Service Manual
Ranger II Storm Series®
Wheelchairs
MWD/FWD
Ranger IIBASIC
Ranger IISTANDARD
Ranger IIJR
Ranger II250 SERIES
DEALER:THIS MANUAL MUST BE GIVEN TO THE USER
OF THE WHEELCHAIR.
USER: BEFORE USING THIS WHEELCHAIR, READ THIS
MANUAL AND SAVE FOR FUTURE REFERENCE.
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TABLE OF CONTENTS
TABLE OF CONTENTS
The procedures in this manual refer to the following models:
RANGER II MWD models: RANGER II BASIC RANGER II STANDARD RANGER II 250 SERIES
RANGER II FWD models: RANGER IIBASIC RANGER IISTANDARD RANGER II 250 Series and RANGER II with
Weight Shift Basic Tilt.
T
A
B
L
.
PROCEDURE 10 - SHROUDS ........................... 33
REMOVING/INSTALLINGSHROUDS .................. 33
E
SPECIAL NOTES ................................................ 2
SPECIFICATIONS ............................................... 4
O
F
PROCEDURE 1 - GENERAL GUIDELINES .......... 7
PROCEDURE 11 - CROSSBRACES ................ 37
REPAIRORSERVICEINFORMATION ................. 7
ADJUSTINGSEATWIDTH-INTEGRATED
C
O
N
T
E
N
T
OPERATINGINFORMATION ............................... 7
SLINGSEATS ............................................. 37
WARNING/CAUTIONLABELLOCATION ............ 8
REPLACING CROSSBRACES - CAPTAIN’S
PROCEDURE 2- TROUBLESHOOTING ........... 12
FIELD LOAD TEST .......................................... 12
USING HYDROMETER TO CHECK BATTERY
CELLS (LEAD ACID)..................................... 12
MOTORTESTING ........................................... 13
MOTORBRUSHINSPECTION ......................... 14
ELECTRO-MECHANICALPARKINGBRAKE
SEATS........................................................ 39
PROCEDURE 12 - BATTERIES ....................... 41
INSTALLING/REMOVINGBATTERIESINTO/
S
FROM BATTERY BOXES ............................ 41
PROCEDURE 13 - FWD WHEELCHAIRS .......... 46
ASSEMBLINGRANGERIIFWD ....................... 46
WHEN TO CHARGE BATTERIES ...................... 48
CHARGINGBATTERIES ................................... 48
REPLACINGBATTERIES ................................. 49
INSTALLING/REMOVINGBATTERYBOXES ....... 50
BATTERYTRAY .............................................. 51
REPLACINGWIRINGHARNESS ..................... 55
REPOSITIONINGMOTORS .............................. 59
TESTING ..................................................... 14
PROCEDURE 3 - FRONT RIGGINGS ................ 15
ADJUSTINGFLIP-UPREMOVABLE
FOOTBOARD ............................................. 16
ADJUSTINGTHEREMOVABLEFOOTBOARD ... 16
PROCEDURE 4 - ARMS .................................... 18
REPLACINGARMRESTPADS .......................... 18
REPLACINGARMRESTPLATE ........................ 18
REPLACING CLUTCH HANDLES - R2BASIC
REPLACING MOTOR/GEARBOX - R2BASIC
.................
60
61
62
................
REPLACING MOTOR/GEARBOX -R2STANDARD
......
PROCEDURE 5 - SEAT/BACK ........................... 19
REPLACINGSEATPOSITIONINGSTRAP .......... 19
REPLACINGBACKUPHOLSTERY ................... 19
REPLACINGCAPTAIN'SSEAT .......................... 20
PROCEDURE 14 - MWD WHEELCHAIRS ......... 64
ASSEMBLINGRANGERIIMWD....................... 64
WHEN TO CHARGE BATTERIES ...................... 66
CHARGINGBATTERIES ................................... 66
REPLACINGBATTERIES ................................. 67
INSTALLING/REMOVINGBATTERYBOXES ....... 68
BATTERYTRAY .............................................. 69
REPLACINGWIRINGHARNESS ..................... 71
STABILIZERIDENTIFICATION .......................... 73
ADJUSTINGSPRINGS .................................... 73
ADJUSTINGSTABILIZERSFORUSER
PREFERENCE ........................................... 74
REPLACINGSTABILIZERCYLINDERS .............. 75
REPLACINGSTABILIZERWHEELS ................... 76
REPLACINGSTABILIZERCYLINDERSPRINGS .. 77
REPOSITIONINGMOTORS .............................. 78
REPLACINGCLUTCHHANDLES
PROCEDURE 6 - SEAT FRAME ......................... 21
ADJUSTINGSEATDEPTH ................................ 21
ADJUSTINGBACKHEIGHT .............................. 21
CHANGINGBACKANGLE ................................ 22
REPLACINGBACKCANES .............................. 22
PROCEDURE 7 - ELECTRONICS ..................... 24
REPOSITIONINGMKIVJOYSTICK ..................... 24
REMOVING/INSTALLINGMKIVCONTROLLER ... 24
PROCEDURE 8 - LIMIT SWITCH ...................... 27
DISCONNECTING/CONNECTINGLIMIT
SWITCH ..................................................... 27
ADJUSTINGLIMITSWITCH ............................... 27
PROCEDURE 9 - WHEELS ............................... 29
REPLACINGPNEUMATICTIRES/TUBES-
-R2BASIC/R2250 series
REPLACING MOTOR/GEARBOX -R2BASIC
REPLACING MOTOR/GEARBOX -R2STANDARD
.....................................................................
78
79
80
.................
........
DRIVE WHEELS/CASTERS ......................... 29
REMOVING/INSTALLINGDRIVEWHEELS ......... 29
REMOVING/INSTALLINGDRIVEWHEELHUB .. 30
REPLACINGCASTERS ................................... 32
REPLACING FORKS ....................................... 32
LIMITED WARRANTY ....................................... 83
3
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SPECIFICATIONS
SPECIFICATIONS
RANG ER II MWD - R2BASIC
NOTE: All specifications are
approximate.
R2STANDARD R2250
SERIES
S
P
E
C
I
F
I
C
A
T
I
INTEGRATED SLING SEAT
CAPTAIN'S SEAT
BACKTYPE
LOW
LOW SOLID SEAT HIGH1
(LOB)
19-in.
17-in.
(LOBSS)
(HIB)
19-in.
17-in.
Seat Width Range:
Seat Depth Range:
16, 18or20-inches
19-in.
16, 17 or 18-in. -in1-inchincrements
(17and18-in. byextension)
17-in.
Back Height Range
Std.:
Opt. Headrest:
Opt. BackrestExt.:
16, 17, 18, 19 or 20-in. - In 1-in increments
16-in.
N/A
23-in.
18-in.
N/A
22-in.
28-in.
N/A
N/A
N/A
N/A
(98o)2
O
N
S
Back Angle Range:
Seat-to-Floor:
90o to 105o - in 5o increments
(55o -114o)2
(35o -170o)2
18-1/4-inches
22-in.
19-1/2-in.
22-in.
Overall Width (No joystick):
Overall Height:
24-7/8-inches
24-3/4-in.
35-in.
24-3/4-in.
35-in.
R2
24-3/4-in.
39-in.
34-3/8-in. -18-in. BackHeight
Weight3,6
W/O Batteries:
W/Batteries (Gel Cell):
Shipping:
R2BASIC/R2250series
110 to 114 lbs.
178 to182 lbs.
134 to 153 lbs.
R2STANDARD
112 to 116 lbs.
190 to194 lbs.
146 to 155 lbs.
R2BASIC /R2
131 to 135 l2b5s0s.eries
206 to210 lbs.
161 to165 lbs.
138 tSoTA1N4D2ARlbDs.
213 to217 lbs.
168 to 172 lbs.
Armrests:
Removable, FlipBack, FixedorAdjustable Flip Back - Adjustable Height - Full Length (Std.)
Height - Desk and Full Length
Vinyl or Cloth with Vinyl (R2250 SERIES - Gray fabric
Upholstery:
Black Nylon
trimmed w/ gray Vinyl)
INTEGRATED SLING SEAT AND CAPTAIN'S SEAT
43-1/2-inches
(With 8-in. rear casters
and 93 front riggings)
35-1/2-inches
(With 8-in. rear casters
and no front riggings)
Overall Length(Drive wheel in Front
Position - RefertoPERCENTAGEOF
WEIGHTDISTRIBUTIONinPROCEDURE
1 of this manual.)
7-inch Urethane
Front Stabilizers
12-1/2 x 2-1/4-in. (Std.); 14-in.x 3-in. (Opt.) (Flat Free or Pneumatic)
Drive Wheels/Tires:
Casters w/Precision Sealed Bearings:
8 x 1-3/4-in. Semi Pneumatic (Std.), 8 x 2-in. Pneumatic (Opt.)
6 x 2-in. Semi Pneumatic (Opt.)
Footrest/Legrest:
Swingaway,RemovableAdjustableFlipUpRemovableFootboard
Battery/Size (Not Supplied):
R2BASIC/R2STANDARD -22NFGelCell(Two(2)Required);R2250-SERIES uses-U1GELCELL)
PERFORMANCE
R2 BA SIC
R2250
R2 STA N DA RD
se rie s
Speed (M.P.H.):
0 to 3.8
> 23-inches
18-22 miles
250 lbs.
0 to 3.6
0 to 5.8
> 23-inches
18-22 miles
300 lbs.
Turning Radius:
> 23-inches
12-14 miles
250 lbs.
Range (variable)4:
vWeight Limitation5:
vNOTE: Refer to PERCENTAGE OF WEIGHT DISTRIBUTION in PROCEDURE 1 of this manual.
Footnotes:
4. Range will vary with battery conditions, surface, ter-
rain and operators weight.
1. High Back not available on model R2250 SERIES
.
2. LowandHighBackTypeshaveanInfiniteadjustment.
Low Backs with Solid Seat have no adjustment.
3. 18-in. wide x 16-in. deep wheelchair with MKIV RII
electronics.
5. Includes seating systems and accessories.
6. Weight varies between motors. R2BASIC AND
R2250 SERIES have clutches. The R2STANDARD has
motor locks.
4
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SPECIFICATIONS
SPECIFICATIONS
RANG ER II FWD -R2BASIC
NOTE: All specifications are
approximate.
R2STANDARD R2250
SERIES
S
P
E
C
I
INTEGRATED SLING SEAT
CAPTAIN'S SEAT
BACKTYPE
LOW SOLID SEAT HIGH
LOW
(LOB)
19-in.
17-in.
(LOBSS)
(HIB)
19-in.
17-in.
Seat Width Range:
Seat Depth Range:
16, 18or20-inches
19-in.
F
I
16, 17 or 18-in. - In 1-in. increments
(17and18-in. byextension)
17-in.
C
A
T
I
O
N
S
Back Height Range Std.:
Opt. Headrest:
Opt. BackrestExt.:
16, 17, 18, 19 or 20-in. - In 1-in. increments
N/A
N/A
90o to 105o - in 5o increments
16-in.
N/A
18-in.
N/A
22-in.
28-in.
N/A
23-in.
N/A
Back Angle Range:
Seat-to-Floor:
(55o -114o)1
(98o)1
19-1/2-in.
24-3/4-in.
35-in.
(35o -170o)1
18-1/2-in.
22-in.
22-in.
Overall Width (No joystick): 24-5/8-in.
24-3/4-in.
35-in.
24-3/4-in.
39-in.
Overall Height:
34-3/8-in. -16-in. BackHeight
Weight2,5
W/O Batteries:
W/Batteries (Gel Cell):
Shipping:
R2
/R2250 series
R2
R2BASIC /R2
R2STANDARD
90 BtoAS1IC00 lbs.
170 to 180 lbs.
105 to 115 lbs.
105 tSoTA1N1D5ARlbDs.
185 to195 lbs.
120 to 130 lbs.
122 to 127 l2b5s0.series
203 to207 lbs.
153 to157 lbs.
138 to 142 lbs.
218 to222 lbs.
168 to 172 lbs.
Armrests:
Removable, FlipBack, FixedorAdjustable Flip Back - Adjustable Height - Full Length (Std.)
Height - Desk and Full Length
Vinyl or Cloth with Vinyl (R2250 SERIES - Gray fabric
Upholstery:
Black Nylon
trimmed w/ gray Vinyl)
INTEGRATED SLING SEAT AND CAPTAIN'S SEAT
vDRIVEWHEELPOSITION
Overall Length
REARPOSITION
MIDDLE POSITION
FORWARDPOSITION
With 8-in. rear casters and
93frontriggings:
With 8-in. rear casters
and no front riggings:
47-1/4-inches
40-1/2-inches
48-1/4-inches
40-1/2-inches
49-1/4-inches
N/A
vNOTE:RefertoPERCENTAGEOFWEIGHTDISTRIBUTIONinPROCEDURE1of
thismanual.
Drive Wheels/Tires:
12-1/2 x 2-1/4-in. (Std.);14-in.x 3-in. (Opt.) (Flat Free or Pneumatic)
Casters w/Precision Sealed Bearings:
8 x 1-3/4-in. Semi Pneumatic (Std.), 8 x 2-in. Pneumatic (Opt.)
6 x 2-in. Semi Pneumatic (Opt.)
Footrest/Legrest:
Swingaway,Removable AdjustableFlipUpRemovableFootboard
22NFGelCell(Two (2)Required);R2250-SERIES uses-U1GELCELL)
Battery/Size (Not Supplied):
PERFORMANCE
R2BASIC
R2250 SERIES
R2 STA N DA RD
Speed (M.P.H.):
Turning Radius:
Range (variable)3:
0 to 3.8
0 to 3.6
> 25.8-inches
12-14 miles
250 lbs.
0 to 4.0
> 25.8-inches
12-16 miles
300 lbs.
> 25.8-inches
17-22 miles
vWeight Limitation4: 250 lbs.
vNOTE: Refer to PERCENTAGE OF WEIGHT DISTRIBUTION in PROCEDURE 1 of this manual.
Footnotes:
3. Range will vary with battery conditions, surface, ter-
rain and operators weight.
4. Includes seating systems and accessories.
1. LowandHighBackTypeshaveanInfiniteadjustment.
Low Backs with Solid Seat have no adjustment.
2. 18-in.widex16-in.deepwheelchairwithMKIVRIIelec- 5. Weight varies between motors. R2BASIC AND
tronics.
R2250 SERIES have clutches. The R2STANDARD has
motor locks.
5
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SPECIFICATIONS
SPECIFICATIONS
NOTE: All specifications
are approximate.
S
P
E
C
I
F
I
C
A
T
I
RANG ER II FWD - R2JR
INTEGRATED SLING SEAT
Seat Width Range:
14-inches
Seat Depth Range:
Back Height Range:
Back Angle Range:
Seat-to-Floor:
16 to 18-inches - In 1-inch increments (17 and 18-inch by extension)
16 to 20-inches - In 1-inch increments
90o to 105o - in 5o increments
18-1/2-inches
Overall Width
(Nojoystick):
20-5/8-inches
O
N
S
Overall Height:
Overall Length
34-3/8-inches - 16-inch Back Height
v REAR DRIVE POSITION
With 8-inch rear casters
and 93 front riggings:
43-1/2-inches
With 8-inch rear casters
and no front riggings:
32-1/2-inches
vNOTE: Refer to PERCENTAGE OF WEIGHT DISTRIBUTION in
PROCEDURE 1 of this manual.
Drive Wheels/Tires
12-1/2 X 2-1/4-inch (Pneumatic-Standard, Flat Free - Optional)
Caster w/Precision
Sealed Bearings:
8 x 1-3/4-inch Semi Pneumatic (Std.), 8 x 2-inch Pneumatic (Opt.)
6 x 2-inch Semi Pneumatic (Opt.)
Footrests/Legrests:
Swingaway, Removable
Weight1
W/O Batteries:
W/Batteries (Gel Cell):
83 lbs.
153 lbs.
Shipping:
Armrests:
Upholstery:
Batteries:
98 lbs.
Removable, Flip Back, Fixed or Adjustable Height - Desk and Full Length
BlackNylon
U1 Gel Cell
PERFORMANCE
Speed (M.P.H.):
0 to 3.6
Turning Radius:
24-inches
14 miles
200 lbs.
Range (variable)2:
vWeight Limitation3:
vNOTE: Refer to PERCENTAGE OF WEIGHT DISTRIBUTION in PROCEDURE 1 of this manual.
Footnotes:
1. 14-in. wide x 16-in. deep wheelchair with MKIV RII electronics.
2. Range will vary with battery conditions, surface, terrain and operators weight.
3. Includes seating systems and accessories.
6
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GENERAL GUIDELINES
PROCEDURE 1
This Procedure Includes the Following:
Repair or Service Information
Operating Information
G
E
N
E
R
A
L
WARNING
CONTROLLER SETTINGS FOR R2JR
Se t-up of the Ele c tronic Control Unit is to b e p e rform e d ONLY b y q ua lifie d te c hnic ia ns.
Fa c tory se tting of the c ontrolle r MUST b e use d for d a ily a c tivitie s. Re p rog ra m m ing the
c ontrolle r to re fle c t a g g re ssive se tting s (i.e . inc re a se d a c c e le ra tion, turning , b ra king e tc ..)
c ould c a use the whe e lc ha ir to tip ove r re sulting in se rious injury to the use r a nd / or d a m -
a g e to the surround ing p rop e rty.
G
U
I
D
E
L
I
N
E
S
REPAIR OR SERVICE INFORMATION
Se t-up of the Ele c tronic Control Unit is to be pe rform e d ONLY by q ua lifie d te c hnic ia ns. The
fina l tuning a d justm e nts of the c ontrolle r m a y a ffe c t othe r a c tivitie s of the whe e lc ha ir.
Da m a g e to the e q uip m e nt c ould oc c ur und e r the se c irc um sta nc e s. If a ny ind ivid ua l othe r
tha n a q ua lifie d te c hnic ia n p e rform s a ny work on the se units, the wa rra nty is void .
O PERATING INFO RMATIO N
GENERAL WARNINGS
Pe rform a nc e a d justm e nts should only b e m a d e b y p rofe ssiona ls of the he a lthc a re fie ld or
p e rsons fully c onve rsa nt with this p roc e ss a nd the d rive r's c a p a b ilitie s. Inc orre c t se tting s
c ould c a use injury to the d rive r, b ysta nd e rs, d a m a g e to the c ha ir a nd to surround ing
p ro p e rty.
