Invacare Torque SP manual

Service Manual STORM SERIES ® WHEELCHAIRS (RWD/MWD/FWD) Arrow ® Torque  S P Ranger X  DEALER: KEEP THIS MANUAL. THE PROCEDURES IN THIS MANUAL MUST BE PERFORMED BY AN AUTHORIZED DEALER ONLY[...]

2 W ARNING W A R N I N G S A VE THESE INSTRUCTIONS W ARNING THE PROCEDURES IN THIS MANUAL SHOULD ONL Y BE PERFORMED BY QUALIFIED TECHNICIAN. DO NOT SER VICE OR OPERA TE THIS EQUIPMENT WITHOUT FIRST READING AND UNDERST ANDING THIS MANUAL AND THE OWNERS MANUAL SUPPLIED WITH THE WHEELCHAIR. IF YOU ARE UNABLE TO UNDERST AND THE W ARNINGS, CAUTIONS, AND[...]

3 T ABLE OF CONTENTS T A B L E O F C O N T E N T S NOTE: The information in this owner's manual applies to the STORM ARROW , ** STORM TORQUE, STORM X, JUNIOR MODELS and the RECLINER Wheelchairs except where specified. NOTE: Procedures 1- 14 apply to rear wheel drive, mid wheel drive and front wheel drive wheelchairs EXCEPT where specified. SPE[...]

4 T ABLE OF CONTENTS TABLE OF CONTENTS (Continued) PROCEDURE 9 - BA TTERIES ............................................................................................................................... .. 4 1 INST ALLING/REMOVING BA TTERIES INTO/FROM BA TTER Y BOX(ES) ............................................................... 4 1 CONNECTING [...]

5 PROCEDURE 16 - RWD WHEELCHAIRS ............................................................................................................... 7 9 REMOVING/INST ALLING GROUP 24 BA TTERY BOX SUB-FRAME ........................................................................ 7 9 REMOVING/INST ALLING GROUP 22 BA TTERY BOX TRA Y ......................[...]

6 S P E C I F I C A T I O N S SPECIFICA TIONS SPECIFICATIONS * in 1-inch increments * * Storm T orque/T orque SP model wheelchairs are available in rear wheel drive ONL Y . Gearless Brushless Motor Option is  available on S torm T orque ONL Y . ✪ With MKIV RII Controller. ● With MKIV Rx or A Controller. u Non-Recliners ONL Y . v Arrow specif[...]

7 SPECIFICA TIONS S P E C I F I C A T I O N S PHYSICAL DIMENSIONS v ARROW ** TORQUE **TORQUE SP X JUNI OR Casters w/Precision Sealed Bearings Semi-Pneumatic 300 lbs. Rating Standard: 8 X 1-3/4-in. 8 X 1-3/4-in. 8 X 1-3/4-in. 8 X 1-3/4-in. 8 X 1-3/4-in. Option: 6 X 2-in. 6 X 2-in. 6 X 2-in. 6 X 2-in. 6 X 2-in. Pneumatic or Foam Filled Standard: 8 X [...]

8 GENERAL GUIDELINES PROCEDURE 1 G E N E R A L G U I D E L I N E S REP AIR OR SER VICE INFORMA TION Set-up of the Electronic Contr ol Unit is to be per formed ONL Y by individuals certified by Invacare. The final tuning adjustments of the controller may affect other activities of the wheelchair. Damage to the equipment could occur under these circu[...]

9 GENERAL GUIDELINES PROCEDURE 1 G E N E R A L G U I D E L I N E S WARNING/CAUTION LABEL LOCATION - RWD MODELS SUSPENSION ARM USED WITH GEARLESS/BRUSHLESS MOTOR NOTE: W ARNING LABEL also found on side frame near the rear of the chair. SUSPENSION ARM USED WITH CONVENTIONAL MOTOR/GEARBOX ASSEMBL Y NOTE: These caution labels are only found on bat- ter[...]

10 MWD MODELS Suspension Arm (located on inside of drive wheel) NOTE: CAUTION LABEL also found on side frame near the front of the chair. GENERAL GUIDELINES PROCEDURE 1 G E N E R A L G U I D E L I N E S WARNING/CAUTION LABEL LOCATION BA TTERY BOX WIRING HARNESS FWD MODELS NOTE: Stablilizer springs are found on models built BEFORE 7/1 1/99 ONL Y .[...]

11 (+) (-) FIGURE 1 - FIELD LOAD TEST Battery Charger Connector Digit al V oltmeter FIELD LOAD TEST (FIGURE 1) NOTE: The following test can also be performed through the controller of the wheelchair along with a remote pro- gram mer . Refer to the individual CONTROLLER MANUAL supplied with each wheelchair . Old batteries lose their ability to store[...]

12 TROUBLESHOOTING PROCEDURE 2 T R O U B L E S H O O T I N G W ARNING When reading a hydrometer, DO NOT al- low any liquid to come in contact with your eyes or skin. It is a form of acid and can cause serious burns, and in some cases, blindness. If you do get battery acid on you, flush the exposed areas with cool water IMMEDIA TEL Y. If the acid co[...]

13 ELECTRO-MECHANICAL PARKING BRAKE TESTING (FIGURE 5) NOTE: This procedure should only be performed on wheelchairs with conventional motor/gearbox assembly . 1 . On the four-pin motor connector , locate the side by side connectors in the black housings. 2 . Set the digital multimeter to read ohms ( Ω ). 3. Measure the resistance between the two [...]

14 PROCEDURE 3 HARDW ARE TORQUE SPECIFICA TIONS T O R Q U E S P E C I F I C A T I O N S HARDWARE TORQUE SPECIFICATIONS *T orque to 60 in/lbs **T orque to 156 in/lbs T orque to 156 in/lbs **T orque to 156 in/lbs **T orque to 156 in/lbs STANDARD SEAT FRAME *Loctite ® and T orque to 75 in/lbs *Loctite and T orque to 75 in/lbs **T orque to 156 in/lbs [...]

