apply Loctite 242 and torque to 60 inch pounds INSIDE Mounting Screws M6 x 1 x 20 millimeters long Apply Loctite 242 and torque to 60 inch pounds On models equipped with motors that have clutches only Battery Tray FIGURE 6 REPLACING THE MOTOR GEARBOX PROCEDURE 12 15 Install the seat Refer to one 1 of the following A REMOVING INSTALLING THE STANDAR
99. y boxes from the wheelchair reverse the following procedure If the wheelchair is equipped with the re movable footboard AND it is installed in the highest position it is necessary to re move the footboard plate BEFORE remov ing the battery boxes Otherwise injury can occur To remove the removable footboard refer to REMOV ING THE REMOVABLE FOOTBOARD ASSEMBLY FROM THE WHEELCHAIR in PROCEDURE 3 of this manual NOTE Motors should be in the engaged position when removing nstalling batteries Refer to ENGAGING DIS ENGAGING MOTORS in PROCEDURE 8 of this manual 1 2 Verify that the ON OFF switch on the joystick is in the OFF position If necessary remove the front and rear shrouds Refer to REMOVING INSTALLING SHROUDS in PROCE DURE 9 of this manual Use extreme care when installing remov ing the battery boxes NEVER unplug the cables by pulling on the wires Unplug the battery cables by pulling on the connector ONLY Otherwise injury or damage may result When removing the battery boxes from the wheelchair remove the rear battery box first NOTE RIGHT and LEFT are determined by sitting in the If applicable verify that the plastic caps are in place wheelchair om um 5 Uu 0 PROCEDURE 11 3 Position the battery boxes onto the battery tray in the following order A TWO 2 connector battery box in FRONT so that the open ends of the connectors a

Invacare Pronto R2 Service Manual

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