Afte r the whe e lc ha ir ha s be e n se t-up, c he c k to m a ke sure tha t the whe e lc ha ir pe rform s to
the sp e c ific a tions e nte re d d uring the se t-up p roc e d ure . If the whe e lc ha ir d oe s NOT p e r-
form to sp e c ific a tions, turn the whe e lc ha ir OFF im m e d ia te ly a nd re e nte r se t-up sp e c ific a -
tions. Re p e a t this p roc e d ure until the whe e lc ha ir p e rform s to sp e c ific a tions.
DO NOT use p a rts, a c c e ssorie s, or a d a p te rs othe r tha n those a uthorize d b y Inva c a re .
TIRE PRESSURE - DO NOT use your whe e lc ha ir unle ss it ha s the prope r tire pre ssure (P.S.I.). DO
NOT ove rinfla te the tire s. Fa ilure to follow the se sug g e stions m a y c a use the tire to e xp lod e
a nd c a use bodily ha rm. The re c omme nde d tire pre ssure is liste d on the side wa ll of the tire .
BATTERIES - The wa rra nty a nd p e rform a nc e sp e c ific a tions c onta ine d in this m a nua l a re
b a se d on the use of d e e p c yc le g e l c e ll or se a le d le a d a c id b a tte rie s. Inva c a re strong ly
re c om m e nd s the ir use a s the p owe r sourc e for this unti.
The use of rub b e r g love s a nd sa fe ty g la sse s is re c om m e nd e d whe n working with b a tte rie s.
Ca re fully re a d b a tte ry/ b a tte ry c ha rg e r inform a tion p rior to insta lling , se rvic ing or op e ra t-
ing your whe e lc ha ir.
ELECTRICAL
Ground ing Instruc tions:
DO NOT, und e r a ny c irc um sta nc e s, c ut or re m ove the round g round ing p rong from a ny
p lug use d with or for Inva c a re p rod uc ts. Som e d e vic e s a re e q uip p e d with thre e -p rong
(g round ing ) p lug s for p rote c tion a g a inst p ossib le shoc k ha za rd s. Whe re a two-p rong wa ll
re c e p ta c le is e nc ounte re d , it is the p e rsona l re sp onsib ility a nd ob lig a tion of the c ustom e r
to c onta c t a q ua lifie d e le c tric ia n a nd ha ve the two-p rong re c e p ta c le re p la c e d with a
p rop e rly g round e d thre e -p rong wa ll re c e p ta c le in a c c ord a nc e with the Na tiona l Ele c tri-
c a l Code . If you must use a n e xte nsion c ord, use ONLY a thre e -wire e xte nsion c ord ha ving
the sa m e or hig he r e le c tric a l ra ting a s the d e vic e b e ing c onne c te d . In a d d ition, Inva c a re
ha s p la c e d RED/ ORANGE WARNING TAGS on som e e q uip m e nt. DO NOT re m ove the se
ta g s. Ca re fully re a d b a tte ry/ b a tte ry c ha rg e r inform a tion p rior to insta lling , se rvic ing or
op e ra ting your whe e lc ha ir.
7
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PROCEDURE 1
GENERAL GUIDELINES
WARNING/ CAUTION LABEL LOCATION - MWD MODELS
G
E
N
E
R
A
L
(R2BASIC/ R2STANDARD / R2250 SERIES
)
C AUTIO N
HIGH BACK CAPTAIN'S
SEATS ONLY - Disc onne c t
lim it switc h BEFORE re -
moving sea t - da ma ge to
se a t c a n oc c ur.
G
U
I
D
E
L
I
N
E
S
Stabilizers may vary depending
on manufacturing date of the
wheelchair
Crossbrace
Push Bracket
NOTE:Thiswarninglabelisfoundonmod-
els built before 3/1/00. For warning label
locations on chairs built after 3/1/00, refer
to the warning label on page 11.
Wiring
Harness for
Battery Box
Lid
8
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GENERAL GUIDELINES
PROCEDURE 1
WARNING/ CAUTION LABEL LOCATION - FWD MODELS
(R2BASIC/ R2STANDARD/ R2250 SERIES
)
G
E
N
E
R
A
L
Side Frame
WARNING
Re p la c e m e nt c on-
tro lle r MUST b e
G
U
I
SAME p a rt num b e r.
Controller
(Back View)
D
E
L
I
N
E
S
C AUTIO N
HIGH BACK CAPTAIN'S SEATS
ONLY - Disconnect limit switch
BEFORE removing sea t - da m-
a ge to se a t c a n oc c ur.
NOTE: Caution Label is
located on side shroud.
Motor
Assembly
C AUTIO N
Re p o sitio ning the m o to rs WILL a f-
fe c t the sta b ility a nd / o r p e rfo r-
m a nc e o f the whe e lc ha ir. Re fe r to
PERCENTAGE OF WEIGHT DISTRIBU-
TION in the Owne r's Ma nua l BEFORE
repositioning motors.
1080267
Crossbrace
Push Bracket
Wiring Harness for
Battery Box Lid
NOTE: This warning label is found on models built before 3/1/
00. Forwarninglabellocationsonchairsbuiltafter3/1/00, refer
to the warning label on page 11.
9
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PROCEDURE 1
GENERAL GUIDELINES
WARNING/ CAUTION LABEL LOCATION - FWD MODELS (R2J R)
G
E
N
E
R
A
L
Side Frame
WARNING
Re p la c e m e nt c on-
tro lle r MUST b e
SAME p a rt num b e r.
Controller
(Back View)
G
U
I
D
E
L
I
N
E
S
Motor
Assembly
C AUTIO N
Re p o sitio ning the m o to rs WILL a f-
fe c t the sta b ility a nd / o r p e rfo r-
m a nc e o f the whe e lc ha ir. Re fe r to
PERCENTAGE OF WEIGHT DISTRIBU-
TION in the Owne r's Ma nua l BEFORE
Battery
Tray
Side Frame
re positioning motors.
1080267
Wiring Harness
for Battery
Box Lid
WARNING
Pinc h Po int
10
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GENERAL GUIDELINES
PROCEDURE 1
BATTERY WARNING LABEL LOCATION
G
E
N
E
R
A
L
WARNING
This POSITIVE (+) RED Ba tte ry Ca b le MUST
c o nne c t to the POSITIVE (+) Ba tte ry
Te rm ina l(s)/ Po st(s), o the rwise se rio us
d a m a g e will oc c ur to the e le c tric a l sys-
te m . Re fe r to the Owne r’s Ma nua l. DO
G
U
I
NOT re m o ve this la b e l.
1095558
D
E
L
I
N
E
S
WARNING
DO NOT a llo w b a tte ry c a b le (s) to c o nta c t
the o p p o site b a tte ry te rm ina l(s)/ p o st(s). Re -
p la c e c a b le (s) im m e d ia te ly if c a b le (s) insu-
la tion b e c om e s d a m a g e d . Fa ilure to ob se rve
the se wa rning s m a y re sult in a n e le c tric a l
sho rt with se rio us p e rso na l injury re sulting .
DO NOT re m o ve this la b e l.
1095561
WARNING
This NEGATIVE (+) BLACK Ba tte ry Ca b le
MUST c o nne c t to the NEGATIVE (+) Ba t-
te ry Te rm ina l(s)/ Post(s), othe rwise se rious
d a m a g e will oc c ur to the e le c tric a l sys-
te m . Re fe r to the Owne r’s Ma nua l. DO
NOT re m o ve this la b e l.
1095559
NOTE: Only U1 battery box top is show for clarity.
Warning Labels are located on the group 22 battery
box top in the same manner.
NOTE: These warning labels are found on models built
after 3/1/00. For warning label locations on chairs built
before 3/1/00, refer to specific drive system for the
wheelchair.
11
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PROCEDURE 2
TROUBLESHOOTING
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
astheytrytopushthroughthestationaryobject. Read
the meter while the motors are straining to determine
thevoltageunderload.
This Procedure Includes the Following:
Field Load Test
T
R
O
U
B
L
E
S
H
O
O
T
Using Hydrometer To Check Battery Cells (Lead
Acid)
Motor Testing
NOTE: If the voltage drops to less than 23.5 volts from a
pairoffullychargedbatterieswhileunderload, theyshould
be replaced regardless of the unloaded voltages.
Motor Brush Inspection
Electro-Mechanical Parking Brake Testing
Battery Charger
(-)
FIELD LOAD TEST (FIGURE 1)
Connector
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
MANUALsuppliedwitheachwheelchair.
(+)
I
N
G
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, thelowerthevoltageavailable. Whenthislostvolt-
age drops the output 1.0 volts under load (2.0 for a pair),
replace the batteries.
Digital Voltmeter
FIGURE 1 - FIELD LOAD TEST
USING HYDROMETER TO CHECK
BATTERY CELLS (LEAD ACID)
(FIGURE 2)
Testing under load is the only way to spot this problem.
While special battery load testing equipment is available,
it is costly and difficult to transport.
NOTE: Perform this procedure when a digital voltmeter is
notavailable.
Useadigitalvoltmetertocheckbatterychargelevelatthe
charger connector. It is located on the base of the wheel-
chair frame.
WARNING
NEVER sm o ke o r strike a m a tc h ne a r the
b a tte rie s. If the c a p s o f the b a tte ry c e lls
a re re m o ve d , NEVER lo o k d ire c tly into
the m whe n c ha rg ing the b a tte ry.
NOTE: READ the instructions CAREFULLY before us-
ing the digital voltmeter.
NOTE: Invacare recommends that ONLY qualified ser-
vice personnel perform this test.
The use of rubbe r glove s a nd sa fe ty gla sse s
is re c om m e nd e d whe n te sting the b a tte ry
c e lls.
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
badone.
Whe n re a d ing a hyd ro m e te r, DO NOT a l-
lo w a ny liq uid to c o m e in c o nta c t with
your e ye s or skin. It is a form of a c id a nd
c a n c a use se rio us b urns, a nd in so m e
c a se s, blindne ss. If you do ge t ba tte ry a c id
on you, flush the e xp ose d a re a s with c ool
wa te r IMMEDIATELY. If the a c id c om e s into
c onta c t with e ye s or c a use s se rious b urns,
g e t m e d ic a l he lp IMMEDIATELY.
3. Place a one (1) piece of wood taller than the axle of
the drive wheels between the wheelchair and a wall,
workbench or other stationary object.
4. Remove the footrests from the wheelchair and place
the stabilizer wheels or the front of the wheelchair
against the piece of wood.
5. Placethevoltmeterleadsintothechargerplugonthe
wheelchair. Mostdigitalvoltmetersarenotaffectedby
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.
The b a tte ry a c id c a n d a m a g e your whe e l-
c ha ir, c lo thing , a nd ho use ho ld ite m s.
The re fo re , ta ke re a d ing s c a utio usly a nd
o nly in d e sig na te d a re a s.
6. Have two (2) individuals (one [1] on each arm) apply
asmuchdownwardpressureaspossibleonthearms
of the wheelchair.
12
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TROUBLESHOOTING
WARNING
ONLY use d istille d wa te r whe n top p ing off
the b a tte ry c e lls.
PROCEDURE 2
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.
T
R
O
U
B
L
E
S
H
O
O
T
10. Replace the battery caps.
Most ba tte rie s a re not sold with instruc tions.
Howe ve r, wa rning s a re fre q ue ntly note d
on the c e ll c a p s. Re a d the m c a re fully.
11. Reinstall battery boxes. Refer to one (1) of the follow-
ing:
FWD WHEELCHAIRS - INSTALLING/REMOVING
BATTERY BOXES in PROCEDURE 13 of this
manual.
1. Remove the battery box(es). Refer to one (1) of the fol-
lowing:
FWD WHEELCHAIRS - INSTALLING/REMOVING
BATTERY BOXES in PROCEDURE 13 of this
manual.
MWD WHEELCHAIRS - INSTALLING/REMOVING
BATTERYBOXESinPROCEDURE14ofthismanual.
MWD WHEELCHAIRS - INSTALLING/REMOVING
BATTERYBOXESinPROCEDURE14ofthismanual.
MOTOR TESTING (FIGURE 3)
I
N
G
1. On the 4-pin motor connector, locate the two (2) con-
tacts in the red and black housings.
2. Remove the battery caps from the battery.
3. Squeeze the air from the hydrometer.
4. Place the hydrometer into a battery cell.
2. Set the digital multimeter to measure ohms (Ω).
3. Measure the resistance between the two (2) motor
contacts.
NOTE: DO NOT fill hydrometer more than 3/4 full.
5. Draw up sufficient acid to cover float balls.
6. Taplightlytoremoveairbubbles.
NOTE: A normal reading is between 1 and 5 ohms
(Ω). A reading of 0 ohms (Ω) or in excess of 15 ohms
(Ω) indicates a problem. High readings are generally
caused by bad connections and/or damaged brushes.
Contact authorized dealer or Invacare.
7. Number of floating balls indicates charge.
Num ber of Floating Balls
0
1
2
3
4
* 5
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.
Ohmmeter
Number of Floating
Balls Will Vary
According to Charge
Motor Connector
FIGURE 3 - MOTOR TESTING
FIGURE 2 - USING A HYDROMETER TO
CHECK BATTERY CELLS (LEAD ACID)
13
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PROCEDURE 2
TROUBLESHOOTING
MOTOR BRUSH INSPECTION
(FIGURE 4)
ELECTRO-MECHANICAL PARKING
BRAKE TESTING (FIGURE 5)
T
R
O
U
B
L
E
S
H
O
O
T
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
are hard to remove they are either overtightened or the
motor has become very hot. Let motors cool. If caps still
cannot be removed, it is recommended that the motor be
sent to Invacare Technical Services for inspection/repair.
side connectors in the black housings.
2. Set the digital multimeter to read ohms (Ω).
3. Measure the resistance between the two (2) brake
contacts. A normal reading is 100 ohms (Ω). A read-
ing of 0 ohms (Ω) or a very high reading; i.e., MEG
ohms or O.L. (out of limit) indicates a shorted brake
or an open connection respectively. If either condition
exists, send the motor to Invacare Technical Service
forinspection/repair.
NOTE: It is very important to note which way the brush
comes out of the motor. The brush MUST be placed into
the motor exactly the same way to ensure good contact
with the commutator.
I
1. Once the motor brush caps have been removed, pull
the brushes out of the motor. The end of the brushes
should be smooth and shiny and the spring should
not be damaged or discolored. If one or both of the
brushes are damaged, only the damaged or worn
brushes need be replaced. It is very important that
any time a brush is replaced, it must be “burned in”.
This is accomplished by running the motor for one
hour in each direction with a half hour break in-be-
tween. This should also be done with little or no load
on the motor, i.e., put the wheelchair up on blocks so
the drive (large) wheels do not contact the ground
and run the wheelchair. A motor with only one brush
replacedwillonlycarryasmallpercentageofitsrated
load capacity until the NEW brush is burned in.
N
G
C AUTIO N
A shorte d e le c tro-m e c ha nic a l b ra ke will
da ma ge the bra ke output se c tion in the c on-
trolle r. DO NOT c onne c t a shorte d e le c tro-
me c ha nic a l bra ke to a good c ontrolle r mod-
ule . A shorte d bra ke MUST be re pla c e d.
NOTE: A bad motor can damage the controller module
but a bad controller should NOT damage a motor.
Motor
Cap
Motor
Cap
4 Pin Motor Connector
Ohmmeter
4 Pin Motor Connector
FIGURE 4 - MOTOR BRUSH INSPECTION
FIGURE 5 - ELECTRO-MECHANICAL
PARKING BRAKE TESTING
14
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FRONT RIGGINGS
PROCEDURE 3
6. Torque the two (2) hex screws to 156-in/lbs.
This Procedure Includes the Following:
Adjusting Flip-Up Removable Footboard
Adjusting the Removable Footboard
7. Reinstall the two (2) caplug caps.
F
R
O
N
T
Height (FIGURE 2)
WARNING
1. If necessary, remove the four (4) caplug caps.
Afte r ANY a djustme nts, re pa ir or se rvic e a nd
BEFORE use , m a ke sure tha t a ll a tta c hing
ha rd wa re is tig hte ne d se c ure ly - othe rwise
injury or da ma ge ma y re sult.
2. Remove the hex screw, two (2) spacers, washers
andlocknutthatsecureone(1)ofthefootboardpivots
to the footboard mounting bracket.
R
I
G
G
I
N
G
S
3. Repeat STEP 2 for opposite side of the wheelchair.
4. Move the footboard pivots to one (1) of the following:
ADJ USTING FLIP-UP REMOVABLE
FOOTBOARD
MWDWHEELCHAIRS:one(1)ofseven(7)positions.
FWD WHEELCHAIRS: one (1) of five (5) positions.
NOTE:Thisfootboardassemblyislocatedonmodelsbuilt
BEFORE 3/1/00. Refer to ADJUSTING THE REMOV-
ABLE FOOTBOARD for the footboard assembly on
modelsbuiltAFTER3/1/00inthisprocedureofthemanual.
HEIGHT - FWD WHEELCHAIRS
Footboard Mounting
Bracket
NOTE: The following procedures are for both FWD and
MWD wheelchairs, unless otherwise noted.
Washer
Angle (FIGURE 1)
Flip Up Footboard
NOTE: This procedure is for FWD wheelchair only.
Hex
Screw
NOTE: Angle availability is limited when the motors are in
the forward-most position.
1. Remove the caplug caps.
Five (5)
Mounting
Positions
2. Remove the front hex screw and caplug washer that
secure the footboard mounting bracket and bushing
to the wheelchair.
Locknut
3. Repeat STEPS 1-2 for the opposite front hex screw
and caplug washer.
Caplug
Cap
Footboard Pivot
4. Move the footboard mounting brackets to one (1) of
three (3) positions.
HEIGHT - MWD WHEELCHAIRS
NOTE:Toensuretheexistinghexscrewstightensecurely,
apply Loctite 242 ® onto the threads.
Footboard
Mounting
Bracket
Seven (7)
Mounting
Positions
5. Reinstall the two (2) hex screws and caplug washers
through the two (2) footboard mounting brackets and
bushings and into the wheelchair.