15 T O R Q U E S P E C I F I C A T I O N S PROCEDURE 3 HARDW ARE TORQUE SPECIFICA TIONS T orque to 75-in/lbs HARDWARE TORQUE SPECIFICATIONS *CAPTAINS VAN SEAT Loctite and T orque to 75 in/lbs T orque to 156 in/lbs *ADJUSTABLE SEAT FRAME T orque to 156 in/lbs T orque to 156-in/lbs T orque to 156-in/lbs T orque to 156-in/lbs T orque to 156-in/lbs * N[...]

16 T orque to 160 in/lbs Loctite and torque to 160 in/lbs T orque to 1020 in/lbs 8 - inch Wheels - T orque to 120 in/lbs 9 - inch Wheels - T orque to 160 in/lbs T orque to 160 in/lbs Loctite and torque to 75 in/lbs Tighten until snug Pneumatic with Flat-Free Wheel Halves - T orque to 160 in/lbs Pneumatic Wheel Halves - 8 - inch - T orque to 18 in/l[...]

17 MID-WHEEL DRIVE BASE FRAME HARDWARE TORQUE SPECIFICATIONS T orque to 160 in/lbs T orque to 1020 in/lbs Loctite and T orque to 75 in/lbs T orque to 160 in/lbs T orque to 160 in/lbs T orque to 160 in/lbs Loctite and torque to 75 in/lbs Tighten until snug T orque to 40 in/lbs Loctite and torque to 160 in/lbs FRONT OF WHEELCHAIR REAR OF WHEELCHAIR 8[...]

18 FRONT-WHEEL DRIVE BASE FRAME HARDWARE TORQUE SPECIFICATIONS T O R Q U E S P E C I F I C A T I O N S T orque to 1020 in/lbs T orque to 156 in/lbs T orque to 156 in/lbs T orque to 156 in/lbs T orque to 15 in/lbs T orque to 360 in/lbs T orque to 156 in/lbs T orque to 360 in/lbs T orque to 156 in/lbs Loctite and T orque to 75 in/lbs FRONT OF WHEELCH[...]

19 A R M S ARMS PROCEDURE 4 REPLACING ARMREST PADS - CAPTAINS VAN SEATS (FIGURE 1) 1 . Remove the mounting screws that secures the front of the armrest pad to the armrest plate. 2 . Remove the mounting screw that secures the rear of the armrest pad and armrest insert to the armrest plate. 3 . Remove the existing armrest pad and position the NEW arm[...]

20 UPHOLSTER Y/POSITIONING STRAP PROCEDURE 5 U P H O L S T E R Y P O S I T I O N I N G S T R A P This Procedure Includes the Following: Replacing Seat Positioning Strap - Captains V a n Seats Replacing Back Upholstery W ARNING After ANY adjustments, repair or service and BE- FORE use, make sure that all attaching har dware is tightened securely - o[...]

21 FIGURE 2 - REPLACING BACK UPHOLSTERY Locknut (STEP 2) Mounting Screw (STEP 2) Locknut (STEP 2) Mounting Screw T orque to 60 in/lbs (STEP 2) Spreader Bar (STEPS 2, 7, 16) Mounting Screw (STEPS 3, 14) W asher (STEPS 3, 14) Back Upholstery (STEPS 3, 7) Back Cane (STEPS 3, 12) Insert Seat Frame Mounting Screws T orque to 75 in/lbs (STEPS 5, 6) W ash[...]

22 PROCEDURE 6 SEA T FRAME S E A T F R A M E This Procedure includes the following: Preparation for Removing/Installing Seat Frame (Standard Frame, Adjustable Frame, and Captains V an Seat) ............................ Page 21 Replacing Exact Same Size Standard Seat Frame .............................................. Page 22 Removing/Installing St[...]

23 3 . Cut tie wraps and disconnect joystick from controller . 4 . T urn the lever on the adjustment lock to release the adjustment lock from the joystick mounting tube. 5 . Remove the joystick from the wheelchair . 6 . Perform one (1) of the following: A. ST ANDARD OR ADJUST ABLE SEA T FRAMES - Remove the flip-back armrests from the wheelchair . R[...]

24 3. Refer back to the starting procedure to complete the desired change. Installing 1. Position NEW standard seat frame subassembly on seat mount plates. 2. Secure NEW standard seat frame subassembly onto seat mounting plates with the existing four (4) mount- ing screws, locknuts and spacers, if applicable. T orque to 156-inch pounds. 3. Refer ba[...]

25 1. Find current seat depth in left hand column in the chart. 2. Follow that row to right under seat frame components. 3. V erify and note the components of the current seat depth. 4. Repeat STEPS 1-3 for the desired seat depth. 5. Compare existing components of the current seat depth and the required components for the desired seat depth. T o ad[...]

26 FIGURE 4 - ADJUSTING SEA T DEPTH - CHANGING SEA T DEPTH BETWEEN 12 AND 15-INCHES CJ Back Bracket Seat Frame Threaded Insert W ashers Back Cane Coved W ashers Mounting Screws (Torque to 75-inch pounds) 1. Remove the armrest s from the wheelchair . Refer to IN- ST ALLING/REMOVING FLIP BACK ARMRESTS in PROCEDURE 4 of the owner s manual, 1081227.[...]

27 ALLOW ABLE SEA T WIDTH AND DEPTH COMBINA TIONS FOR ADJUST ABLE SEA T FRAME NOTE: The seat widths and seat depths enclosed in the outlined box will require the use of CJ back brackets and a 17-inch deep seat pan. 3. Remove the two (2) mounting screws, coved washers, spacers, and locknuts that secure the side frame to the center frame. 4 . Adjust [...]