Hex
Screw
Wheelchair Frame
Bushing
Washer
Footboard
Caplug
Mounting
Washer
Bracket
Locknut
Footboard Pivot
Flip Up Footboard
Hex
Screw
Caplug
Cap
FIGURE 2 - ADJUSTING FLIP-UP
REMOVABLE FOOTBOARD (HEIGHT)
FIGURE 1 - ADJUSTING FLIP-UP
REMOVABLE FOOTBOARD (ANGLE)
Loctite - Registered Trademark of Loctite Corporation.
15
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PROCEDURE 3
FRONT RIGGINGS
5. Resecurethetwo(2)footboardpivotstothefootboard
mounting brackets with the hex screws, spacers,
washersandlocknuts. RefertoFIGURE2 forthecor-
rect hardware orientation.
ADJUSTING DEPTH
F
R
O
N
T
Flat Head Screws
6. Torque the two (2) hex screws to 156in/lbs. and back
off the hex screws 1/8-1/4 of a revolution.
7. If necessary, reinstall the four (4) caplug caps.
Removable
Footboard
R
I
G
G
I
N
G
S
ADJ USTING THE REMOVABLE
FOOTBOARD
NOTE:This footboard assembly is available on models
built AFTER 3/1/00. Refer to ADJUSTING THE FLIP-UP
REMOVABLE FOOTBOARD for the footboard assem-
bly on models built BEFORE 3/1/00 in this procedure of
the manual.
Mounting
Positions
Barrel Nut
Footplate
Clamps
NOTE: The following procedures are for both FWD and
MWD fwheelchairs, unless otherwise noted.
Barrel Nut
DETAIL "A"
Depth (FIGURE 3)
Proper
Footplate
Clamp
Position for
MWD
NOTE: There is no footboard depth adjustment for 16-
inch wide MWD wheelchairs.
Proper
Footplate
Clamp
Position for
FWD
1. Remove the four (4) flat head screws and barrel nuts
that secure the removable footboard to the two (2)
footplate clamps.
Wheelchairs
2. Move the removable footboard to one (1) ofthe four (4)
positions.
Wheelchairs
NOTE: Before reinstalling the four (4) flat head screws,
make sure the footplate clamps are in the proper position
as shown in DETAIL "A".
ADJUSTING FO O TBO ARD ANG LE
3. Reinstall the four (4) flat head screws and barrel nuts
that secure the removable footboard to the two (2)
footplate clamps. Tighten securely.
Flat
Head
Screw
An gle
Removable
Footboard
ADJ USTING FOOTBOARD ANGLE (FIGURE 3).
1. Loosen, butdonotremove,thefour(4)flatheadscrews
and barrel nuts that secure the removable footboard
to the two (2) footplate clamps.
NOTE:Becauseofthetwo(2)supporttubes, theangleof
theremovablefootboardcanbeadjusteddownwardONLY.
FRONT
2. Graspthefrontoftheremovablefootboardandrotate
it DOWNWARD until the desired angle is reached.
Footplate
Clamp
3. Whileholdingtheremovablefootboardinplace,tighten
the four (4) flat head screws and barrel nuts securely.
Barrel Nut
Angle Can Be Adjusted
Downward ONLY
FIG URE 3 - ADJUSTING FLIP-UP
REMO VABLE FO O TBO ARD
16
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FRONT RIGGINGS
PROCEDURE 3
4. Removethenut,flatwasherand thatsecurethethreaded
arm on the height adjustment bracket to the footboard
bracket. Refer toDETAIL “B”.
ADJ USTING FOOTBOARD MOUNTING
BRACKET ANGLE - FWD MODELS ONLY
(FIGURE 4).
F
R
O
N
T
5. Perform one (1) of the following:
NOTE: Angle availability is limited when the motors
are in the forward-most position.
A. MWD WHEELCHAIRS - Move the height adjust-
mentbrackettoone(1)ofseven(7)heightpositions.
1. Remove the caplug cap.
B. FWDWHEELCHAIRS-Movetheheightadjustment
2. Remove the front hex screw and caplug washer that
secure the footboard mounting bracket and bushing
to the wheelchair.
bracket to one (1) of five (5) height positions.
R
I
G
G
I
N
G
S
6. Reinstalltheflatwasherandnutthatsecuresthethreaded
arm on the height adjustment bracket to the footboard
bracket. Refer toDETAIL “B”.
3. RepeatSTEPS1-2fortheoppositefootboardmount-
ing bracket.
7. Reinstallmountingscrew,caplugwasher,flatwasherand
nut that secures the two (2) large washers and support
tube to the height adjustment bracket and footboard
bracket.RefertoDETAIL“A”.
4. Move the footboard mounting brackets to one (1) of
three (3) positions.
NOTE:Toensuretheexistinghexscrewstightensecurely,
apply Loctite 242 onto the threads.
8. Reinstall the caplug caps.
9. Repeat STEPS 2-8 for the opposite footboard bracket.
5. Reinstall the two (2) hex screws and caplug washers
through the two (2) footboard mounting brackets and
bushings and into the wheelchair.
10. Reinstalltheremovablefootboardplate.RefertoREMOV-
ING/INSTALLING THE REMOVABLE FOOTBOARD
ONTO/FROM THE WHEELCHAIR in PROCEDURE
6. Torque the two (2) hex screws to 13-ft/lbs.
7. Reinstall the two (2) caplug caps.
3 of the Owner’s Manual.
Nut
Height Adjustment
Flat Washer
Bracket
Battery
Tray
Two (2) Large
Caplug
Washers
Washer
3 Mounting
Positions
Bushing
Caplug
Cap
Caplug
Footboard
Cap
Mounting
Screw
Mounting
Bracket
Footboard
Bracket
Support Tube
Front Hex
DETAIL “A”
DETAIL “B”
Footboard
Screw
Pivot
Caplug
Assemblies
Nut
Washer
FIG URE 4 - ADJUSTING
REMO VABLE FO O TBO ARD - ADJUSTING
FO O TBO ARD MO UNTING BRAC KET ANG LE
Footboard
Bracket
Flat Washer
Mounting
Positions
Height (FIGURE 5)
Height
Adjustment
Bracket
1. Remove the removable footboard plate. Refer to
PREPARING REMOVABLE FOOTBOARD FOR
WHEELCHAIR TRANSPORTATION in PROCE-
DURE 3 of the Owner’s Manual.
Threaded Arm
2. Remove the caplug cap.
NOTE: MWDfootboardbracketshownforclarity.Footboard
bracket on FWD models adjusts in the same manner.
3. Removethemountingscrew,caplugwasher,flatwasher
and nut that secures the two (2) large washers and sup-
port tube to the height adjustment bracket and footboard
bracket.RefertoDETAIL“A”.
FIG URE 5 - ADJUSTING FLIP-UP
REMO VABLE FO O TBO ARD -
HEIG HT
17
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PROCEDURE 4
ARMS
REPLACING ARMREST PLATE
(FIGURE 2)
This Procedure Includes the Following:
Replacing Armrest Pads
1. If necessary, remove the three (3) hex bolts, spacers
andlocknutsthatsecurethejoystickmountingbracket
to the armrest plate.
Replacing Armrest Plate
NOTE: The following procedures are for Captain's
seats only.
2. Remove armrest pad. Refer to REPLACING ARM-
REST PADS in this procedure of the manual.
A
R
M
S
WARNING
Afte r ANY a d justm e nts, re p a ir o r se rvic e
a nd BEFORE use , m a ke sure tha t a ll a t-
ta c hing ha rd wa re is tig hte ne d se c ure ly -
o the rwise injury o r d a m a g e m a y re sult.
3. Remove the lug bolt, washers and locknut that secure
the existing armrest plate to the seat frame assembly.
4. Position the new armrest plate on the seat frame as-
semblyandsecurewiththelugbolt,washersandlock-
nut. Refer to FIGURE 2 for correct hardware orienta-
tion.
REPLACING ARMREST PADS
(FIGURE 1)
5. Reinstall armrest pad. Refer to REPLACING ARM-
REST PADS in this procedure of the manual.
1. Remove the mounting screws that secures the front 6. If necessary, reinstall the three (3) hex bolts, spacers
of the armrest pad to the armrest plate.
andlocknutsthatsecurethejoystickmountingbracket
to the armrest plate.
2. Remove the mounting screw that secures the rear of
the armrest pad and armrest insert to the armrest 7. Repeat STEPS 1-6 for the opposite armrest plate, if
plate.
necessary.
Armrest Pad
3. Remove the existing armrest pad and position the
new armrest pad on the armrest plate.
Armrest Plate
Lug Bolt
4. Lineupthemountingholesinthearmrestinsert, arm-
rest plate and new armrest pad.
Armrest Insert
5. Reinstall the rear mounting screw through the arm-
rest insert, armrest plate and armrest pad and tighten
securely.
Locknuts
Phillips Screw
Locknuts
6. Reinstall the front mounting screw into the armrest
plate and new armrest pad and tighten securely.
REAR
FRO NT
Washers
Armrest
Insert
Armrest
Pad
Phillips
Screw
Mounting
Screw
Hex Bolts
Armrest Plate
Washers
Mounting
Screw
Seat Frame
Assembly
Spacers
FIGURE 1 - REPLACING ARMREST PADS
Joystick Mounting Bracket
FIGURE 2 - REPLACING ARMREST PLATE
18
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SEAT/BACK
PROCEDURE 5
7. Reinstall the Captain's seat onto the wheelchair. Re-
fertoREMOVING/INSTALLINGCAPTAIN'SSEATin
PROCEDURE 5 of the owner's manual, part number
1080722.
This Procedure Includes the Following:
Replacing Seat Positioning Strap
Replacing Back Upholstery
Replacing Captain's seat
S
E
A
T
REPLACING BACK UPHOLSTERY
(FIGURE 2)
WARNING
Afte r ANY a d justm e nts, re p a ir o r se rvic e
a nd BEFORE use , m a ke sure tha t a ll a t-
ta c hing ha rd wa re is tig hte ne d se c ure ly -
o the rwise injury o r d a m a g e m a y re sult.
NOTE: The following procedure is for Integrated sling
seat wheelchairs only.
/
1. Flip the armrests up and out of the way. Refer to US-
ING/ADJUSTINGFLIPBACKARMRESTSinPRO-
CEDURE 4 of the owner's manual, part number
1080722.
B
A
C
K
REPLACING SEAT POSITIONING
STRAP
2. Cut the tie-wraps that secure the bottom of the exist-
ing back upholstery to the wheelchair frame.
Captain's Seats (FIGURE 1)
1. Remove the Captain's seat from the wheelchair. Refer 3. Remove the two (2) phillips screws and washers that
toREMOVING/INSTALLINGCAPTAIN'SSEATinPRO-
CEDURE 5 of the owner's manual, part number
1080722.
securetheexistingbackupholsterytothebackcanes.
4. Remove the two (2) hex bolts, washers and locknuts
thatsecureone(1)backcanetothewheelchairframe.
2. Remove the two (2) hex bolts, washers and locknuts
that secure the seat positioning strap to the seat frame
assembly.
NOTE: It is necessary to remove only one (1) back cane
to replace the back upholstery.
5. Pull the loose back cane out of the existing back
upholstery.
3. Remove the two (2) halves of the seat positioning strap
from the seat frame assembly.
6. Pull the existing back upholstery up and over the
mounted back cane.
4. Positionthetwo(2)newseatpositioningstraphalveson
the inside of the seat frame assembly as shown in
FIGURE1.
7. Installnewbackupholsteryovermountedbackcane.
5. Position the mounting holes in the two (2) new seat po-
sitioningstraphalveswiththemountingholesintheseat
frame assembly.
Back Upholstery
Washer
6. Reinstall the two (2) hex bolts, washers and locknuts
that secure the seat positioning strap to the seat frame
assembly and tighten securely.
Phillips
Screw
Seat Positioning
Strap
Tie Wrap Mounting Holes
Back Cane
Washers
Washer
Seat Frame
Assembly
Locknuts
Locknut
Hex Bolts
(Apply Loctite
242 and torque
to 75-inch
Hex Bolt
pounds)
FIGURE 1 - REPLACING SEAT POSITIONING
STRAP - CAPTAIN'S SEATS
FIGURE 2 - REPLACING BACK UPHOLSTERY
19
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PROCEDURE 5
SEAT/BACK
8. Slide the loose top half of the back cane through the
new back upholstery.
REPLACING CAPTAIN'S SEAT
(FIGURE 3)
9. Usingthemountedbackcaneasaguide, reinstallthe
two (2) hex bolts that secure the top half of the back
cane to the bottom half of the back cane.
1. Remove the Captain's seat from the wheelchair. Refer
toREMOVING/INSTALLINGCAPTAIN'SSEATinPRO-
CEDURE 5 of the owner's manual part number
1080722.
S
E
A
T
NOTE: Make sure the back canes are mounted to the
same height.
2. Remove the four (4) hex screws and washers that
secure the existing captain's seat to the seat frame
assembly.
WARNING
/
The top a nd bottom ha lf of the ba c k c a ne s
MUST b e tig hte ne d se c ure ly to g e the r BE-
FORE using the whe e lc ha ir, o the rwise in-
jury or da ma ge m a y oc c ur. Use Loc tite 242
o n the he x b o lts a nd to rq ue to 75-inc h
p o und s.
B
A
C
K
3. Line up mounting holes in the new captain's seat with
mounting holes in the seat frame assembly.
4. Apply Loctite 242 to the hex screws.
5. Install the four (4) hex screws and washers through
the seat frame assembly and into the new captain's
seat. Tighten securely.
10. Use Loctite 242 on the hex bolts and torque into the
back canes to 75-inch pounds.
6. Installthenewcaptain'sseatontothewheelchair. Re-
fertoREMOVING/INSTALLINGCAPTAIN'SSEATin
PROCEDURE 5 of the owner's manual, part number
1080722.
11. While holding the hex bolt, reinstall the locknut and
torque to 75-inch pounds.
12. Repeat STEP 11 for the other hex bolt and locknut.
13. Securely tighten the new back upholstery to the back
canes with the two (2) phillips screws and washers.
Captain's Seat
14. Secure the bottom of the new back upholstery to the
wheelchair frame with tie-wraps.
Seat Frame
NOTE:CleanupholsterywithwarmDAMPclothandmild
detergent to remove superficial soil.
Seat Frame
Assembly
Assembly
WARNING
La und e ring o r m o isture will re d uc e fla m e
re ta rd a tio n o f the up ho lste ry.
Washers
Hex Screws (Apply
Loctite 242)
FIG URE 3 - REPLAC ING C APTAIN'S SEAT
20
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SEAT FRAME
PROCEDURE 6
NOTE: Make sure to line up the mounting holes in the seat
extensiontubeswiththenewseatupholstery.
This Procedure Includes the Following:
Adjusting Seat Depth
5. Installplugbuttonsintoendsoftheseatextensiontubes.
Adjusting Back Height
Changing Back Angle
ADJ USTING BACK HEIGHT
(FIGURE 2)
S
E
A
T
Replacing Back Canes
NOTE: The instructions in this procedure are for IN-
TEGRATED SLING SEAT wheelchairs ONLY.
1. Remove the two (2) hex bolts, washers and locknuts
that secure the top half of the back cane to the bottom
half of the back cane.
F
R
A
M
E
WARNING
Afte r ANY a d justm e nts, re p a ir o r se rvic e
a nd BEFORE use , m a ke sure tha t a ll a t-
ta c hing ha rd wa re is tig hte ne d se c ure ly -
o the rwise injury o r d a m a g e m a y re sult.
2. Reposition the back cane to one (1) of five (5) pairs of
height adjustment holes:
✪✪HOLE PAIR #
1
2
3
4
5
Back Height (in inches)
16 17 18 19 20
✪ Holes numbered from bottom to top for reference only.
(There are no numbers on the back canes.)
ADJ USTING SEAT DEPTH
(FIGURE 1)
3. Reinstall the two (2) hex bolts that secure the top half of
the back cane to the bottom half of the back cane.
1. Remove the existing seat upholstery from the wheel-
chair. Refer to REPLACING SEAT UPHOLSTERY in
PROCEDURE 5 of the owner's manual, part number
1080722.
WARNING
The top a nd bottom ha lf of the ba c k c a ne s
MUST b e tig hte ne d se c ure ly tog e the r BE-
FORE using the whe e lc ha ir, othe rwise in-
jury or da ma ge m a y oc c ur. Use Loc tite 242
on the he x b olts a nd torq ue to 75-inc h
p o und s.
NOTE: If adjusting seat depth of the wheelchair, the seat
upholstery MUST be changed as well.
2. Remove the two (2) plug buttons from the ends of the
crossbraces that are towards front of wheelchair.
NOTE: The two (2) plug buttons will be used in the ends of
the seat extensions.
4. UseLoctite242onthehexboltsandtorqueintotheback
canes to 75-inch pounds.
3. Installthetwo(2)seatextensiontubesintotheendson
the crossbraces. Line up the second mounting hole
from the rear of the seat extension tube with the front
mounting hole in the crossbrace.
5. Whileholdingthehexbolt,reinstallthelocknutandtorque
to 75-inch pounds.
6. Repeat STEP 5 for the other hex bolt and locknut.
7. Repeat STEPS 1-6 for the opposite back cane.
4. Install the new seat upholstery onto the wheelchair.
RefertoREPLACINGSEATUPHOLSTERYinPRO-
CEDURE 5 of the owner's manual, part number
1080722.
HO LE
PAIR #
Top Half of
Back Cane
5
4
3
2
1
Washer
Phillips
Screws
Locknuts
Bottom Half
of Back Cane
Hex Bolts (Apply
Loctite 242 and torque
to 75-inch pounds)
Plug Button
Crossbrace
Seat Extension Tube
FIGURE 2 - ADJUSTING BACK HEIGHT
FIGURE 1 - ADJUSTING SEAT DEPTH
21
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PROCEDURE 6
SEAT FRAME
CHANGING BACK ANGLE
(FIGURE 3)
REPLACING BACK CANES
(FIGURE 4)
1. Flip the armrests up and out of the way. Refer to US- Top Half of Back Canes
ING/ADJUSTING FLIP BACK ARMRESTS in PRO-
CEDURE 4 of the owner's manual, part number
1080722.