28 FIGURE 6 - INST ALLING/REMOVING ADJUST ABLE SEA T FRAME SUBASSEMBL Y AND/OR COMPONENT REPLACEMENT Mounting Screws (T orque to 156-inch pounds) Side Frame Side Frame Center Frame Spacer Locknuts Support Bracket Base Frame Coved Washer Locknuts Locknuts Support Bracket Mounting Screws (T orque to 156-inch pounds) Mounting Screws (T orque to 156-in[...]

29 3. Perform one (1) of the following: A . If center frame needs replaced, repeat STEP 2 for opposite side frame and proceed to STEP 4. B. If opposite side frame needs replaced, repeat STEP 2, then proceed to STEP 6. Otherwise proceed to STEP 6. 4. Remove the four (4) mounting screws and locknuts that secure the center frame to the support bracket[...]

30 6. Perform the instructions outlined in PREP ARA TIONS FOR REMOVING/INST ALLING SEA T FRAME (ST AN- DARD FRAME, ADJUST ABLE FRAME, AND CAP- T AINS V AN SEA T) in this procedure of the manual. CONVERTING FROM ADJUSTABLE SEAT FRAME TO CAPTAINS VAN SEAT OR VICE VERSA 1. Perform the instructions outlined in PREP ARA TIONS FOR REMOVING/INST ALLING SE[...]

31 3. Remove the six (6) mounting screws, locknuts, and spac- ers that secure the seat pan, seat positioning strap, and quick release pin to the seat frame. NOTE: When removing seat pan, note tab position of quick release pin to the seat positioning strap. Installing 1. Position the NEW seat pan on the seat frame, aligning the mounting holes of the[...]

32 B. Reinstall the flip-back armrests from the wheelchair . Refer to INST ALLING/REMOVING FLIP BACK ARM- RESTS in PROCEDURE 4 of th e owner s manual, 1081227. MOUNTING PLATE - SEAT ANGLE ADJUSTMENT AND INSTALLATION ORIENTATION (FIGURE 10 ) Seat Angle Adjustment NOTE: The angle of the seat is factory set providing the user w i t h a 5 o seat dum[...]

33 This Procedure Includes the Following: Replacing Seat Mounting Plates Replacing Seat Support Brackets Replacing Seat Support Bracket T-Nuts Replacing Battery Charger Bracket and T-Nut Removing/Installing Seat Stop Screws WARNING After ANY adjustments, repair or service and BE- FORE use, make sure that all attaching hardware is tightened securely[...]

34 BASE FRAME PROCEDURE 7 B A S E F R A M E B. Remove adjustable seat frame subassembly . Re- fer to INST ALLING/REMOVING ADJUST ABLE SEA T FRAME ASSEMBL Y AND OR COMPO- NENT REPLACEMENT in PROCEDURE 6 of this manual. C. Remove captains van seat. Refer to I NST ALLING/ REMOVING CAPT AINS V AN SEA T ASSEMBL Y in PROCEDURE 6 of this manual. 3. Remove[...]

35 8 . Secure the battery charger connector to the mount bracket with the EXISTING two (2) mounting screws. T ighten securely . 9. Reverse STEP 2A , 2 B or 2 C . 10 . Perform the instructions outlined in P REP ARA TIONS FOR REMOVING/INST ALLING SEA T FRAME (ST AN- DARD FRAME, ADJUST ABLE FRAME, AND CAP- T AINS V AN SEA T ) in PROCEDURE 6 of this ma[...]

36 FIGURE 6 - REMOVING/INST ALLING SEA T STOP SCREWS Base Frame Front Seat Stop Screw Rear Seat Stop Screw Seat Support Bracket REMOVING/INSTALLING SEAT STOP SCREWS (FIGURE 6) NOTE: This procedure is for RWD and MWD wheel- chairs ONL Y . NOTE: The front seat stop screw should only be removed if replacing a T-nut for either the seat support bracket [...]

37 PROCEDURE 8 B A C K F R A M E This Procedure includes the following: Removing/Installing CJ Back Brackets Changing Back Height Back Angle Adjustment W ARNING After ANY adjustments, repair or service and BEFORE use, make sure that all attach- ing hardware is tightened securely - oth- erwise injury or damage may result. NOTE: The procedures in thi[...]

38 NOTE: If needing a reference for proper mounting holes for the back angle required, or if changing the original back angle, refer to BACK ANGLE ADJUSTMENT in this pro- cedure of the manual. W ARNING The back canes MUST be fastened se- curely to the seat frame BEFORE using the wheelchair. T orque to 75-inch pounds. 13. Secure the two (2) NEW back[...]

39 FIGURE 2 - CHANGING BACK HEIGHT Locknut (STEPS 6,1 1 ) Mounting Screw T orque to 60 in/lbs (STEPS 6,1 1 ) Spreader Bar (STEPS 6,17) Mounting Screw (STEPS 2, 14) W asher (STEPS 2, 14) Back Upholstery Back Cane (STEPS 3, 10) Insert (STEPS 4,8) Seat Frame Mounting Screws T orque to 75 in/lbs (STEPS 3, 13) W ashers (STEPS 3, 13) Mounting Screws (STE[...]

40 BACK ANGLE ADJUSTMENT (FIGURE 3) 1 . Remove armrests from the wheelchair . Refer to IN- ST ALLING/REMOVING FLIP BACK ARMRESTS in PROCEDURE 4 of the owner s manual, 1081227. 2 . Remove the mounting screw and washer from the top mounting hole of back angle plate and back cane . NOTE: T o avoid losing the insert in each back cane, thread the mou[...]

41 NOTE: If there is battery acid in the bottom or on the sides of the battery box(es) or battery(ies), apply baking soda to these areas to neutralize the battery acid. Before reinstalling the NEW or existing battery(ies), clean the baking soda from the battery box(es) or battery(ies). NOTE: When securing battery lifting strap to battery , ob- serv[...]

42 PROCEDURE 9 B A TTERIES B A T T E R I E S CONNECTING BATTERY CABLES (FIGURE 2) W ARNING NEVER allow any of your tools and/or battery cable(s) to contact BOTH battery post(s) at the same time. An electrical short may occur and se- rious personal injury or damage may occur. The use of rubber gloves and chemical goggles or face shields is recommend[...]

43 PROCEDURE 9 B A TTERIES B A T T E R I E S P N FIGURE 2 - CONNECTING BA TTERY CABLE(S) - GROUP 24 BA TTERIES Battery Box Bottom POSITIVE (+) Battery T e rminal/ Post NEGA TIVE (-) Battery T e rminal/ Post Battery ONE (1) CONNECTOR BA TTERY BOX TWO (2) CONNECTOR BA TTERY BOX BLACK Battery Clamp Cover RED Battery Clamp Cover Red POSI- TIVE (+) Batt[...]

44 B A T T E R I E S Group 22 Battery Base Frames (FIGURE 3) NOTE: Refer to W ARNINGS and CAUTIONS in th e front of this procedure. NOTE: Note polarity of white battery cable (jumper) battery terminal ends. 1 . Remove battery terminal cap(s) from battery terminal(s) ends. Refer to DET AIL A in FIGURE 3. 2. Connect WH ITE battery cable (jumper[...]

45 PROCEDURE 9 B A TTERIES STEPS 3 AND 4 Battery Box T op (Under Side shown) NEGA TIVE (-) BLACK Battery Cable Front Battery Rear Battery STEPS 5 AND 6 Battery Box T op Front Battery Battery Box Bottom FRONT POSITIVE (+) RED Battery Cable Fuse Block POSITIVE (+) RED Battery Cable Battery Box Bottom Rear Battery NEGA TIVE (-) Battery T erminal/Post [...]

46 PROCEDURE 9 B A TTERIES FIGURE 6 - WHEN TO CHARGE BA TTERIES MKIV- A JOYSTICK MKIV- A+ JOYSTICK Battery Discharge Indicator (BDI) (in LCD Readout) MKIV- X JOYSTICK Battery Discharge Indicator (BDI) Battery Discharge Indicator (BDI) CHARGING BATTERIES (FIGURE 7 ) NOTE: New batteries MUST be fully charged prior to initial use of the wheelchair . W[...]

47 NOTE: If performing the charging procedures independently , READ and CAREFULL Y follow the individual instructions for each charger (supplied or purchased). NOTE: If charging instructions are not supplied, consult a qualified service technician for proper procedures. Required Items: TOOL Q UANTITY C OM M ENTS Battery Charger 1 Supplied u Extensi[...]

48 PROCEDURE 9 B A TTERIES B A T T E R I E S It is advantageous to recharge frequently rather than only when necessary . In fact, a batterys life is extended if the charge level is maintained well above a low condition. REPLACING BATTERIES NOTE: Invacare recommends that both batteries be replaced if one (1) battery is defective. Recommended Batt[...]

49 B A T T E R I E S FIGURE 9 - INST ALLING/ REMOVING G ROUP 22 BA TTERY BOX Battery Box Retention Strap Arrows FIGURE 8 - INST ALLING/REMOVING GROUP 24 BA TTERY BOXES Battery Box Sub-Frame T wo (2) Connector Battery Box One (1) Connector Battery Box NOTE: Position carrying strap on top of battery box Guide Pins Guide Pins Battery Box Retainer Bar [...]

50 PROCEDURE 10 WIRING HARNESS R EMOVING/INSTALLING THE WIRING HARNESS (FIGURE 1) NOTE: This procedure is for the FWD and MWD models ONL Y . For the removing and installing the wir- ing harness on the Arrow FWD refer to REMOVING/ INST ALLING WIRING HARNESS in PROCEDURE 17 of this manual. Removing 1. Remove the battery box(es). Refer to INST ALLING/[...]

51 FRONT OF CHAIR REAR OF CHAIR Wiring Harness Bracket Mounting Screws Battery Box Sub-Frame Base Frame Locknuts DET AIL A - GROUP 24 BA TTERIES DET AIL B - GROUP 22 BA TTERIES DET AIL “ C ” -SECOND GENERA TION WHEELCHAIRS Tie-Wraps A and B Wiring Harness Connector (BLUE) Tie-Wrap C Controller Connector (BLUE) Charger Mount Bracket W iring Harn[...]

52 ADJUSTING LIMIT SWITCH (FIGURE 2 ) NOTE: The following procedure is for high back captains van seat model wheelchairs only . W ARNING NEVER operate the wheelchair while in any recline position over 114 o RELA TIVE TO THE SEA T FRAME. If the limit switch does not stop the wheelchair from operating in a recline posi- tion greater than 114 o RELA T[...]

53 REPLACING BATTERY BOX RETAINER BAR/RETAINER CLIP - GROUP 24 BATTERY BASE FRAMES (FIGURE 1) 1. Remove the battery box. Refer to INST ALLING/RE- MOVING GROUP 24 BA TTER Y BOXES in PROCE- DURE 9 of this manual. Replacing Retainer Clip 1. Perform one (1) the following: A. RWD AND MWD MODELS - Remove the mounting screw that secures the retainer clip [...]

54 PROCEDURE 12 WHEELS/MOTORS Retainer Clip Mounting Screws Battery Box Sub-frame Base Frame Angled End (Facing Upward) Retainer Bar Shock Assembly T op of Shock Assembly Spacer RWD AND MWD MODELS FWD MODELS Retainer Bar Mounting Screws W ashers Spacer Retainer Clip Spacer Locknuts Battery Box Sub-Frame ASSEMBLED VIEW W H E E L S / M O T O R S FIGU[...]