S
E
A
T
1. Flip the armrests up and out of the way. Refer to US-
ING/ADJUSTING FLIP BACK ARMRESTS in PRO-
CEDURE 4 of the owner's manual, part number
1080722.
2. Remove the TOP hex bolt, two (2) washers and lock-
nut that secure the back cane to the mounting plate
on the wheelchair frame.
NOTE: If the back height of the wheelchair is staying the
same, note the position of the existing top half of the back
cane(s) before removing from the wheelchair.
F
R
A
M
E
3. Refer to DETAIL "B" in FIGURE 3 to determine the
mounting plate hole for the desired back angle.
2. Removethephillipsscrewandwasherthatsecurethe
backupholsterytotheexistingtophalfofthebackcane.
4. Reposition the back cane to the position determined
in STEP 3.
3. Slidethebackupholsteryuptoexposethe two(2)hex
bolts, washers and locknuts.
5. Reinstall TOP hex bolt, two (2) washers and locknut.
Refer to FIGURE 3 for correct hardware orientation.
4. Remove the two (2) hex bolts, washers and locknuts
that secure the existing top half of the back cane to the
bottom half of the back cane.
WARNING
The b a c k c a ne s MUST b e tig hte ne d se -
c ure ly to the whe e lc ha ir fra m e BEFORE
using the whe e lc ha ir, o the rwise injury o r
d a m a g e m a y o c c ur. Use Lo c tite 242 o n
the he x bolt a nd torque to 75-inc h pounds.
5. Removetheexistingtophalfofthebackcanefromthe
bottom half of the back cane.
6. Perform one (1) of the following:
A. Install the new top half of the back cane through
the back upholstery and into the bottom half of the
back cane at the existing position noted.
6. Use Loctite 242 on the hex bolt and torque the hex
bolt to 75-inch pounds.
7. Repeat STEPS 2-6 for opposite side of wheelchair.
B. Installthenewtophalfofthebackcanethroughthe
backupholsteryandintothebottomhalfoftheback
cane to one (1) of the following new positions:
Washers
Locknut
✪✪HOLE PAIR #
1
2
3
4
5
TOP Hex Bolt
(Apply Loctite
Back Height (in inches)
16 17 18 19 20
✪Holes numbered from bottom to top for reference only.
(There are no numbers on the back canes.)
242 and torque
to 75-inch
Washers
pounds)
7. Reinstall the two (2) hex bolts that secure the new top
half of the back cane to the bottom half of the back
cane.
DETAIL "B"
95O 100O
90O
105O
WARNING
The top a nd bottom ha lf of the ba c k c a ne s
MUST b e tig hte ne d se c ure ly to g e the r BE-
FORE using the whe e lc ha ir, o the rwise in-
jury or da ma ge ma y oc c ur. Use Loc tite 242
o n the he x b o lts a nd to rq ue to 75-inc h
p o und s.
8. Use Loctite 242 on the hex bolts and torque into the
back canes to 75-inch pounds.
FIGURE 3 - CHANGING BACK ANGLE
9. Whileholdingthehexbolt,reinstallthelocknutandtorque
to 75-inch pounds.
10. Repeat STEP 9 for the other hex bolt and locknut.
22
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SEAT FRAME
PROCEDURE 6
11. Securely tighten back upholstery to the new top half of 12. Use Loctite 242 on the hex bolts and torque the hex
the back cane with the phillips screw and washer. bolts to 75-inch pounds.
12. RepeatSTEPS2-11fortheoppositesideofthewheel- 13. Securely tighten back upholstery to the top half of the
chair, if necessary.
back cane with the phillips screw and washer.
S
E
A
T
14. RepeatSTEPS2-13fortheoppositesideofthewheel-
chair, if necessary.
Bottom Half of Back Canes
1. Flip the armrests up and out of the way. Refer to US-
ING/ADJUSTINGFLIPBACKARMRESTSinPRO-
CEDURE 4 of the owner's manual, part number
1080722.
HO LE
PAIR #
Top Half of
Back Cane
F
R
A
M
E
5
Locknuts
2. Remove phillips screw and washer that secure back
upholstery to the existing top half of the back cane.
4
3
Washers
3. Slidethebackupholsteryuptoexposethe two(2)hex
bolts, washers and locknuts.
2
1
4. Remove the two (2) hex bolts, washers and locknuts
that secure the top half of the back cane to the existing
bottom half of the back cane.
Hex Bolts (Apply
Loctite 242 and
torque to 75-inch
pounds)
5. Removethetophalfofthebackcanefromthe existing
bottom half of the back cane.
NOTE: If the back angle of the wheelchair is staying the
same, note the position of the existing bottom half of the
back cane(s) before removing from the wheelchair.
Bottom Half
of Back
Cane
Insert
6. Remove the two (2) hex bolts, four (4) washers and
two(2)locknutsthatsecurethebottomhalfoftheback
cane to the wheelchair.
Locknuts
Washers
7. Removetheexistingbottomhalfofthebackcanefrom
the wheelchair.
Wheelchair
Frame
NOTE: The existing insert will be reused.
Washers
8. Remove the insert from the existing bottom half of the
back cane.
FIGURE 4 - REPLACING BACK CANES
9. Install the insert into the new bottom half of the back
cane and line up the mounting holes.
10. Install the new bottom half of the back cane onto the
wheelchair at the position noted.
NOTE: If the back angle needs to be changed, refer to
CHANGINGBACKANGLEinthisprocedureofthemanual.
11. Reinstall the two (2) hex bolts, four (4) washers and
two (2) locknuts that secure the new bottom half of the
back cane to the wheelchair.
WARNING
The b a c k c a ne s MUST b e tig hte ne d se -
c ure ly to the whe e lc ha ir fra m e BEFORE
using the whe e lc ha ir, o the rwise injury o r
d a m a g e m a y o c c ur. Use Lo c tite 242 o n
the he x bolts a nd torque to 75-inc h pounds.
23
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PROCEDURE 7
ELECTRONICS
11. Position the armrest pad on the armrest plate.
This Procedure Includes the Following:
Repositioning MKIV Joystick
12. Line up the mounting holes in the armrest insert, arm-
rest plate and armrest pad.
Removing/Installing MKIV Controller
13. Reinstall rear phillips screw through the armrest insert,
armrest plate and armrest pad and tighten securely.
E
L
E
C
T
R
O
N
I
WARNING
Afte r ANY a d justm e nts, re p a ir o r se rvic e
a nd BEFORE use , m a ke sure a ll a tta c hing
ha rd wa re is tig hte ne d se c ure ly - o the r-
wise injury or d a m a g e m a y re sult.
14. Reinstall the front phillips screw into the armrest plate
and armrest pad and tighten securely.
15. Repeat STEPS 11-14 for opposite side of wheelchair.
16. Install Loctite 242 onto the three (3) hex bolts.
REPOSITIONING MKIV J OYSTICK
Captain’s Seats (FIGURE 1)
17. Installthethree(3)hexbolts, spacersandlocknutsthat
secure joystick mounting bracket to armrest plate.
18. Slide the joystick mounting tube through the joystick
mounting bracket to the desired position.
1. Turn the lever on the adjustment lock to release the
adjustment lock from joystick mounting tube.
C
S
19. Secure adjustment lock to joystick mounting tube by
turning lever on adjustment lock.
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.
REMOVING/ INSTALLING MKIV
CONTROLLER
4. Remove the phillips screw that secures the front of the
armrest pad to the armrest plate.
WARNING
5. Remove the phillips screw that secures the rear of the
armrest pad and armrest insert to the armrest plate.
Re pla c e me nt c ontrolle r MUST be sa me pa rt
num b e r a s fa c to ry insta lle d c o ntro lle r -
Othe rwise , injury o r d a m a g e m a y re sult.
6. Remove the armrest pad from the armrest plate.
7. Remove the lug bolt, washers and locknut that secure
the existing armrest plate to the seat frame assembly.
16, 18, or 20-inch Wide Models (FIGURE 2)
8. Repeat STEPS 4-7 for opposite side of wheelchair.
REMOVING.
1. If necessary, remove the rear shroud and rear compart-
ment (if equipped). Refer to REMOVING/INSTALLING
SHROUDS in PROCEDURE 10 of this manual.
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.
2. Remove the battery boxes. Refer to REMOVING/
INSTALLING THE BATTERY BOXES for one (1)
of the following:
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.
Lug Bolt
(STEPS 7, 9)
FWD WHEELCHAIRS - in PROCEDURE 13
of this manual.
Armrest Plate
Armrest Insert
Armrest Pad
MWD WHEELCHAIRS - in PROCEDURE 14
of this manual.
PhillipsScrew
(STEPS 5, 13)
Locknuts
(STEPS 3, 17)
Locknuts
3. Disconnect the following connections:
(STEPS 7, 9)
A. The right hand motor and controller connection.
B. The left hand motor and controller connection.
C. Batterywiringharnessandcontrollerconnection.
Washers
(STEPS 7, 9)
Hex Bolts
(STEPS 3, 16)
4. Remove the two (2) locknuts that secure the existing
MKIV controller and washer(s) tothe wheelchair.
PhillipsScrew
(STEPS 4, 14)
5. RemoveexistingMKIVcontrollerfromthewheelchair.
Adjustment Lock
Washers (STEPS 7, 9)
INSTALLING.
1. Install washer(s) onto rear mounting stud.
Spacers
(STEPS 3, 17)
Seat Frame Assembly
2. Install new/existing MKIV controller onto wheelchair
frame.
FIGURE 1 - REPOSITIONING MKIV JOYSTICK
- CAPTAIN’S SEATS
24
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ELECTRONICS
PROCEDURE 7
4. Disconnect the following connections:
3. Secure the new/existing MKIV controller to the wheel-
chair with NEW locknuts. Torque to 156-in/lbs.
A. The right hand motor and controller connection.
B. The left hand motor and controller connection.
C. Battery wiring harness and controller connection.
4. Connect the following connections:
E
L
E
C
T
R
O
N
I
A. The right hand motor and controller connection.
B. The left hand motor and controller connection.
C. Battery wiring harness and controller connection.
5. Cut the tie-wrap that secure the the left hand motor
cable and controller cable together.
6. Remove the two (2) locknuts that secure the existing
MKIV controller and washer(s) to the wheelchair.
5. Installthebatteryboxes.RefertoREMOVING/INSTALL-
ING THE BATTERY BOXES for one (1) of the follow-
ing:
7. Remove existing MKIV controller from the wheelchair.
FWD WHEELCHAIRS - in PROCEDURE 13
of this manual.
INSTALLING.
1. On models without shrouds, install washer onto rear
mounting stud.
C
S
MWD WHEELCHAIRS - in PROCEDURE 14
of this manual.
6. If necessary, install the rear shroud and rear compart-
ment(ifequipped).RefertoREMOVING/INSTALLING
SHROUDS in PROCEDURE 10 of this manual.
2. Install new/existing MKIV controller onto wheelchair
frame.
3. Secure the new/existing MKIV controller to the wheel-
chair with NEW locknuts. Torque to 156-in/lbs.
4. Connect the following connections:
Mounting Stud on
A. The right hand motor and controller connection.
B. The left hand motor and controller connection.
C. Battery wiring harness and controller connection.
Wheelchair Frame
Washer
MKIV
Controller
NOTE: See FIGURE 3 for proper positioning of the con-
nections noted in STEP 4 on the wire connector support.
Washer -
MWD
Locknuts
Only
5. Secure the connections noted in STEP 4 to the wire
connector support with a tie-wrap
NOTE: Make sure to thread tie-wrap around crossbrace
and through slot in wire connector support.
FIGURE 2 - REMOVING/ INSTALLING MKIV
CONTROLLER - 16,18, 20-INCH WIDE
MO DELS
6. Secure the left hand motor cable and the controller
cable to the crossbrace with a tie-wrap .
14-inch Wide Models (FIGURE 3)
7. Install the battery boxes. Refer to REMOVING/IN-
STALLING THE BATTERY BOXES in PROCE-
DURE 12 of this manual.
REMOVING.
1. Remove the front and rear shrouds. Refer to RE-
MOVING/INSTALLINGSHROUDSinPROCEDURE
10 of this manual.
8. Installthefrontandrearshroud. Referto REMOVING/
INSTALLING SHROUDS in PROCEDURE 10 of this
manual.
2. Remove the battery boxes. Refer to REMOVING/
INSTALLING THE BATTERY BOXES in PROCE-
DURE 12 of this manual.
3. Cutthetiewrapthatsecurethefollowingconnections
to the wire connector support:
A. The right hand motor and controller connection.
B. The left hand motor and controller connection.
C. Batterywiringharnessandcontrollerconnection.
(BLUE)
25
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PROCEDURE 7
ELECTRONICS
Mounting Stud on
Wheelchair Frame
E
L
E
C
T
R
O
N
I
Washer
MKIV
Controller
Locknuts
C
S
MKIV
Controller
Tie-Wrap
Right Hand Motor/Controller
Connection
Tie-Wrap
Left Hand Motor/Controller
Connection
Wire Connector Support
Controller
Cable
Battery Wiring Harness
and Controller Connection
(BLUE)
Slot
Left Hand
Motor Cable
FIGURE 3 - REMOVING/ INSTALLING MKIV CONTROLLER - 14-INCH WIDE MODELS
26
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LIMIT SWITCH
PROCEDURE 8
ADJ USTING LIMIT SWITCH
(FIGURE 2)
This Procedure Includes the Following:
Disconnecting/Connecting Limit Switch
Adjusting Limit Switch
L
I
NOTE:ThefollowingprocedureisforHighBackCaptain's
seat model wheelchairs only.
M
I
T
WARNING
WARNING
Afte r ANY a d justm e nts, re p a ir o r se rvic e
a nd BEFORE use , m a ke sure a ll a tta c hing
ha rd wa re is tig hte ne d se c ure ly - o the r-
wise injury or d a m a g e m a y re sult.
NEVER o p e ra te the whe e lc ha ir while in
a ny re c line p o sitio n o ve r 114o RELATIVE
TO THE SEAT FRAME. If the lim it switc h d oe s
no t sto p the whe e lc ha ir fro m o p e ra ting
in a re c line p o sitio n g re a te r tha n 114o
RELATIVE TO THE SEAT FRAME, DO NOT op -
e ra te the whe e lc ha ir. Ad just the lim it
switc h o r ha ve the whe e lc ha ir se rvic e d
b y a d e a le r o r q ua lifie d te c hnic ia n, o th-
e rwise injury o r d a m a g e m a y o c c ur.
S
W
I
T
C
H
DISCONNECTING/ CONNECTING
LIMIT SWITCH (FIGURE 1)
NOTE:ThefollowingprocedureisforHighBackCaptain's
seat model wheelchairs only.
C AUTIO N
Disc o nne c t lim it switc h BEFORE re m o ving
se a t o r d a m a g e to switc h m a y o c c ur.
1. Place the wheelchair on a level surface.
2. Recline the captain's seat back to a 24o to achieve
the 114o angle relative to the seat frame. Refer to AD-
JUSTING CAPTAIN'S SEAT in PROCEDURE 5 of
the owner's manual, part number 1080722.
NOTE: The captain's seat frame is at a 5o angle relative
to the ground. When the back angle is adjusted to 114o
relativetotheseat,itwillmeasure61o relativetotheground.
NOTE: To determine 114o back angle relative to the seat
frame, place a magnetic protractor (available at any hard-
ware store) on the back as shown in FIGURE 3 and ad-
just the back until the magnetic protractor reads 61o.
1. Perform one (1) of the following:
DISCONNECTING-
Whileholdingthebodyofthe
limitswitchphonoplug,liftup
gently.
NOTE:Whenthelimitswitchisunpluggedthewheel-
chair will NOT operate.
CONNECTING-
Plug limit switch plug into
the limit switch phono jack.
3. Turn the wheelchair power switch on the joystick to
the ON position.
NOTE: The wheelchair should not operate.
4. IFwheelchairoperates, proceedtothefollowingsteps
toadjusttheactuatorontheupperlimitswitchbracket:
A. Fully recline the back. Refer to ADJUSTING
CAPTAIN'S SEAT in PROCEDURE 5 of the
owner's manual, part number 1080722.
M W D
FWD
NOTE:Thiswillmakeaccesstothelimitswitcheasier.
Limit Switch
Phono Plug
Body
B. Loosen, but do not remove, the two (2) phillips
screws, washers and locknuts that secure the
actuator to the upper limit switch bracket.
Limit Switch
Phono Jack
C. SlidetheactuatorUP(towardsthetopofthewheel-
chair).
C AUTIO N
DO NOT o ve r tig hte n the p hillip s sc re ws
tha t se c ure the a c tua tor to the up p e r lim it
switc h b ra c ke t. Da m a g e to the a c tua to r
m a y o c c ur.
FIGURE 1 - DISCONNECTING/ CONNECTING
LIMIT SWITCH
27
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PROCEDURE 8
LIMIT SWITCH
D. Only tighten the two (2) phillips screws, washers
and locknuts that secure the actuator to the up-
perlimitswitchbracketuntiltheactuatordoesnot
move.
L
I
M
I
E. Repeat STEPS 1-3 until the wheelchair does not
operate when the captain's seat back is at a 24o
angle.
T
114o
24o Back
Recline Angle
S
W
I
T
C
H
5-3/4 inches
Magnetic Protractor - (Will
read 61o when back recline
angle is at 114o relative to the
seat frame)
61o
5o Seat Angle
Upper Limit
Switch
Bracket
Phillips
Screws,
Washers
and Lock-
nuts
Actuator
FIG URE 2 - ADJUSTING LIMIT SWITC H
28
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WHEELS
PROCEDURE 9
INSTALLING.
NOTE: The keystock in the wheel hub MUST lineup with
the cutout in the gearbox drive shaft.
This Procedure Includes the Following:
Replacing Pneumatic Tires/Tubes -
Drive Wheels/Casters
Removing/Installing Drive Wheels
Removing/Installing Drive Wheel Hub
Replacing Casters
1. Install 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.
W
H
E
E
L
2. Install washer onto motor drive shaft.
Replacing Forks
3. 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.
WARNING
Afte r ANY a djustme nts, re pa ir or se rvic e a nd
BEFORE use , m a ke sure a ll a tta c hing ha rd -
wa re is tig hte ne d se c ure ly - othe rwise in-
jury or da ma ge ma y re sult.