55 W H E E L S / M O T O R S This Procedure includes the following: Replacing Pneumatic Tires/Tubes - Drive Wheels/ Casters Removing/Installing Drive Wheels Removing/Installing Drive Wheel Hub Installing Wheel Lock Bracket onto Wheelchair Removing/Installing Casters Replacing Forks Motor Replacement W ARNING After ANY adjustments, repair or service[...]

56 PROCEDURE 12 WHEELS/MOTORS REMOVING/INSTALLING DRIVE WHEEL HUB (FIGURE 1) NOTE: This procedure can only be performed on sec- ond generation storm wheelchairs with the conven- tional motor/gearbox assembly . On second genera- tion storm wheelchairs with the gearless/brushless motor , the drive wheel hub CANNOT be removed. Return motor to manufact[...]

57 REMOVING/INSTALLING THE MOTOR (CONVENTIONAL MOTOR WITH GEARBOX) (FIGURE 5) Removing RWD AND MWD MODELS. 1. Disconnect the right and/or left motor connector from the controller . 2. Remove the two (2) allen screws and washers that secure the motor to the gearbox. CAUTION DO NOT damage the motor/gearbox coupling. 3. Carefully pull the motor away f[...]

58 PROCEDURE 12 WHEELS/MOTORS W H E E L S / M O T O R S 4. Remove the two (2) mounting screws, spacers, and washers that secure the MKIV controller to the base frame. Set MKIV controller onto ground/floor . NOTE: STEPS 5, 6, and 7 are necessary to obtain easier access to the motor/controller connection. 5. Remove the mounting screw and spacer that [...]

59 3. Secure motor to the suspension arm with existing four (4) mounting screws. T orque to 13 foot/pounds. 4. Slide the motor lock lever along brake release shaft until the end is flush with the bushing guide. 5. Slide alignment pin, located inside of bushing guide, into the end of the motor lock lever and secure in place with existing mounting sc[...]

60 Mounting Screw Washer Mounting Screws Mounting Screws W asher Motor Suspension Arm Motor Lock Lever Adjustment Screw Mounting Screw W asher *Alignment Pin *NOTE: Alignment pin exploded away suspension arm for clarification purposes only . Brake Release Shaft Guide Bushing PROCEDURE 12 WHEELS/MOTORS W H E E L S / M O T O R S Mounting Screws DETAI[...]

61 FIGURE 2 - REMOVING/INSTALLING MKIV CONTROLLER Mounting Plate Mounting Screws Hex Bolts MKIV Controller Base Frame NOTE: Controller for gearless/brushless motor re- moves in the same manner. FIGURE 1 - REPOSITIONING MKIV JOYSTICK - VAN SEAT MODELS Locknuts (STEPS 3,16) Phillips Screws (STEPS 4, 14) Lug Bolt (STEPS 7, 9) Joystick Mounting Bracket[...]

62 Arrow Fwd Model REMOVING. 1. Remove the front shroud . R efer to REMOVING/IN- ST ALLING FRONT SHROUD in PROCEDURE 17 of this manual. 2. Remove the counterweight. Refer to REMOVING/IN- ST ALLING COUNTER WEIGHT in P ROCEDURE 1 7 of this manual. 3. Remove the battery box(es). Refer to INST ALLING/RE- MOVING GROUP 24 BA TTER Y BOXES in PROCE- DURE 9[...]

63 Mounting Screws Mounting Screws (DO NOT Overtighten) Actuator Tie Wraps Wire Retainer Limit Switch Sensor Seat Frame Mounting Screws (DO NOT Over Tighten) Washers Limit Switch Sensor FIGURE 1 - POSITIONING LIMIT SWITCH Gas Cylinder Pivot Block Actuator Washers POSITIONING LIMIT SWITCH (FIGURE 1) NOTE: The battery charger connector , as well as, [...]

64 PROCEDURE 14 RECLINER FIGURE 2 - ADJUSTING LIMIT SWITCH R E C L I N E R Mounting Screws and Washers (DO NOT Over-Tighten) Actuator Gas Cylinder Rod Measures 3-21/32-inches POSITION OVER 105 O RELA TIVE TO THE SEA T FRAME Gas Cylinder Pivot Block 6. Remove the operator of the existing recliner cable assembly from the pivot block. 7. Make sure the[...]

65 Gas Cylinder Rod Jam Nut Gas Cylinder NO Movement in Operator of the Recliner Cable Assembly Gas Cylinder Rod Threads Handle No Slack in Cable FIGURE 4 - REPLACING/ADJUSTING GAS CYLINDERS Handle Cable Fitting Seated Properly Pivot Block Cable Snapped into Slot Nylon Washer Locknut Washer Mounting Screw Mounting Bracket If slack in the recliner c[...]

66 R E C L I N E R Adjusting Gas Cylinder 1 . T o adjust the LEFT gas cylinder: Squeeze the handle of the RIGHT recliner cable assembly and try to re- cline the back. The back should not recline. 2. If the LEFT side of the back releases without squeezing the handle of the LEFT recliner cable assembly , perform the following steps: A . Finger tighte[...]

67 PROCEDURE 14 RECLINER Hex Screws Seat Pan Seat Frame FIGURE 6 - CHANGING SEAT DEPTH Locknuts Seat Positioning Strap CHANGING SEAT WIDTH T o change seat width, the seat frame must be changed to the desired width. Refer to INST ALLING/REPLACING AD- JUST ABLE 16 T O 19-INCH DEEP RECLINER SEA T FRAME ONTO ARROW OR X BASE FRAME in this procedure of t[...]