4. Apply Loctite 242 to the hex screw.
S
5. Install the hex screw. Use a torque wrench only and
torque to 90-inch pounds.
C AUTIO N
As with a ny ve hic le , the whe e ls a nd tire s
should b e c he c ke d p e riod ic a lly for c ra c ks
a nd we a r a nd sho uld b e re p la c e d .
Keystock
REPLACING PNEUMATIC TIRES/
TUBES - DRIVE WHEELS/ CASTERS
Chamfered
Side of Wheel
WARNING
Hub
Motor
Driveshaft
DO NOT use your whe e lc ha ir unle ss it ha s
the prope r tire pre ssure (p.s.i.). DO NOT ove r-
infla te the tire s. Fa ilure to follow the se sug -
ge stions ma y c a use the tire to e xplode a nd
c a use b od ily ha rm .
Keyway
Locking Tab
Washer
If tire s a re p ne um a tic , re p la c e m e nt of tire
or tub e MUST b e p e rform e d b y a q ua lifie d
te c hnic ia n.
NOTE: If drive wheels or casters are pneumatic, under-
inflation causes excessive wear which results in poor per-
formance of the tires.
Washer
Hex Screw (Apply Loctite 242 and use a Torque
Wrench only to Torque to 90-inch pounds)
REMOVING/ INSTALLING DRIVE
WHEELS
TIGHTEN Hex Screw if Locking Tab is not
Parallel with Flat on Head (STEP 9)
WARNING
NEVER use a lo c king ta b wa she r m o re
tha n onc e . ALWAYS use a NEW loc king ta b
wa she r whe n insta lling the d rive whe e ls.
Locking Tab Parallel
Flat on Head
with Flat on Head of
of Hex Screw
Hex Screw (STEP 9)
12-inch Drive Wheel (FIGURE 1)
Locking
Tab
REMOVING.
1. The tab of the locking washer that is bent 90o up
against the head of the mounting screw MUST be
flattenedbeforethemountingscrewcanberemoved.
Bend Tab up tight against Flat on
Head of Hex Screw (STEP 10)
2. Removethehexscrew,lockingtabwasherandwasher
that secure the existing front wheel to the wheel hub.
3. Use a wheel puller to remove the existing front wheel
from the motor drive shaft.
FIGURE 1 - REMOVING/ INSTALLING 12-
INCH DRIVE WHEELS
29
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PROCEDURE 9
WHEELS
6. Examinetheheadofthehexscrewandthelockingtab INSTALLING.
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.
1. Installdrivewheelontowheelhub
2. Securethedrivewheelontothedrivewheelhubwiththe
existingfour(4)beveledlocknuts.Torquelocknutsto160-
inch pounds.
7. If one (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 locking tab are parallel.
W
H
E
E
L
3. Repeat STEPS 1-2 for opposite side if necessary.
4. Installthebatteryboxes.RefertoINSTALLING/REMOV-
ING BATTERY BOXES for one (1) of the following:
NOTE:Tightenhexscrewonly.DONOTloosenhexscrew
to make one of the tabs on the locking washer parallel.
FWD WHEELCHAIRS - in PROCEDURE 13 of this
manual.
8. Bend the parallel tab of locking tab washer up tight
against flat of the hex screw (FIGURE 1).
S
MWD WHEELCHAIRS - in PROCEDURE 14 of this
manual.
14-inch Drive Wheel (FIGURE 2)
REMOVING.
REMOVING/ INSTALLING DRIVE
WHEEL HUB (FIGURE 3)
1. Remove the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES for one (1) of the
following:
NOTE: Drive wheel hubs are only on 14-inch drive wheels.
FWD WHEELCHAIRS - in PROCEDURE 13 of this
manual.
WARNING
NEVER use a loc king ta b wa she r more tha n
onc e . ALWAYS use a NEW loc king ta b wa she r
whe n insta lling the d rive whe e ls.
MWD WHEELCHAIRS - in PROCEDURE 14ofthis
manual.
2. Remove the four (4) beveled locknuts that secure
the drive wheel to the wheel hub.
Rem oving
3. Removetheexistingdrivewheelfromthewheelhub. 1. Remove the drive wheels. Refer to REMOVING/IN-
STALLING THE DRIVE WHEELS in this procedure of
the manual.
Wheel Hub
NOTE: The tab of the locking washer that is bent 90o up
against the head of the mounting screw MUST be flattened
before the mounting screw can be removed.
Assembly
Drive Wheel Assembly
2. Flatten the tab of the locking washer that is bent 90o up
against the head of the mounting screw.
3. Remove the mounting screw, locking tab washer and
washerthatsecuretheexistingdrivewheeltothewheel
hub.
4. Remove the wheel hub and keystock from drive shaft.
Installing
1. Position the keystock on the drive shaft
C AUTIO N
Four (4) Beveled
DO NOT a pply more tha n a one (1)-inc h (in
le ng th) thin film of a nti-se ize c om p ound to
the d rive sha ft. Ap p lying m ore tha n one
(1)-inc h (in le ngth) c a n c a use the a nti-se ize
c om p ound to le a k re sulting in d a m a g e to
flooring (c a rp e t, tile , e tc .).
Hex Nuts
FIGURE 2 - REMOVING/ INSTALLING 14-
INCH DRIVE WHEELS
30
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WHEELS
PROCEDURE 9
2. Applyathinfilmofanti-seizecompoundone(1)inchin
length to the end of the drive shaft.
Keystock
3. Reinstalldrive wheelhubontothegearboxdriveshaft.
Locking
Washer
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.
W
H
E
E
L
Mounting
Screw
Drive
Shaft
4. Install the washer and NEW locking tab washer onto
thewheelhub. Makesurethelockingtabisinlinewith
the keyway of the wheel hub.
Keyway
5. Apply Loctite 242 to the mounting screw.
6. Install the mounting screw. Use a torque wrench only
and torque to 90-inch pounds.
S
Washer
7. Examinetheheadofthehexscrewandthelockingtab
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.
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)
8. If one (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 locking tab are parallel.
Locking Tab Parallel
Flat on Head
with Flat on Head of
Hex Screw (STEP 9)
of Hex Screw
NOTE:Tightenhexscrewonly.DONOTloosenhexscrew
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).
Locking
Tab
10. Reinstall the drive wheel onto the wheel hub. Refer to
REMOVING/INSTALLINGDRIVEWHEELSinthispro-
cedure of the manual.
Bend Tab up tight against Flat on
Head of Hex Screw (STEP 10)
11. Repeat procedure for the opposite side of the wheel-
chair, if necessary.
FIGURE 3 - REMOVING/ INSTALLING DRIVE
WHEEL HUB
31
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PROCEDURE 9
WHEELS
NOTE: Check bearing assemblies and replace if nec-
essary.
REPLACING CASTERS (FIGURE 4)
1. Remove the hex screw, washers and locknut that
secure the caster to the fork.
7. Ensure that new fork slides completely into the
caster head tube.
2. Remove the caster from the fork.
3. Install Loctite 242 onto the hex screw.
4. Replace caster and reverse STEPS 1-3.
5. Torque the locknut to 120-inch pounds.
6. Loosen the locknut 1/8 of a turn.
7. Move the caster side to side.
8. Install nylon washer and secure with locknut.
W
H
E
E
L
WARNING
Im p ro p e r p o sitio ning o f the wa she r will
p ro hib it the fre e m o ve m e nt o f the fo rks.
9. Install Loctite 242 onto the hex screw.
10. Position the caster into the new fork.
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.
S
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.
Locknut
Fork
Hex Screw
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 1080737.
Washer
Caster Headtube
Dust Cover
Caster
Washer
Locknut
FIG URE 4 - REPLACING CASTERS
Nylon Washer
Locknut
Fork
REPLACING FORKS (FIGURE 5)
1. Remove the hex screw, washers and locknut that
secure the caster to the existing fork.
2. Remove the caster from the existing fork.
3. Remove the dust cover.
Washer
Hex Screw
4. Remove the locknut and nylon washer.
5. Drop the existing fork out of the caster head tube.
6. Slide the new fork into the caster head tube.
Caster
FIG URE 5 - REPLAC ING FO RKS
Washer
32
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SHROUDS
PROCEDURE 10
2. Remove rear shroud and rear storage compartment (if
equipped) from the wheelchair. Refer to REMOVING/
INSTALLINGREARSHROUDANDREARSTORAGE
COMPARTMENT in this procedure of the manual.
This Procedure Includes the Following:
Removing/Installing Shrouds
WARNING
3. Perform one (1) of the following:
Afte r ANY a d justm e nts, re p a ir o r se rvic e
a nd BEFORE use , m a ke sure a ll a tta c hing
ha rd wa re is tig hte ne d se c ure ly - o the r-
wise injury or d a m a g e m a y re sult.
A. INTEGRATEDSLINGSEATMODELS -Foldthe
wheelchair.RefertoTRANSPORTINGRANGER
II MWD - INTEGRATED SLING SEATS in PRO-
CEDURE 12 of this manual.
S
H
R
O
U
D
S
B. CAPTAIN'S SEAT MODELS - Remove the
Captain's Seat from the wheelchair. Refer to RE-
MOVING/INSTALLINGCAPTAIN'SSEATinPRO-
CEDURE 5 of this manual.
REMOVING/ INSTALLING
SHROUDS
C. WEIGHT SHIFT BASIC TILT MODELS - Pro-
ceed to STEP 4.
MWD Wheelchairs (FIGURE 1)
REMOVING FRONT SHROUD.
4. Remove the phillips screws and washers that secure
side shroud to wheelchair frame. Refer to FIGURE 1
for phillips screw and washer locations.
1. Turn the two (2) 1/4-turn bolts that secure front shroud
to the two (2) side shrouds COUNTERCLOCKWISE.
2. Remove the front shroud from the wheelchair.
5. Remove the phillips bolt and locknut that secure the
sideshroudtothewheelchairframe. RefertoFIGURE
1for phillips bolt and locknut location.
INSTALLING FRONT SHROUD.
1. Positionthetwo(2)1/4-turnboltswiththetwo(2)mount-
ing holes in the side shrouds.
6. Repeat STEPS 4-5 for the opposite side of the wheel-
chair, if necessary.
2. Install the front shroud onto the two (2) side shrouds.
INSTALLING SIDE SHROUDS.
1. Position the side shroud on the wheelchair frame.
3. Turn the two (2) 1/4-turn bolts that secure the front
shroud to the two (2) side shrouds CLOCKWISE.
2. Line up the mounting holes in the side shroud with the
mounting holes in the wheelchair frame.
REMOVING REAR SHROUD AND REAR
STORAGE COMPARTMENT.
NOTE: The rear storage compartment is available on
C AUTIO N
wheelchairs NOT equipped with weight shift basic tilt only.
DO NOT ove rtighte n the phillips sc re ws a nd
p hillip s b olt tha t se c ure the sid e shroud to
the whe e lc ha ir fra m e - othe rwise d a m a g e
to the sid e shroud c a n oc c ur.
1. Lift up on rear shroud and remove from wheelchair.
2. Turn the two (2) 1/4-turn bolts that secure the rear stor-
agecompartmenttothewheelchairframeCOUNTER-
CLOCKWISE.
3. Install the phillips bolt and locknut that secure the side
shroud to the wheelchair frame and tighten securely.
DO NOT OVERTIGHTEN. Refer to FIGURE 1 for
phillipsboltandlocknutlocation.
3. Remove rear storage compartment from wheelchair.
INSTALLING REAR SHROUD AND REAR
STORAGE COMPARTMENT.
4. Install the phillips screws and washers that secure the
side shroud to the wheelchair frame and tighten se-
curely. DONOTOVERTIGHTEN. RefertoFIGURE1
for phillips screw and washer locations.
1. Positionthetwo(2)1/4-turnboltswiththetwo(2)mount-
ing holes in the wheelchair frame.
2. Install rear storage compartment onto chair frame.
5. Repeat STEPS 1-4 for the opposite side of the wheel-
chair, if necessary.
3. Turn two (2) 1/4-turn bolts that secure the rear storage
compartment to the wheelchair frame CLOCKWISE.
6. Perform one (1) of the following:
4. Position rear shroud on the two (2) side shrouds and
slide towards the front of the wheelchair until it stops.
A. INTEGRATED SLING SEAT MODELS - Unfold
the wheelchair. Refer to TRANSPORTING
RANGERIIMWD-INTEGRATEDSLINGSEATS
in PROCEDURE 12 of this manual.
5. Press down on the rear shroud until the two (2) clips
secure the rear shroud to the two (2) side shrouds.
REMOVING SIDE SHROUDS.
B. CAPTAIN'S SEAT MODELS - Reinstall the
Captain's Seat onto the wheelchair. Refer to RE-
MOVING/INSTALLINGCAPTAIN'SSEATinPRO-
CEDURE 5 of this manual.
1. Removethefrontshroudfromthewheelchair. Referto
REMOVING/INSTALLING FRONT SHROUD in this
procedure of the manual.
33
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PROCEDURE 10
SHROUDS
C. WEIGHT SHIFT TILT MODELS - Proceed to
STEP 7.
8. Reinstall the front shroud onto the wheelchair. Refer
toREMOVING/INSTALLINGFRONTSHROUDinthis
procedure of the manual.
7. Reinstall the rear shroud and rear storage compart-
ment (if equipped) onto the wheelchair. Refer to RE-
MOVING/INSTALLINGREARSHROUDANDREAR
STORAGECOMPARTMENTinthisprocedureofthe
manual.
S
H
R
O
U
D
S
WHEELCHAIRS NOT EQUIPPED WITH WEIGHT SHIFT BASIC TILT
Rear Shroud
Side Shroud
Phillips Screws
Rear Storage
Compartment
Washers
Wheelchair
Frame
Side Shroud
1/4-Turn Bolts
Front Shroud
Phillips Bolts
Locknut
WHEELCHAIRS EQUIPPED WITH WEIGHT SHIFT BASIC TILT
Rear Shroud
Side Shroud
Washers
Wheelchair
Frame
Phillips Screws
Side Shroud
1/4-Turn Bolts
Front Shroud
Phillips Bolts
Locknut
FIGURE 1 - REMOVING/ INSTALLING SHROUDS - MWD WHEELCHAIRS
34
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SHROUDS
PROCEDURE 10
FWD Wheelchairs (FIGURE 2)
REMOVING SIDE SHROUDS AND FILLERS.
1. Remove the front shroud from the wheelchair. Refer
toREMOVING/INSTALLINGFRONTSHROUDinthis
procedure of the manual.
REMOVING FRONT SHROUD.
1. Unclip the retaining strap securing the front shroud
and battery box to the wheelchair.
2. Remove the rear shroud from the wheelchair. Refer
toREMOVING/INSTALLINGREARSHROUDinthis
procedure of the manual.
2. Feed the retaining strap through the front shroud.
3. Remove the front shroud from the wheelchair.
S
H
R
O
U
D
S
3. Perform one (1) of the following:
INSTALLING FRONT SHROUD.
1. Feed the retaining strap through the front shroud as
shown in FIGURE 2.
A. INTEGRATEDSLINGSEATMODELS-Foldthe
wheelchair. RefertoTRANSPORTINGRANGER
II FWD in PROCEDURE 12 of this manual.
2. Position the bottom of the front shroud between the
battery box and the battery tray.
B. CAPTAIN'S SEAT MODELS - Remove the
Captain's Seat from the wheelchair. Refer to RE-
MOVING/INSTALLINGCAPTAIN'SSEATinPRO-
CEDURE 5 of the owner's manual, part number
1080722.
3. Clip the retaining strap together.
4. Pull end of retaining strap to secure front battery box
and front shroud in place.
4. HIGH BACK CAPTAIN'S SEAT MODEL WHEEL-
CHAIRSONLY(DETAIL"A")-Removethephonojack
nut that secures the phono jack to the side shroud.
REMOVING REAR SHROUD.
1. Perform one (1) of the following:
5. Remove the phillips screws, bolts, washers and lock-
nuts that secure side shroud and filler to the wheel-
chairframe. RefertoFIGURE2 forphillipsscrewand
washer locations.
A. For 16,18, and 20-inch wide chairs:
l Unclip the retaining strap securing the rear
shroud and battery box to the wheelchair.
6. Remove side shroud and filler from the wheelchair.
l Feed the retaining strap through the rear
7. RepeatSTEPS5-6 fortheoppositesideofthewheel-
chair, if necessary.
shroud.
l Removetherearshroudfromthewheelchair.
INSTALLING SIDE SHROUDS AND FILLERS.
1. Positionsideshroudandfilleronthewheelchairframe.
B. For 14-inch wide chairs:
l Liftuponrearshroudandremovefromwheel-
2. Line up the mounting holes in the side shroud and
filler with the mounting holes in the wheelchair frame.
chair.
INSTALLING REAR SHROUD.
1. Perform one (1) of the following:
C AUTIO N
DO NO T o ve rtig hte n the p hillip s sc re ws
a n d p h illip s b o lt th a t se c u re th e sid e
sh ro u d to th e wh e e lc h a ir fra m e - o th -
e rwise d a m a g e to the sid e shro ud c a n
o c c u r.
A. For 16,18, and 20-inch wide chairs:
l Feed the retaining strap through the rear
shroud as shown in FIGURE 2.
l Clip the retaining strap together.
3. Install the phillips screws, bolts, washers and lock-
nutsthatsecurethesideshroudandfillertothewheel-
chair frame and tighten securely. DO NOT OVER-
TIGHTEN. Refer to FIGURE 2 for phillips screw, bolt,
washer and locknut locations.
l Press down on the rear shroud until the two
(2) clips secure the rear shroud to the two (2)
side shrouds.
l Pull end of retaining strap to secure rear bat-
4. RepeatSTEPS1-3 fortheoppositesideofthewheel-
chair, if necessary.
tery box and shroud in place.
B. For 14-inch wide chairs:
5. HIGH BACK CAPTAIN'S SEAT MODEL WHEEL-
CHAIRS ONLY - If necessary, perform the following:
l Algin clips of rear shroud with tabs on side
shrouds.
A. Position the phono jack on the side shroud.
l Press down on rear shroud until the two clips
andduallockfastenersecuretherearshroud
in place.
B. Reinstall the phono jack nut onto the phono jack
and tighten securely.
35
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PROCEDURE 10
SHROUDS
7. Reinstall the rear shroud onto the wheelchair. Refer
toREMOVING/INSTALLINGREARSHROUDinthis
procedure of the manual.
6. Perform one (1) of the following:
A. INTEGRATED SLING SEAT MODELS - Unfold
the wheelchair. Refer to TRANSPORTING
RANGER II FWD in PROCEDURE 12 of this
manual.
8. Reinstall the front shroud onto the wheelchair. Refer
toREMOVING/INSTALLINGFRONTSHROUDinthis
procedure of the manual.
S
H
R
O
U
D
S
B. CAPTAIN'S SEAT MODELS - Reinstall the
Captain's Seat onto the wheelchair. Refer to RE-
MOVING/INSTALLINGCAPTAIN'SSEATinPRO-
CEDURE 5 of the owner's manual, part number
1080722.
Rear Shroud
14-inch wide chairs.
Pull this end of
retaining strap to
Clip
secure battery
box in place
Locknut
Phillips Screws
Clip
Phillips Screws
Side Shroud
Retaining
Strap
Rear Shroud
16,18,20-inch
wide chairs.
Washers
Wheelchair
Frame
Battery Charger
Cover
Phillips Bolts
Phono Jack
Nut
Retaining Strap
Pull this end of
retaining strap to
secure battery
box in place
Filler
Side
Shroud
Battery Box
Phono Jack
Battery Tray
Front Shroud
DETAIL "A"
FIGURE 2 - REMOVING/ INSTALLING SHROUDS - FWD WHEELCHAIRS
36
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CROSSBRACES
PROCEDURE 11
6. Cut the tie wraps that secure the wiring harness to
the crossbrace.
This Procedure Includes the Following:
Adjusting Seat Width - Integrated Sling Seats
Replacing Crossbraces - Captain's Seats
7. Removethehexbolts, washersandlocknutsthatse-
cure the bottom of the two (2) crossbraces to the
wheelchair frame.
C
R
O
S
S
B
R
A
C
E
S
WARNING
8. Remove the hex bolt, coved spacers, washers and
locknut that secure the two (2) existing crossbraces
together.
Afte r ANY a d justm e nts, re p a ir o r se rvic e
a nd BEFORE use , m a ke sure a ll a tta c hing
ha rd wa re is tig hte ne d se c ure ly - o the r-
wise injury or d a m a g e m a y re sult.
NOTE: Note coved spacer, washer and locknut order for
reinstallation.
9. Removethefour(4)pivottubeplugpinsfromthebot-
tom of the two (2) existing crossbraces.
ADJ USTING SEAT WIDTH -
INTEGRATED SLING SEATS
(FIGURE 1)
10. Install the four (4) pivot tube plug pins into the bottom
of the two (2) new crossbraces.
11. Assemble the two (2) new crossbraces together. Re-
fer to DETAIL "A" in FIGURE 1 for hardware orienta-
tion.
1. If necessary remove the shrouds. Refer to REMOV-
ING/INSTALLINGSHROUDSinPROCEDURE10of
this manual.
NOTE: FWD wheelchairs only - There are right and left
crossbraces. Refer to DETAIL "B" in FIGURE 1.
2. Perform one (1) of the following:
FWD WHEELCHAIRS -
12. Reinstall the hex bolts, washers and locknuts that se-
cure the bottom of the two (2) new crossbraces to
the wheelchair frame and tighten securely.
A. Remove the battery boxes from the wheelchair.
INSTALLING/REMOVINGBATTERYBOXESin
PROCEDURE 13 of this manual.
13. Reinstall the hex bolts and locknuts that secure the
new/existing pivot links to the wheelchair frame and
crossbraces and tighten.
B. Foldthebatterytray.RefertoFOLDINGBATTERY
TRAY FOR TRANSPORT in PROCEDURE 13
of this manual.
NOTE: Seat widths are stamped on the pivot links.
MWD WHEELCHAIRS -
14. Secure wiring harness to the new crossbraces with
new tie wraps.
A. Remove the battery boxes from the wheelchair.
INSTALLING/REMOVING BATTERY BOXES
in PROCEDURE 14 of this manual.
15. Reinstall the black dust covers onto the bottom of the
crossbraces.
B. Remove the battery tray from the wheelchair.
Refer to INSTALLING/REMOVING BATTERY 16. Install the new back and seat upholstery onto the
TRAY in PROCEDURE 14 of this manual.
wheelchair. Refer to REPLACING BACK UPHOL-
STERY in PROCEDURE 5 of this manual and RE-
PLACING SEAT UPHOLSTERY in PROCEDURE
5 of the owner's manual, part number 1080722.
3. Remove the existing back and seat upholstery from the
wheelchair. Refer to REPLACING BACK UPHOL-
STERY in PROCEDURE 5 of this manual and RE-
PLACING SEAT UPHOLSTERY in PROCEDURE 5 17. Change the width of the battery tray. Refer to one (1)
of the owner's manual, part number 1080722.
of the following:
NOTE:Ifadjustingtheseatwidthofthewheelchair, theback
and seat upholstery MUST be changed as well.
FWD WHEELCHAIRS - CHANGING WIDTH OF
BATTERYTRAYinPROCEDURE13ofthismanual.
4. Remove the hex bolts and locknuts that secure the two
(2) pivot links to the wheelchair frame and crossbraces.
Refertothefollowingcharttodetermineifnewpivotlinks
willbeneeded:
MWD WHEELCHAIRS - CHANGING WIDTH OF
BATTERYTRAYinPROCEDURE14ofthismanual.
18. Perform one (1) of the following:
FWD WHEELCHAIRS -
PIVOT LINK SEAT WIDTH RANGE (in inc he s)
A. Unfold the battery tray. Refer to FOLDING BAT-
TERY TRAY FOR USE in PROCEDURE 13 of
this manual.
16-18 or 20
5. Remove the dust covers from the bottom of the cross-
braces.
B. Reinstall the battery boxes onto the wheelchair.
INSTALLING/REMOVINGBATTERYBOXESin
PROCEDURE 13 of this manual.
NOTE: Note position of the tie wraps that secure the wir-
ing harness to the crossbraces.
37
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PROCEDURE 11
CROSSBRACES
MWD WHEELCHAIRS -
19. If necessary, reinstall the shrouds. Refer to REMOV-
ING/INSTALLINGSHROUDSinPROCEDURE10of
this manual.
A. Reinstallthebatterytrayontothewheelchair. Re-
fertoINSTALLING/REMOVINGBATTERYTRAY
in PROCEDURE 14 of this manual.
C
R
O
S
S
B
R
A
C
E
S
B. Reinstall the battery boxes onto the wheelchair.
INSTALLING/REMOVINGBATTERYBOXESin
PROCEDURE 14 of this manual.
Locknut
(STEPS
7, 12)
Crossbrace
Hex Bolt
(STEPS
4, 13)
Wheelchair Frame
Locknut
(STEPS 4, 13)
Washer (STEPS 7, 12)
Hex Bolts (STEPS 7, 12)
Black Dust Cover (STEPS 5, 15)
Pivot Tube Plug Pin (STEPS 9, 10)
Pivot Link
Hex Bolts (STEPS 4, 13)
Locknut (STEPS 4, 13)
DETAIL "B" - FWD WHEELCHAIRS
O NLY
RIG HT
LEFT
Tie Wraps (STEPS 6, 14)
NOTE: Right and left is determined by sit-
tinginthewheelchair.
DETAIL "A" - (STEPS 8, 11)
MWD WHEELCHAIRS
FWD WHEELCHAIRS
Front of
Wheelchair
Front of Wheelchair
Note orientation of hex bolt, washers, coved washers and locknut for installation of new crossbraces.
FIGURE 1 - ADJUSTING SEAT WIDTH - INTEGRATED SLING SEAT S
38
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CROSSBRACES
PROCEDURE 11
11. Install the four (4) pivot tube plug pins into the bottom
of the two (2) new crossbraces.
REPLACING CROSSBRACES -
CAPTAIN'S SEATS (FIGURE 2)
12. Assemble the two (2) new crossbraces together. Refer
toDETAIL"C"inFIGURE2 forhardwareorientation.
1. Remove the captain's seat from the wheelchair. Refer
toREMOVING/INSTALLINGCAPTAIN'SSEATinPRO-
CEDURE 5 of the owner's manual, part number
1080722.
C
R
O
S
S
B
R
A
C
E
S
13. Reinstall the hex bolts, washers and locknuts that se-
cure the bottom of the two (2) new crossbraces to the
wheelchair frame and tighten.
2. Removetheshrouds.RefertoREMOVING/INSTALL-
ING SHROUDS in PROCEDURE 10 of this manual.
14. Secure the wiring harness to the new crossbraces with
new tie wraps.
3. Perform one (1) of the following:
15. Reinstall the dust covers onto the bottom of the new
crossbraces.
FWD WHEELCHAIRS -
A. Remove the battery boxes from the wheelchair.
INSTALLING/REMOVINGBATTERYBOXESin
PROCEDURE 13 of this manual.
16. Reinstall the hex bolts, spacers, washers and locknuts
thatsecurethe(2)pushbracketstothenewcrossbraces
andtightensecurely.
B. Foldthebatterytray.RefertoFOLDINGBATTERY
TRAY FOR TRANSPORT in PROCEDURE 13
of this manual.
17. Reinstall the hex bolts, washers and locknuts that se-
cure the pivot links to the crossbraces and tighten se-
curely.
MWD WHEELCHAIRS -
A. Remove the battery boxes from the wheelchair.
INSTALLING/REMOVINGBATTERYBOXESin
PROCEDURE 14 of this manual.
18. Perform one (1) of the following:
FWD WHEELCHAIRS -
B. Removethebatterytrayfromthewheelchair.Refer
toINSTALLING/REMOVINGBATTERYTRAYin
PROCEDURE 14 of this manual.
A. Unfold the battery tray. Refer to FOLDING BAT-
TERY TRAY FOR USE in PROCEDURE 13 of
this manual.
4. Remove the hex bolts and locknuts that secure the
two (2) pivot links to the existing crossbraces.
B. Reinstall the battery boxes onto the wheelchair.
INSTALLING/REMOVINGBATTERYBOXESin
PROCEDURE 13 of this manual.
5. Remove the hex bolts, spacers, washers and locknuts
that secure the two (2) push brackets to the existing
crossbraces.
MWD WHEELCHAIRS -
A. Reinstallthebatterytrayontothewheelchair. Re-
fertoINSTALLING/REMOVINGBATTERYTRAY
in PROCEDURE 14 of this manual.
6. Removethedustcoversfromthebottomoftheexisting
crossbraces.
NOTE: Note position of the tie wraps that secure the wiring
harness to the existing crossbraces.
B. Reinstall the battery boxes onto the wheelchair.
INSTALLING/REMOVINGBATTERYBOXESin
PROCEDURE 14 of this manual.
7. Cut the tie wraps that secure the wiring harness to the
existing crossbrace.
19. Reinstallshrouds. RefertoREMOVING/INSTALLING
SHROUDS in PROCEDURE 10 of this manual.
8. Remove the hex bolts, washers and locknuts that se-
cure the bottom of the two (2) existing crossbraces to
the wheelchair frame.
20. Reinstall the Captain's seat. Refer to REMOVING/IN-
STALLING CAPTAIN'S SEAT in PROCEDURE 5 of
the owner's manual, part number 1080722.
9. Removethehexbolt,covedspacers,washersandlock-
nutthatsecurethetwo(2)existingcrossbracestogether.
NOTE: Note coved spacer, washer and locknut order for
reinstallation.
10. Removethefour(4)pivottubeplugpinsfromthebot-
tom of the two (2) existing crossbraces.
39
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PROCEDURE 11
CROSSBRACES
Hex Bolt
(STEPS 4, 17)
Wheelchair Frame
Dust Cover (STEPS 6, 15)
Washer
(STEPS 5, 16)
Pivot Link
C
R
O
S
S
B
R
A
C
E
S
Locknut (STEPS 8, 13)
Spacer (STEPS 8, 13)
Hex Bolts
(STEPS 5, 16)
Hex Bolts
(STEPS 5, 16)
Push Bracket
Crossbrace
Hex Bolts
(STEPS 8, 13)
Locknut
(STEPS 5, 16)
Pivot Tube Plug Pin (STEPS 10, 11)
Spacer
(STEPS 5, 16)
Locknut
(STEPS 4, 17)
Tie Wraps (STEPS 7, 14)
DETAIL "A" - (STEPS 9, 12)
MWD WHEELCHAIRS
FWD WHEELCHAIRS
Front of
Wheelchair
Front of
Wheelchair
Note orientation of hex bolt, washers, coved washers and locknut for installation of new crossbraces.
FIGURE 2 - REPLACING CROSSBRACES - CAPTAIN'S SEATS
40
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BATTERIES
PROCEDURE 12
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.
This Procedure includes the following:
Installing/Removing Batteries into/From Battery
Boxes
Connecting Battery Cables
B
A
T
T
E
R
I
1. If necessary, remove the battery boxes from the
wheelchair. RefertoINSTALLING/REMOVINGBAT-
TERY BOXES in PROCEDURE 13 - FWD or PRO-
CEDURE 14 - MWD of this manual.
WARNING
Ma ke sure powe r to the whe e lc ha ir is OFF be -
fore pe rforming this proc e dure .
The use of rubber gloves a nd sa fety gla sses is rec-
omme nde d whe n working with ba tte rie s.
2. Secure the battery lifting strap to battery terminal(s)/
post(s) (FIGURE 1).
Inva c a re strongly re c omme nds tha t ba tte ry in-
sta lla tion a nd ba tte ry re pla c e me nt ALWAYS be
done by a qua lifie d te c hnic ia n.
CAUTION
E
S
Some ba ttery ma nufa cturersmold a ca rrying stra p
a nd/or hold down fla nges directly into the ba t-
tery c a se . Ba tte rie s whic h inte rfe re with the ba t-
te ry box c a nnot be use d for the se a pplic a tions.
Attempting to “wedge” a ba ttery into a ba ttery
box ma y da ma ge the box a nd/or the ba ttery.
Afte r ANY a djustme nts, re pa ir or se rvic e a nd BE-
FORE use , ma ke sure a ll a tta c hing ha rdwa re is
tighte ne d se c ure ly - othe rwise injury or da ma ge
ma y re sult.
NOTE: For changing or removing/installing the bat-
tery boxes, refer to PROCEDURE 13 - FWD wheel-
chairs or PROCEDURE 14 - MWD wheelchairs.
3. Place batteries into battery box bottom.
Battery Lifting Strap
Molded Carrying Strap
Or Hold Down Flanges
INSTALLING/ REMOVING
BATTERIES INTO/ FROM BATTERY
BOXES (FIGURE 1)
NOTE:Toremovethebattery(ies)fromthebatterybox(es),
reverse the following procedure.
NOTE: Have the following tools available:
Battery
TOOL
QTY
COMMENTS
Battery Lifting Strap
1
1
1
1
1
See Note
Group 22 ONLY
1/2-inch (6 pt) Box Wrench
7/16-inch (6pt) Box Wrench
3/8-inch (6pt) Box Wrench
Diagonal Cutters
Not Supplied
Not Supplied
Not Supplied
Not Supplied
Battery Terminal(s)/Post(s)
U1 Battery Box
Bottom
*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 removal/installation.
22 NF Battery
Box Bottom
WARNING
ALWAYS use a ba tte ry lifting stra p whe n lifting a
ba tte ry. It is the most c onve nie nt me thod a nd
a ssure s tha t the ba tte ry a c id will not spill. It a lso
he lps to prolong the life of the ba tte ry.
FIGURE 1 - INSTALLING/REMOVING BATTERIES INTO/
FROM BATTERY BOXES
DO NOT tip the ba tte rie s. Ke e p the ba tte rie s in
a n upright position.
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. Be-
fore reinstalling the NEW or existing battery(ies), clean
the baking soda from the battery box(es) or battery(ies).
41
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PROCEDURE 12
BATTERIES
CONNECTING BATTERY CABLES
CAUTION
Whe n c onne c ting the ba tte ry c a ble s to the
ba tte ry(ie s), the ba tte ry c a ble (s) MUST be c on-
ne c te d to the b a tte ry te rm ina l(s)/ p ost(s) a s
shown in DETAIL “A” or DETAIL “B” of FIGURE 3
(de pe nding on ba tte ry type ), othe rwise da m-
a ge to the ba tte ry c a ble ma y re sult whe n in-
sta lling ba tte ry te rmina l c a ps.
WARNING
NEVER a llow a ny of your tools a nd/or ba tte ry
cable(s)to contactBOTHbattery terminal(s)/post(s)
a t the sa me time. An electrica l short ma y occur
a nd serious persona l injury or da ma ge ma y occur.
B
A
T
T
E
R
I
The use of rubber gloves a nd sa fety gla sses is rec-
omme nde d whe n working with ba tte rie s.
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):
Dual U1 or Dual Group 22 Battery Boxes
Perform one (1) of the following methods for connecting
the battery cable(s):
A. NEGATIVE (-) BLACK battery cable to NEGA-
TIVE (-) battery terminal/post.
E
S
A. FOR DUAL U1 BATTERIES - Use direct mount
B. POSITIVE (+) RED battery cable to POSITIVE
(+) battery terminal/post.
method. Refer to FIGURES 2, and 3.
B. FOR DUAL GROUP 22 NF BATTERIES THAT
HAVE MOUNTING HOLES IN THE BATTERY
TERMINAL(S)/POST(S) - Use direct mount
method. Refer to FIGURES 2, 3 AND 4.
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 “A” or DETAIL
“B”of FIGURE 3, depending on battery type).
C. FOR DUAL GROUP 22 NF BATTERIES THAT
DO NOT HAVE MOUNTING HOLES IN THE
BATTERYTERMINAL(S)/POST(S)-Usebattery
clamp method. Refer to FIGURES 4, 5 AND 6.
4. Verifyallbatterycable(s)/ringterminal(s)arecorrectly
installed and securely tightened.
DIRECT MOUNT METHOD (FIGURE 2 AND 3).
1. Install battery terminal cap(s) onto battery cable(s) as
follows (FIGURE 2):
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).
DUAL U1 BATTERIES:
A. ORANGE battery terminal cap onto RED bat-
tery cable.
NOTE: It will benecessary to trim excess tie-wrap in order to
install the battery box top(s).