68 R E C L I N E R PROCEDURE 14 RECLINER FIGURE 7 - INSTALLING/REPLACING ADJUSTABLE 16 TO 19-INCH DEEP RECLINER SEAT FRAME ONTO ARROW OR X BASE Mounting Screws Base Frame Spacer Recliner Seat Assembly Seat Mount Plate Locknuts If the seat width required is within the range of the original back canes, spreader bar and headrest pillow , the original [...]

69 PROCEDURE 15 MWD WHEELCHAIRS M W D W H E E L C H A I R S This Procedure includes the following: Removing/Installing Group 24 Battery Box Sub-Frame Removing/Installing Group 22 Battery Box Tray Converting Group 22 Batteries To Group 24 Batteries Shock Replacement Shock Spring Replacement Replacing Stabilizer Fork Assembly Replacing Stabilizer Whe[...]

70 PROCEDURE 15 MWD WHEELCHAIRS Battery Box T ray Base Frame Front Locknuts Mounting Screws FIGURE 2 - REMOVING/INSTALLING GROUP 22 BATTERY BOX TRAY REAR OF CHAIR FRONT OF CHAIR Rear Locknuts Battery Mount Bracket EQUIPMENT OPTION CONVERTING GROUP 22 BATTERY BOX TRAY T O GROUP 24 BATTERY BOX SUB FRAME NOTE: The battery box tray and battery mount br[...]

71 FIGURE 4 - INSTALLING GROUP 24 COMPONENTS Mounting Screws Wiring Harness w/Bracket Battery Box Sub-Frame Locknuts REAR OF CHAIR FRONT OF CHAIR Spacer Battery Box Retainer Bar Battery Box Sub-frame REAR OF CHAIR Mounting Screws Base Frame Shock Closed End Retainer Clip STEPS 1-2 STEPS 3-6 FRONT OF CHAIR W ARNING The Battery Box Retainer/Retainer [...]

72 PROCEDURE 15 MWD WHEELCHAIRS 8. Secure the bottom of the NEW shock, suspension arm, and stabilizer bracket together with the mounting screw , two (2) flat washers, two (2) spring washers, two (2) inner link spacers, and locknut. T orque to 160-inch pounds. W ARNING The Battery Box Retainer/Retainer Clip MUST be fastened securely in place be- for[...]

73 10. Apply Loctite 242 and torque the mounting screw that secures the spacer between the battery mount bracket and base frame. T orque to 160-inch pounds. 1 1. Reassemble large wheel to hub assembly and T orque to 160-inch pounds. 12. Repeat this procedure for the opposite shock. 13. Reinst all the battery box. Refer to INST ALLING/RE- MOVING GRO[...]

74 PROCEDURE 15 MWD WHEELCHAIRS FIGURE 8 - REPLACING ST ABILIZER FORK ASSEMBL Y/REPLACING ST ABILIZER WHEELS Base Frame Stabilizer Fork Assembly* Mounting Screw Flat W asher W asher Spring Washer Outer Link Spacers Locknut NOTE: Remove this mounting screw and locknut only when replacing the stabilizer fork assembly . Stabilizer Bracket Locknut Moun[...]

75 FIGURE 9 - REPLACING ST ABILIZER CYLINDER SPRING Base Frame Adjustment Barrel Stabilizer Rod Jam Nut Adjustment Nut Spring Retainer Stabilizer Spring REPLACING STABILIZER CYLINDER SPRING (FIGURE 9) NOTE: Stabilizer springs are only on wheelchair mod- els built before 7/1/1999. 1 . Remove mounting screw and locknut that secures top of the stabili[...]

76 W ARNING The threaded rod must be engaged in the adjustment barrel at least eight (8) full threads. Otherwise, injury or damage may occur. 5 . Realign the top of stabilizer fork assembly with the mounting hole in the base frame noted earlier . NOTE: Further height adjustment can be accomplished by using the alternate mounting hole in the base fr[...]

77 2 . Count the number of exposed threads and repeat this procedure for the opposite shock. 3 . Proceed to STEP 9 in HEIGHT ADJUSTMENT OF ST ABILIZERS in this procedure of the manual. REMOVING/INSTALLING GEARBOX (FIGURE 12 ) CAUTION Per form the following procedure in a des- ignated work area to prevent damage to flooring (carpeting, tile, etc.). [...]

78 NOTE: When installing the tubular end of the NEW sus- pension arm, the beveled washer MUST be placed on the inside and outside of the base frame, with the bevels facing each other . 10. Secure tubular end of the NEW suspension arm as- sembly to base frame with existing mounting screw . 1 1. T orque suspension arm mounting screw (1/2 x 7- inches)[...]

79 RWD WHEELCHAIRS PROCEDURE 16 R W D W H E E L C H A I R S This Procedure includes the following: Removing/Installing Group 24 Battery Box Sub-Frame Re moving/Installing Group 22 Ba tt er y Box Tray Converting Group 22 Batteries to Group 24 Batteries Shock Replacement Shock Spring Replacement Rubber Element Replacement Converting T orque and X Rub[...]

80 RWD WHEELCHAIRS PROCEDURE 16 R W D W H E E L C H A I R S Battery T ray Locknuts Bolts FIGURE 2 - REMOVING/INSTALLING GROUP 22 BATTERY BOX TRAY *NOTE: Illustration depicts the rubber element. Battery Box T ray removes in the same manner for shock assembly . *Rubber Element 4. Remove the four (4) mounting screws that secure the battery mount brack[...]

81 SHOCK REPLACEMENT (FIGURE 5) 1 . Remove the group 22 battery box or group 24 battery boxes. Refer to INST ALLING/REMOVING GROUP 22 BA TTER Y BOX or INST ALLING/REMOVING GROUP 24 BA TTER Y BOXES in PROCEDURE 9 of this manual. 2. Remove the drive wheel from the wheel hub . Refer to REMOVING/INST ALLING THE DRIVE WHEELS in PROCEDURE 12 of this manu[...]

82 Battery Box Sub-frame REAR OF CHAIR FRONT OF CHAIR Spacer Mounting Screw (LOOSEN) Retainer Clip (Closed End) GROUP 24 BATTERIES GROUP 22 BATTERIES Mounting Screw Shock Mounting Screw Locknut Suspension Arm FIGURE 5 - SHOCK REPLACEMENT T op of Shock Battery Box Retainer Bar TOP OF SHOCK BOTTOM OF SHOCK GROUP 22 AND GROUP 24 BATTERIES NOTE: Suspen[...]

83 SHOCK SPRING REPLACEMENT (FIGURE 6) 1 . Remove the group 22 battery box or group 24 battery boxes. Refer to INST ALLING/REMOVING GROUP 22 BA TTER Y BOX or INST ALLING/REMOVING GROUP 24 BA TTER Y BOXES in PROCEDURE 9 of this manual. 2. GROUP 24 B A TTERIES ONL Y - Loosen the mount- in g screw that secures the battery box retainer b ar to the base[...]

84 Spacer Battery Mount Bracket Rubber Element Mounting Screw Base Frame FIGURE 7 - RUBBER ELEMENT REPLACEMENT Mounting Screw (LOOSEN) EQUIPMENT OPTION CONVERTING TORQUE AND X RUBBER ELEMENTS TO ARROW SHOCKS (FIGURE 8) 1. Remove the battery box. Refer to INST ALLING/REMOV - ING GROUP 22 BA TTER Y BOX in PROCEDURE 9 of this manual. 2. Remove the exi[...]

85 REMOVING/INSTALLING GEARBOX (FIGURE 10 ) CAUTION Per form the following procedure in a des- ignated work area to prevent damage to flooring (carpeting, tile, etc.). Removing 1. Remove the drive wheels from the wheelchair . Refer to REMOVING/INST ALLING DRIVE WHEELS in PRO- CEDURE 12 of this manual. 2. Remove the drive wheel hub from the existing[...]

86 W asher Base Frame FIGURE 11 - ADJUSTING WEIGHT DISTRIBUTION Seat Support Bracket REPOSITIONING THE MOTOR/ GEARBOX (FIGURE 12 ) NOTE: The motor/gearbox assembly c a n be repositioned to lengthen or shorten the wheelbase by 2-inches in 1-inch in- crements. ST ANDARD POSITION - LENGTHENS the wheelbase and gives you the most stability and standard [...]

87 RWD WHEELCHAIRS PROCEDURE 16 R W D W H E E L C H A I R S Standard - Approximately 65% of weight over rear wheels 1 - Inch Forward - Approximately 70% of weight over rear wheels 2 - Inch Forward - Approximately 75% of weight over rear wheels REPOSITIONING THE GEARLESS/BRUSHLESS MOTOR (FIGURE 1 3,14 ) Acceptable mounting positions for the gearless[...]

88 Suspension Arm Hex Screw (1/2 x 7-inches) FIGURE 15 - REPLACING SUSPENSION ARM F O R WHEELCHAIRS WITH MOTOR/GEARBOX ASSEMBLY Suspension Arm Plug Button Beveled W ashers REPLACING SUSPENSION ARM F O R WHEELCHAIRS WITH MOTOR/ GEARBOX ASSEMBLY (FIGURE 15 ) 1. Remove the drive wheels from the wheelchair . Refer to REMOVING/INST ALLING DRIVE WHEELS i[...]

89 1 2 . Install the shock onto the new suspension arm. Refer to REMOVING/INST ALLING THE SHOCK ASSEM- BL Y in this procedure of the manual. 1 3 . Install the motor onto the new suspension arm. Refer to REMOVING/INST ALLING THE MOT OR in PRO- CEDURE 12 of this manual. 1 4 . Install anti-tip assembly onto the rear of the new sus- pension arm. Refer [...]

90 REMOVING/INSTALLING THE ANTI-TIP ASSEMBLY Removing 1. Remove the mounting screw , washers, and spacers that secure the top of the anti-tip bracket to the suspen- sion arm. 2. Remove the mounting screw and locknut that secure the extension spring in place. 3. Remove the mounting screw , washers, and spacers that secure the bottom of the anti-tip [...]

91 FWD WHEELCHAIRS PROCEDURE 17 F W D W H E E L C H A I R S This Procedure includes the following: Removing/Installing Rear Shroud Removing/Installing Front Shroud Removing/Installing Side Shroud Assembly Removing/Installing Counterweight R e p l a c i n g Group 24 Battery Box Sub-Frame Removing/Installing Shocks Shock Spring Replacement Tie Rod Re[...]

92 FWD WHEELCHAIRS PROCEDURE 17 F W D W H E E L C H A I R S 3 . Remove the two (2) socket screws that secure the side shroud bracket to the suspension arm. 4 . Remove the mounting screw and washer that se- cures the REAR of the side shroud to the suspension arm. 5 . Remove the side shroud assembly . Installing 1 . Position the side shroud on the wh[...]

93 FWD WHEELCHAIRS PROCEDURE 17 F W D W H E E L C H A I R S FIGURE 4 - REMOVING/INST ALLING COUNTERWEIGHT Bottom Shoulder Screw Bottom Slot in Mounting Bracket T op Shoulder Screw Counterweight DET AIL “ C ” - REMOVING - STEP 4; INST ALLING - STEP 2 DET AIL “ B ” - REMOVING - STEP 3; INST ALLING - STEPS 3, 4 DET AIL “ A ” - REMOVING - S[...]