B. GRAY battery terminal cap onto BLACK battery
cable.
7. Install the battery box top(s).
8. Install the battery box(es) into the wheelchair. Refer
to INSTALLING/REMOVINGBATTERYBOX(ES) in
the PROCEDURE 13 - FWD MODELS or PROCE-
DURE 14 - MWD MODELS of this manual.
DUAL GROUP 22 NF BATTERIES:
A. REDbatteryterminalcaponto REDbatterycable.
B. BLACK battery terminal cap onto BLACK bat-
tery cable.
NOTE: New Battery(ies) MUST be fully charged BE-
FORE using, otherwise the life of the battery(ies) will be
reduced.
INSTALLING BATTERY TERMINAL CAPS
9. If necessary, charge the battery(ies). Refer to
CHARGING BATTERIES in the PROCEDURE 13 -
FWD MODELS or PROCEDURE 14 - MWD MOD-
ELS of this manual.
Battery Cable
Battery Terminal
Cap
NOTE:Onlyone(1)batterycableandterminalcapshown
for clarity. Both caps install in the same manner.
FIGURE 2 - CONNECTING BATTERY CABLES -
DIRECT MOUNT METHOD
42
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BATTERIES
PROCEDURE 12
DETAIL “A”
DETAIL “B”
DUAL U1 BATTERIES
DUAL GROUP 22 NF BATTERIES
POSITIVE (+) Battery Terminal/Post
1/4-20 x 7/8-Inch
Hex Flange Screw
Negative (-)
Battery Terminal/
Post
1/4-20 x 7/8-Inch
Hex Flange Screw
POSITIVE (+) Red
Battery Cable
B
A
T
T
E
R
I
1/4-20
Hex
Flange
Locknut
1/4-20
Hex
Flange
Locknut
U
Bat
E
S
Group 22NF
Battery
NEGATIVE (-)
Black Battery
Cable
Positive (+) Battery
Terminal/Post
NEGATIVE (-) Battery
Terminal/Post
CONNECT BATTERY
CABLE TO BATTERY
TERMINAL AS SHOWN.
CONNECT
BATTERY
CABLE(S) RING
TERMINAL(S) TO
THIS SIDE OF
BATTERY
TERMINAL(S)/
POST(S)
DUAL U1 BATTERIES
DUAL GROUP 22 NF BATTERIES
Gray
Battery
Terminal
Cap
POSITIVE
RED
Battery
Terminal
Cap
NEGATIVE
(-) Battery
Terminal/
Post
NEGATIVE
(+) Battery
Terminal/
Post
POSITIVE
(+) Battery
Terminal/
Post
(-) Battery
Terminal/
Post
Tie-
Wrap
Tie-
Wrap
Tie-
Wrap
Tie-
Wrap
U-1
Battery
Orange Battery
Terminal Cap
BLACK BatteryTerminal
Cap
Group 22 NF
Battery
FIGURE 3 - CONNECTING BATTERY CABLES - DIRECT MOUNT METHOD
43
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PROCEDURE 12
BATTERIES
BATTERY CLAMP METHOD (FIGURES 4, 5
AND 6).
2. Install battery clamp covers onto battery cables as
follows (FIGURE 5):
WARNING
A. REDbatteryclampcoverontoREDbatterycable.
The ba tte ry c la mp of the POSITIVE (+) ba tte ry
te rmina l/ post MUST be mounte d in the posi-
tion shown in FIGURE 5, othe rwise the ba tte ry
box top c a nnot be insta lle d prope rly.
B. BLACK battery clamp cover onto BLACK bat-
tery cable.
B
A
T
T
E
R
I
NOTE:Onlyone(1)batterycableandbatteryclampcover
are shown for clarity. Both battery clamp covers install in
the same manner.
1. Perform one (1) of the following:
A. If the battery clamp of the POSITIVE (+) battery
terminal/post is NOT mounted in the orientation
shown in FIGURE 5, perform the following:
INSTALLING BATTERY CLAMP COVERS
Battery Clamp
Battery Cable
Cover
E
S
✪ Loosen the hex nut that secures the battery
clamptothePOSITIVE(+)batteryterminal/post.
CAUTION
Whe n tig hte ning the c la m p s, a lwa ys
use a box wre nc h. Plie rs will “round off”
the nuts. NEVER wig g le the b a tte ry
te rmina l(s)/ post(s) whe n tighte ning. The
ba tte ry ma y be c ome da ma ge d.
FIGURE 5 - CONNECTING BATTERY CABLES -
BATTERY CLAMP METHOD
CAUTION
When connecting the batterycable/ring terminal(s)
to the ba ttery(ies) cla mp(s), the ba ttery ca ble(s)
MUST be connected in the position shown in DETAIL
“A”, otherwise da ma ge ma y occur to the ba ttery
ca ble a nd/or ba ttery cla mp covers.
✪ Remove the battery clamp from the POSI-
TIVE (+) battery terminal/post.
✪ Reposition the battery clamp on the POSI-
TIVE (+) battery terminal/post as shown in
FIGURE 4.
3. Connect battery cable(s) to battery(ies) terminal(s)/
post(s) as follows (DETAIL “A”):
✪ Securely tighten the hex nut that secures
the battery clamp to the positive (+) battery
terminal/post.
A. NEGATIVE (-) BLACK battery cable/ring termi-
nal between the mounting plate and battery
clamp of NEGATIVE (-) battery terminal/post.
B. If the battery clamp on the POSITIVE (+) battery
terminal/post is positioned as shown in FIGURE
4, proceed to STEP 2.
B. POSITIVE(+)REDbatterycable/ringterminalbe-
tween the mounting plate and battery clamp bat-
tery clamp of POSITIVE (+) battery terminal/post.
CORRECT ORIENTATION OF THE POSITIVE (+)
BATTERY TERMINAL/POST BATTERY CLAMP
4. Secure the battery cable(s)/ring terminal(s) to the battery
clamp(s), BLACK to NEGATIVE (-) and RED to POSI-
TIVE (+), with exisitng hex screws. Securely Tighten.
(DETAIL “A”)
POSITIVE (+) Battery Terminal/Post
(Note position of battery clamp)
NEGATIVE (-) Battery
Terminal/Post and Battery Clamp
5. Verify battery cable ring terminal(s) are correctly installed
and securely tightened.
Hex
Nut
6. Slidebatteryclampcoversdownbatterycablesandonto
battery terminals. (DETAIL “B”)
7. Secure each terminal cap in place with a tie-wrap (Use
tie-wraps 11-1/2-inches long). (DETAIL “B”)
NOTE: It will benecessary to trim excess tie-wrap in order to
install the battery box top(s).
Group 22NF
Battery
8. Install the battery box top(s).
FIGURE 4 - CONNECTING BATTERY CABLES -
BATTERY CLAMP METHOD
44
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BATTERIES
PROCEDURE 12
9. Install the battery box(es) into the wheelchair. Refer 10. If necessary, charge the battery(ies). Refer to
toINSTALLING/REMOVINGBATTERYBOX(ES) in
the PROCEDURE 13 - FWD MODELS or PROCE-
DURE 14 - MWD MODELS of this manual.
CHARGING BATTERIES in the PROCEDURE 13 -
FWD MODELS or PROCEDURE 14 - MWD MOD-
ELS of this manual.
NOTE:NewBattery(ies)MUSTbefullychargedBEFORE
using, otherwise the life of the battery(ies) will be reduced.
B
A
T
T
E
R
I
CONNECTING BATTERY CABLE(S) TO BATTERY(IES) TERMINAL(S)/POST(S)
POSITIVE (+) Battery Terminal/
Post and Battery Clamp
NEGATIVE (-) Battery Terminal/
Post and Battery Clamp
Fuse Box placement
when box top
is installed
Negative (-) BLACK
Battery Cable
E
S
Positive (+) RED
Battery Cable
TOP VIEW
Group 22NF Battery
Fuse
Box
DETAIL "A"
Positive (+) RED
Battery Cable
Hex Screw
Mounting Plate
Battery Clamp
EXPLODED
Negative (-) BLACK
Battery Cable
VIEW
POSITIVE (+) Battery
Terminal/Post
Group 22NF Battery
NEGATIVE (-) Battery Terminal/Post
NOTE: Battery clamps exploded away for clarification purposes only.
DETAIL “B”
RED Battery Clamp Cover
POSITIVE (+) Battery
Terminal/Post
NEGATIVE (-) Battery
Terminal/Post
Tie-Wrap
Tie-Wrap
BLACK Battery Clamp Cover
FIGURE 6 - CONNECTING BATTERY CABLES - BATTERY CLAMP METHOD
Group 22NF Battery
45
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PROCEDURE 13
FWD WHEELCHAIRS
ASSEMBLING RANGER II FWD-
This Procedure Includes the Following:
Assembling Ranger II FWD
When to Charge Batteries
Charging Batteries
Integrated Sling Seats (FIGURE 1)
F
W
D
WARNING
The weight of the wheelcha ir without the user a nd
ba tteries is still between 83 a nd 100 lbs. Use proper
lifting techniques (lift with your legs) to a void injury.
Extreme ca ution is a dvised when it is necessa ry to
move a n UNOCCUPIED power wheelcha ir. Inva c-
a re recommendsusing two (2)a ssista ntsa nd ma k-
ing thorough prepa ra tions. Ma ke sure to use ONLY
secure, non-deta cha ble pa rts for ha nd-hold sup-
ports.
Replacing Batteries
W
H
E
E
L
Installing/Removing Battery Boxes
Battery Tray
Replacing Wiring Harness
Repositioning Motors
C
H
A
I
R
S
Replacing Clutch Handles - R2BASIC
Replacing Motor/Gearbox - R2BASIC
Replacing Motor/Gearbox - R2STANDARD
Keep ha nds a nd fingers clea r of moving pa rts to
a void injury.
The overa ll performa nce of the wheelcha ir WILL
be a ffected by the front wheel mounting posi-
tion. Re fe r to REPOSITIONING MOTORS - FWD
WHEELCHAIRS in this procedure of the ma nua l
BEFORE opera ting the wheelcha ir.
WARNING
Afte r ANY a djustme nts, re pa ir or se rvic e a nd BE-
FORE use , ma ke sure a ll a tta c hing ha rdwa re is
tighte ne d se c ure ly - othe rwise injury or da ma ge
ma y re sult.
UNFOLDING THE WHEELCHAIR.
1. Push down on the seat rails until the seat rails are
positioned in the seat guides.
2. Assemble the wheelchair. Refer to FIGURE 1.
FOLDING THE WHEELCHAIR.
1. Remove the batteries and footrests/legrests from the
wheelchair. Refer to FIGURE 1.
2. Lift the battery tray UP and out of the way. Refer to
FIGURE 1.
Install the electronics. Refer to
PREPARINGMKIVJOYSTICK
FOR USE in PROCEDURE 7
of this manual.
3. Lift up on the seat rails of the wheelchair.
Install the footrests/legrests. Refer to
INSTALLING/REMOVING FOOT-
RESTS or INSTALLING ELEVAT-
ING LEGRESTS in PROCEDURE
3of the owner's manual, part num-
ber 1080722.
Seat
Rails
Seat
Guides
Determine the proper motor
mounting position. Refer to RE-
POSITIONING MOTORS -
FWDWHEELCHAIRSONLYin
this procedure of the manual.
Position the battery tray for use. Re-
fer to BATTERY TRAY in this pro-
cedure of the manual.
Installthebatteries. Referto INSTALL-
ING/REMOVING BATTERY BOXES
in this procedure of the manual.
FIGURE 1 - ASSEMBLING RANGER II FWD- INTEGRATED SLING SEATS
46
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FWD WHEELCHAIRS
PROCEDURE 13
Unfolding/ Folding - Captain's Seat (FIGURE 2) FOLDING.
1. HIGH BACK CAPTAIN'S SEATS ONLY - Discon-
nect the limit switch. Refer to DISCONNECTING/
CONNECTING LIMIT SWITCH in PROCEDURE 6
of this manual.
UNFOLDING.
F
W
D
1. Push down on the push brackets until they are flush
with the pivot links on the crossbraces.
2. Assemble the wheelchair. Refer to FIGURE 2.
2. Remove the Captain's Seat. Refer to REMOVING/
INSTALLING CAPTAIN'S SEATin PROCEDURE 5
of this manual.
W
H
E
E
L
C
H
A
I
3. Install the shrouds. Refer to REMOVING/INSTALL-
ING SHROUDS in PROCEDURE 9 of this manual.
4. Install the Captain's Seat. Refer to REMOVING/IN- 3. Removetheshrouds.RefertoREMOVING/INSTALL-
STALLING CAPTAIN'S SEATin PROCEDURE 5 of
this manual.
ING SHROUDS in PROCEDURE 9 of this manual.
4. Remove the batteries, battery tray and footrests/leg-
rests from the wheelchair. Refer to FIGURE 2.
5. HIGH BACK CAPTAIN'S SEATS ONLY - Connect
the limit switch. Refer to DISCONNECTING/CON-
NECTINGLIMITSWITCHinPROCEDURE6ofthis
manual.
5. Lift up on push brackets located on the crossbraces.
R
S
Install the electronics. Refer to
PREPARINGMKIVJOYSTICK
FOR USE in PROCEDURE 7
of this manual.
Determine the proper mo-
tor mounting position. Re-
fer to REPOSITIONING
MOTORS - in this proce-
dure of the manual.
Install the footrests/legrests. Refer to
INSTALLING/REMOVING FOOT-
RESTS or INSTALLING ELEVAT-
ING LEGRESTS in PROCEDURE
3of the owner's manual, part num-
ber 1080722.
Push Brackets
Position the battery tray for use. Re-
fer to BATTERY TRAY in this pro-
cedure of the manual.
Crossbraces
Installthebatteries. Referto INSTALL-
ING/REMOVING BATTERY BOXES
in PROCEDURE 10 of this manual.
FIGURE 2 - TRANSPORTING RANGER II FWD - CAPTAIN'S SEATS
47
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PROCEDURE 13
FWD WHEELCHAIRS
WHEN TO CHARGE BATTERIES
(FIGURE 5)
CHARGING BATTERIES (FIGURE 6)
F
W
D
WARNING
NOTE: As a general rule, batteries should be recharged
daily to assure longest possible life and minimize required
charging time. In fact, a battery’s life is extended if the
charge level is maintained well above a low condition.
Plan to recharge batteries when it is anticipated wheel-
chair will not be used for a long period of time.
Ne ve r a tte mpt to re c ha rge the ba tte rie s by a t-
ta c hing c a ble s dire c tly to the ba tte ry te rmina ls
or c la mps. Alwa ys use the re c ha rging plug lo-
c a te d on the side of the whe e lc ha ir fra me .
W
H
E
E
L
C
H
A
I
DO NOT a tte mpt to re c ha rge the ba tte rie s a nd
ope ra te the powe r whe e lc ha ir a t the sa me time .
MCC-MKIV X, A or A+ J oystick
During use a nd c ha rging, unse a le d ba tte rie s will
ve nt hydroge n ga s whic h is e xplosive in the right
c onc e ntra tion with a ir.
BATTERY GAUGE DISPLAY (BGD) is the bar graph
display located on the MKIV X, A or A+ joystick. It will keep
you informed as to power availability. A visual warning is
given before the power becomes too low to operate the
wheelchair. At full charge the two (2) LEFT segments and
the farthest RIGHT segment of the bar graph will be
illuminated. As the battery becomes discharged, the
farthest RIGHT segment will progressively move to the
LEFTuntilonlythelasttwo(2)bars(LEFT)areilluminated.
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.
CAUTION
Alwa ys c ha rge ne w ba tte rie s fully BEFORE initia l
use or ba tte ry life will be re duc e d.
R
S
NOTE: As a general rule, batteries should be recharged
dailytoassurelongestpossiblelifeandminimizerequired
charging time. In fact, a battery’s life is extended if the
charge level is maintained well above a low condition.
Plan to recharge batteries when it is anticipated wheel-
chair will not be used for a long period of time.
MKIV RII J oystick
The range per battery charge using recommended batte-
ries should be approximately 5 to 9 hours of typical
operation. Extensive use on inclines may substantially
reduce per charge mileage.
BATTERY DISCHARGE INDICATOR (BDI) is located
at the rear of the joystick housing and provides informa-
tion on the remaining charge in the batteries. At FULL
charge the BDI will be GREEN. As the battery becomes
discharged, the BDI indicator will turn AMBER (YEL-
LOW), then RED and finally FLASHING RED. If the BDI
is FLASHING RED, the user should charge the batteries
as soon as possible.
Description and Use of Battery Chargers
The charger automatically reduces the charge from an
initially high rate to a zero reading at a fully charged condi-
tion. If left unattended, the charger should automatically
shut-off when full charge is obtained.
NOTE: Accurate readings are displayed when in neu-
tral.
There are some basic concepts which will help you
understand this automatic process:
Battery Gauge
Display
Battery Discharge
Indicator
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, as indicated by the green light on the char-
ger. Initially, the green light will stay illuminated for a short
period of time followed by a longer period of off time. As
a charge builds up, the charge rate is reduced, and the
green light will stay illuminated for a longer period of time
followed by a shorter off time.
MKIV X, A OR A+
JOYSTICK
NOTE: MKIV X Shown.
MKIV- RII
JOYSTICK
FIGURE 5 - WHEN TO CHARGE BATTERIES
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.
48
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FWD WHEELCHAIRS
PROCEDURE 13
Required Item s:
Recom m ended Battery Types
TOOL
QUANTITY
COMMENTS
WARNING
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Battery Charger
✪ Extension Cord
1
1
Supplied
Not Supplied
Only de e p c yc le , se a le d c a se c onstruc tion
ba tte rie s should be use d in this de vic e .
✪ 3-prong plug, 15 ampere current rating; industrial type
CAUTION
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Fa ilure to use the c orre c t ba tte ry size a nd/or volt-
a ge ma y c a use da ma ge to your whe e lc ha ir
a nd give you unsa tisfa c tory pe rforma nc e .
1. Attach the battery charger connector to the charger
cable/battery harness.
2. Plug the charger’s AC power cord, or extension, into
CHAIR SEAT
WIDTH
QTY VOLTS
BATTERY
SIZE
REMARKS
the grounded 120 VAC wall outlet.