94 FWD WHEELCHAIRS PROCEDURE 17 F W D W H E E L C H A I R S FIGURE 5 - REMOVING/INST ALLING GROUP 24 BA TTER Y BOX SUB-FRAME REAR OF CHAIR FRONT OF CHAIR Mounting Screw (STEPS 6 and 13) Locknut Wiring Harness W/ Bracket Battery Box Sub-frame Sub-Frame Mounting Screw (STEPS 8 and 12) Washer (STEP 8 and 12) Position Tie Wrap A Here REMOVING/INS[...]

95 FWD WHEELCHAIRS PROCEDURE 17 F W D W H E E L C H A I R S SHOCK SPRING REPLACEMENT (FIGURE 7 ) 1 . Remove the shock. Refer to REMOVING/INST ALL- ING SHOCKS in this procedure of this manual. 2 . Hold the spring retainer and turn the shock eyelet as- sembly counterclockwise to unthread it from the shock. 3 . Remove the spring retainer and spring. 4[...]

96 FWD WHEELCHAIRS PROCEDURE 17 F W D W H E E L C H A I R S REMOVING/INSTALLING GEARBOX (FIGURE 9 ) CAUTION Per form the following procedure in a des- ignated work area to prevent damage to flooring (carpeting, tile, etc.). Removing 1 . Remove the rear shroud. Refer to REMOVING/IN- ST ALLING REAR SHROUD in this procedure of the manual. 2 . Remove t[...]

97 PROCEDURE 17 F W D W H E E L C H A I R S Installing CAUTION The longer socket screws MUST be posi- tioned in the mounting holes on the OUT- SIDE of the suspension arm, and the SHORTER socket screws MUST be positioned in the mounting holes on the INSIDE of the sus- pension arm. Otherwise, damage to the gearbox may result. 1 . Install the EXISTING[...]

98 FWD WHEELCHAIRS PROCEDURE 17 F W D W H E E L C H A I R S Tie Wrap A Sensor Cable Sensor Bracket LEFT Motor Cable Sensor Cable Tie Wrap B Battery Box Sub- Frame Lego Block Connector Of The Battery Wiring Harness Base Frame Mounting Screw Washer Locknut Sensor Sensor Bracket FIGURE 10 - SENSOR CABLE ASSEMBL Y REPLACEMENT Tie Wrap C Battery B[...]

99 F W D W H E E L C H A I R S R EMOVING/INSTALLING WIRING HARNESS (FIGURE 12 ) Removing 1 . Remove the battery boxes. Refer to INST ALLING/RE- MOVING GROUP 24 BA TTER Y BOXES in PRO- CEDURE 9 of this manual. 2 . Remove the two (2) mounting screws that secure the battery charger port to the mounting bracket and remove the battery charger port (DET [...]

100 Lego Block Connector Of The Battery Wiring Harness Base Frame Tie Wrap A RIGHT Motor Cable Battery Charger Cable Tie Wrap B Battery Box Sub- Frame FIGURE 12 - REMOVING/INST ALLING WIRING HARNESS DET AIL B DET AIL C DET AIL D Mounting Screws Locknuts Wiring Harness W/ Bracket Battery Box Sub- Frame DET AIL E Battery[...]

101 PROCEDURE 17 FWD WHEELCHAIRS ADJUSTING WEIGHT DISTRIBUTION (FIGURE 1 3 ) NOTE: Depending on the seat depth ordered, the position of the seat support brackets is factory set b etween 2.25 and 6 inches (measured f ro m th e fr on t of th e b ase frame to the front of the seat support brackets) . This will put approximately 65 % of the total weigh[...]

102 PROCEDURE 17 F W D W H E E L C H A I R S FIGURE 14 - INST ALLING 90 o FOOT BOARD Flat Screws Washers Locknuts 90 o Footrest Support Mounting Screws (STEP 7) Washer 90 o Footboard Mounting Screw (STEP 6) FOOTBOARD ADJUSTMENTS- DEPTH/HEIGHT/ANGLE (FIGURE 15) W ARNING DO NOT remove detent pin from footrest assembly. Otherwise, injury may result. D[...]

103 F W D W H E E L C H A I R S FWD WHEELCHAIRS PROCEDURE 17 FOOTREST ANGLE ADJUSTMENTS W ARNING DO NOT remove detent pin from footrest assembly. Otherwise, injury may result. Footrest Angle Adjustment Relative to the Vertical Position of the Front Shroud (FIGURE 16) NOTE: The angle of the footrest relative to the vertical position of the front shr[...]

104 FIGURE 16 - FOOTREST ANGLE ADJUSTMENTS Mounting Screw Locknut Cams Cam Upper Mounting Bracket DET AIL “ A ” DET AIL “ B ” DET AIL “ C ” - SIDE VIEW OF FOOTREST DET AIL “ D ” - TOP VIEW OF FOOTREST Vertical Position of Front Shroud NOTE: Angle is increased or decreased depending on direction of footrest rotation Right Cam Left Ca[...]

105 NOTES NOTES N O T E S[...]

106 NOTES NOTES N O T E S[...]

107 LIMTIED W ARRANTY L I M I T E D W A R R A N T Y LIMITED WARRANTY PLEASE NOTE: THE W ARRANTY BELOW HAS BEEN DRAFTED TO COMPL Y WITH FEDERAL LA W APPLICABLE TO PRODUCTS MANUF ACTURED AFTER JUL Y 4, 1975. This warranty is extended only to the original purchaser/user of our products. This warranty gives you specific legal rights and you may also ha[...]

Invacare Corporation www.invacare.com U S A Canada Invacare, Storm Series, and Arrow are registered trademarks of One Invacare W ay 5970 Chedworth W ay Invacare Corporation. Elyria, Ohio USA Mississauga, Ontario Y es, Y ou can., Ranger X, and Tor que are trademarks of 44036-2125 L5R 3T9, Canada Invacare Corporation. 800-333-6900 905-890-8838 Loctit[...]