3. Wait until charging is complete.
14-inch
16,18, 20-inches
2
2
12
12
U1
22NF
Deep Cycle
Deep Cycle
NOTE: Allow eight (8) hours for normal charging. Larger
batteries (greater than 55 ampere-hours) or severely dis-
charged batteries may require up to sixteen (16) hours
to be properly charged and equalized. If the charger op-
erates for sixteen (16) hours and is unable to fully charge
the batteries, an internal timer turns the charger off and
begins to fast blink the green light.
1. Remove the battery boxes from the wheelchair. Re-
fer to REMOVING/INSTALLING BATTERY BOXES
in this procedure of the manual.
R
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2. Remove existing batteries from the battery boxes. Refer
toINSTALLING/REMOVINGBATTERIESINTO/FROM
BATTERY BOXES in this procedure of the manual.
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 authorized dealer for service.
3. Clean the new battery terminals.
4. Install the new batteries into the battery boxes. Refer
to INSTALLING/REMOVING BATTERIES INTO/
FROM BATTERY BOXES in this procedure of the
manual.
Battery Charger
Connector (on side
of Wheelchair)
Cleaning Battery Term inals
WARNING
DO NOT a llow the liquid in the ba tte ry to c ome
in c onta c t with skin, c lothe s or othe r posse ssions.
It is a form of a c id a nd ha rmful or da ma ging
burns ma y re sult. Should the liquid touc h your
skin, wa sh the a re a imme dia te ly a nd thoroughly
with c ool wa te r. In se rious c a se s or if e ye c onta c t
is ma de , se e k me dic a l a tte ntion IMMEDIATELY.
From Battery Charger
NOTE: Position of Battery Charger Connector may
vary depending on wheelchair options.
The use of sa fe ty gla sse s is re c omme nde d whe n
c le a ning the ba tte ry te rmina ls.
FIGURE 6 - CHARGING BATTERIES
NEVER smoke or strike a ma tc h ne a r ba tte rie s. If
the c a ps of the ba tte ry c e lls a re re move d, NEVER
look dire c tly into the m while c ha rging ba tte rie s.
REPLACING BATTERIES
1. Examine battery clamps and terminals for corrosion.
WARNING
2. Verify that the plastic caps are in place over the bat-
tery cell holes.
Most ba tteries a re not sold with instructions. How-
ever, wa rnings a re frequently noted on the cell
c a ps. Re a d the m c a re fully, othe rwise injury or
da ma ge ca n occur.
3. Clean the terminals and inside the battery clamps by
using a battery cleaning tool, wire brush, or medium
grade sand paper.
NOTE: Invacare recommends that both batteries be re-
placed if one (1) battery is defective.
NOTE: When done, these areas should be shiny, not dull.
4. Carefully dust off all metal particles.
49
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PROCEDURE 13
FWD WHEELCHAIRS
14. If necessary, install the Captain's Seat. Refer to RE-
MOVING/INSTALLING CAPTAIN'S SEAT in PRO-
CEDURE 5 of this manual.
INSTALLING/ REMOVING BATTERY
BOXES
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DETAIL "A"
WARNING
Joystick Cable
NEVER unplug the ba tte ry c a ble s by pullling on
the wire s. Unplug the ba tte ry c a ble s by pulling
on the connector ONLY. Otherwise, injury or da m-
a ge ma y oc c ur.
Rear Battery
Box
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NOTE: To remove the battery boxes, reverse the follow-
ing procedure.
Retaining
Tie-Wrap
Strap
NOTE: Motors should be in the engaged position when
removing/installing batteries. Refer to ENGAGING/DIS-
ENGAGINGMOTORSinPROCEDURE8ofthismanual.
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Retaining
Strap Clip
Retaining
Strap
Installing
Front
Battery Box
Rear
Battery
Box
R2BASIC AND R2STANDARD (FIGURE 7).
1. Verify that the ON/OFF switch on the joystick is in the
OFF position.
Front of the
Wheelchair
2. If necessary, remove the captain's seat. Refer to
REMOVING/INSTALLING THE CAPTAIN'S
SEAT in PROCEDURE 5 of this manual.
Battery
Tray
Battery Connections on
Side of Wheelchair Frame
3. If necessary, remove the front and rear shrouds. Re-
fer to REMOVING/INSTALLING THE SHROUDS in
PROCEDURE 9 of this manual.
NOTE: Wheelchair Frame
not shown for clarity.
4. Position the battery boxes onto the battery tray.
FIGURE 7 - INSTALLING/REMOVING BATTERY BOXES
ALL MODELS EXCEPT R2JR
NOTE: Make sure the battery cable on the battery boxes
are on the same side as the battery connectors on the
wheelchair frame.
R2J R (FIGURE 8).
1. Verify that the ON/OFF switch on the joystick is in the
OFF position.
5. Feed the retaining strap through the slot located on
the top of the front shroud.
2. If necessary, remove the front and rear shrouds. Re-
fer to REMOVING/INSTALLING SHROUDS in PRO-
CEDURE 9 of this manual.
6. Position the bottom of the front shroud in-between
the battery box and the battery tray.
7. Clip the retaining strap together and pull strap tight to
secure the front shroud and battery box in place.
NOTE:Makesurethebatterycablesonthebatteryboxes
are on the same side as the battery connectors on the
wheelchair frame.
8. Feed the retaining strap through the slot located on
the top of the rear shroud.
NOTE: The battery cables of the front battery box must be
connected to the battery connectors on the wheelchair
before placing battery on battery tray.
9. Bundle excess joystick cable and tie wrap together.
See DETAIL "A".
3. Connect the battery cables from the front battery box
to the battery connectors on the wheelchair frame.
10. Positionbundledjoystickcablebetweenretainingstrap
and rear battery box. See DETAIL "A".
4. Position the front battery box onto the battery tray as
shown in FIGURE 8.
11. Clip the retaining strap together to secure the rear
shroud and battery box in place.
5. Feed the front retaining strap through the slot located
on the top of the front shroud.
12. Press down on the rear shroud until the two (2) clips
secure the rear shroud to the two side shrouds.
6. Position the bottom of the front shroud in-between
the front battery box and edge of battery tray.
13. Connect the battery cables from the battery boxes
to the battery connectors on the wheelchair frame.
7. Clip the front retaining strap together.
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FWD WHEELCHAIRS
PROCEDURE 13
8. Pull end of retaining strap to secure front battery box
and front shroud in place.
BATTERY TRAY
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WARNING
9. Position the rear battery box onto the battery tray as
shown in FIGURE 8.
Pinc h point e xists be twe e n ba tte ry tra y a nd ba t-
te ry bra c ke t.
10. Connect the battery cable from the rear battery box to
the rear battery connectors on the wheelchair frame.
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Folding Battery Tray for Transport (FIGURE 9)
11. Bundle excess joystick cable and tie wrap together.
See DETAIL "A".
1. If necessary, remove the front and rear shroud. Refer
to REMOVING/INSTALLING SHROUDS - FWD
WHEELCHAIRS in PROCEDURE 9 of this manual.
12. Position excess joystick cable between retaining strap
and rear battery box. See DETAIL "A".
2. Remove the battery boxes from the wheelchair. Refer
toINSTALLING/REMOVINGBATTERYBOXESinthis
procedure of the manual.
13. Clip the rear retaining strap together.
14. Pull end of retaining strap to secure battery box and
joystick in place.
3. Perform one (1) of the following:
A. FOR R2BASIC and R2STANDARD - Lift up on the pin
side of the battery tray and rotate UP towards the
battery tray pivot.
15. Installtherearshroud.RefertoREMOVING/INSTALL-
ING SHROUDS in PROCEDURE 9 of this manual.
R
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B. FOR R2JR - Lift up on the notched side of the bat-
tery tray and rotate UP towards the battery tray
pivot.
DETAIL "A"
Joystick
Cable
Rear Battery
Box
4. Fold the wheelchair. Refer to TRANSPORTING
RANGER II FWD in this procedure of the manual.
Unfolding Battery Tray for Use (FIGURE 10)
1. Unfold the wheelchair. Refer to TRANSPORTING
RANGER II FWD in this procedure of the manual.
Tie-Wrap
Retaining
Strap
2. Perform one (1) of the following:
A. FOR R2BASIC and R2STANDARD
-
Rear Shroud
Pull this end of
WARNING
Retaining
Strap
retaining strap to
secure battery
box in place
Ma ke sure pins of ba ttery tra y a re secure in
the mounting slots of the ha nger bra cket,
otherwise injury or da ma ge ma y result.
Slot
Rotate the pin side of the battery tray DOWN
against the mounting slots on the hanger bracket.
Rear
Battery
Box
B. FOR R2JR - Rotate the notched side of the battery
tray and DOWN against the battery tray stop.
3. Install the battery boxes. Refer to INSTALLING/RE-
MOVING BATTERY BOXES in this procedure of the
manual.
Retaining
Strap
4. If necessary install the front shroud. Refer to REMOV-
ING/INSTALLING SHROUDS - FWD WHEEL-
CHAIRS in PROCEDURE 9 of this manual.
Battery
Battery
Tray
Front
Battery
Box
Connections
on Side of
Wheelchair
Frame
Front
Shroud
FIGURE 8 - INSTALLING/REMOVING BATTERY BOXES
R2JR
51
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PROCEDURE 13
FWD WHEELCHAIRS
R2BASIC AND R2STANDARD
Pins
R2BASIC AND R2STANDARD
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Hanger Bracket
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Pins
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Mounting
Slots
Battery Tray
Pivot
Battery Tray
R2JR
R2JR
Battery
Bracket
Battery
Tray
Stop
l
Battery Tray
Pivot
Notch
Notch
Battery Tray
FIGURE 9 - BATTERY TRAY - FOLDING BATTERY TRAY
FOR TRANSPORT
FIGURE 10 - BATTERY TRAY - UNFOLDING BATTERY
TRAY FOR USE
52
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FWD WHEELCHAIRS
PROCEDURE 13
Changing Width of Battery Tray (FIGURE 11)
INSTALLING (FIGURE 12).
1. Line up mounting holes in the new/existing battery tray
with the mounting holes in the battery tray hanger
bracket.
NOTE:ThisprocedureappliestoR2BASIC AND R2STANDARD
only.
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NOTE: This procedure is only necessary when changing
the width of the wheelchair.
2. Position one (1) of the washers between the battery
hanger bracket and the new/existing battery tray.
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1. Fold the battery tray. Refer to FOLDING BATTERY
TRAY FOR TRANSPORT in this procedure of the
manual.
3. Reinstall one (1) of the hex bolts and washers through
the new/existing battery tray, washer and battery tray
hanger bracket and loosely tighten with a locknut.
2. Remove the hex bolt and locknut that secure one (1) of
the battery tray pins to the battery tray.
4. Repeat STEPS 2-3 for the remaining washers, hex
bolt, and locknut.
3. Refer to FIGURE 11 to determine mounting hole in the
battery tray that corresponds to width of the wheelchair.
5. Tighten the two (2) hex bolts and locknuts.
NOTE: Tighten the Two (2) hex bolts and locknuts until
the tray stays up by itself. Over tightening the hex bolts
and locknuts will make the battery tray difficult to flip up.
4. Reposition the battery tray pin to the mounting hole
determined in STEP 3.
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5. Secure the battery tray pin to the battery tray with the
hex bolt and locknut.
6. Reinstall the battery boxes. Refer to INSTALLING/RE-
MOVING BATTERY BOXES in this procedure of the
manual.
6. Repeat STEPS 2-5 for remaining battery tray pin and
two battery tray pivots.
Battery Tray Hanger Bracket
Washers
Battery Tray Pin
Battery Tray
Hex Bolts
Locknuts
Hex Bolts
Locknuts
Battery Tray
Pivot
16-inch Wheelchair
18-inch Wheelchair
20-inch Wheelchair
Battery Tray
FIGURE 12 - REMOVING/INSTALLING BATTERY TRAY
FOR R2BASIC AND R2STANDARD
.
Rem oving/ Installing Battery Tray R2J R.
(FIGURE 13)
REMOVING.
1. Remove the battery boxes from the wheelchair. Refer
toINSTALLING/REMOVINGBATTERYBOXESinthis
procedure of the manual.
FIGURE 11 - BATTERY TRAY - CHANGING WIDTH OF
BATTERY TRAY
2. Remove the two (2) mounting screws, four (4) wash-
ers, and two (2) locknuts that secure the battery tray
to the battery tray bracket.
Rem oving/ Installing Battery Tray for R2BASIC
and R2STANDARD
.
REMOVING (FIGURE 12).
3. Remove the battery tray from the wheelchair.
1. Remove the battery boxes from the wheelchair. Refer
toINSTALLING/REMOVINGBATTERYBOXESinthis
procedure of the manual.
INSTALLING.
1. Position batterytrayinsidetabof batterytraybracket.
2. Remove the two (2) hex bolts, four (4) washers and
two (2) locknuts that secure the existing battery tray
and washers to the battery tray hanger bracket.
2. Secure battery tray to battery bracket with the exist-
ing two (2) mounting screws, four (4) washers, and
two (2) locknuts. Torque mounting screws to 72-inch
pounds. See Figure 12 for hardware orientation.
3. Remove the existing battery tray from the wheelchair.
53
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PROCEDURE 13
FWD WHEELCHAIRS
B. WHEELCHAIRNOTEQUIPPEDWITHFLIP-UP
REMOVABLE FOOTBOARD - Remove the front
hex screw that secures the existing left battery
tray bracket to the wheelchair frame.
FOR MODEL R2J R (FIGURE 15).
NOTE: Right and left is determined by sitting in wheel-
chair.
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1. Remove the footrests. Refer to INSTALLING /RE-
MOVING FOOTRESTS in PROCEDURE 3 of the
Owner's Manual, part number 1080722.
4. Remove the locknut that secures existing left battery
tray hanger bracket and MKIV controller from the
wheelchair.
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2. Remove the battery boxes from the wheelchair. Refer
toINSTALLING/REMOVINGBATTERYBOXESinthis
procedure of the manual.
5. Remove the existing left battery tray hanger bracket
from the wheelchair.
6. Line up the mounting holes in the new battery tray
hanger bracket with the front mounting hole and rear
stud on the wheelchair frame.
3. Remove the battery tray. Refer to REMOVING BAT-
TERY TRAY in this procedure of the manual.
4. Remove the two (2) mounting screws that secures
the existing right battery tray hanger bracket to
wheelchair frame.
7. Perform one (1) of the following:
A. WHEELCHAIR EQUIPPED WITH FLIP-UP RE-
MOVABLE FOOTBOARD - Reinstall the hex
screw and spacer that secures the new left bat-
tery tray hanger bracket and footboard mounting
bracket to the wheelchair frame. Use Loctite 242
and torque to 156-in/lbs.
R
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5. Secure NEW battery tray hanger bracket to wheel-
chair frame with the existing two (2) mounting
screws. Securely tighten.
R
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6. Reinstall battery tray, battery boxes, and footrests
by reversing STEPS 1-3.
B. WHEELCHAIR NOT EQUIPPED WITH FLIP-
UP REMOVABLE FOOTBOARD - Reinstall the
front hex screw that secures the new left battery
tray hanger bracket to the wheelchair frame. Use
Loctite 242 and torque to 156-in/lbs.
Mounting Screws
8. Reinstall locknut. Use Loctite 242 and torque to 156-
in/lbs.
9. Torque the rear locknut that secures MKIV controller to
the wheelchair to 156-in/lbs.
Battery Tray
Hanger Bracket
Wheelchair
Frame
Battery Tray Hanger Bracket
Wheelchair
Frame
FIGURE 15 - REPLACING RIGHT BATTERY TRAY
HANGER BRACKET FOR MODEL R2JR
MKIV
Controller
Replacing Left Battery Tray Hanger Bracket
FOR MODELS R2BASIC AND R2STANDARD
(FIGURE 16).
NOTE: Right and left is determined by sitting in wheel-
chair.
Spacer
1. Remove the battery boxes from the wheelchair. Re-
fer to INSTALLING/REMOVING BATTERY BOXES
in this procedure of the manual.
Hex Screw
Locknut
Footboard
Mounting
Bracket
Rear Locknut - Loosen,
but Do Not Remove
2. Loosen, but do not remove the rear locknut that se-
cures MKIV controller to the wheelchair.
3. Perform one (1) of the following:
FIGURE 16 - REPLACING LEFT BATTERY TRAY
HANGER BRACKET FOR MODELS R2BASIC AND
R2STANDARD
A. WHEELCHAIR EQUIPPED WITH FLIP-UP RE-
MOVABLE FOOTBOARD - Remove the hex
screw and spacer that secures the existing left
battery tray hanger bracket and footboard mount-
ing bracket to the wheelchair frame.
54
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FWD WHEELCHAIRS
PROCEDURE 13
11. Reinstall locknut that secures the front of the MKIV
controller and rear of the left battery tray hanger
bracket to the wheelchair frame. Use Loctite 242
and torque to 156-in/lbs.
FOR MODEL R2J R (FIGURE 17).
NOTE: Right and left is determined by sitting in wheel-
chair.
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1. Remove the footrests. Refer to INSTALLING /RE-
MOVING FOOTRESTS in PROCEDURE 3 of the
Owner's Manual, part number 1080722.
12. Tighten the rear locknut that secures MKIV controller
to the wheelchair and torque to 156-in/lbs.
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2. Remove the front and rear shrouds. Refer to RE-
MOVING/INSTALLING SHROUDS in PROCE-
DURE 10 in this manual.
REPLACING WIRING HARNESS
(FIGURE 18)
3. Remove the battery boxes from the wheelchair. Re-
fer to INSTALLING/REMOVING BATTERY BOXES
in this procedure of the manual.
16, 18, and 20-inch Wide Models
1. If necessary, remove the front and rear shrouds. Re-
fertoREMOVING/INSTALLINGSHROUDSinPRO-
CEDURE 10 of this manual.
4. Fold battery tray. Refer to FOLDING/UNFOLD-
ING BATTERY TRAY in this procedure of the
manual.
R
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2. Remove the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure
of the manual.
5. Loosen, but do not remove the rear locknut that se-
cures MKIV controller to the wheelchair.
3. HIGH BACK CAPTAIN'S SEAT MODEL WHEEL-
CHAIRS ONLY (DETAIL "A") - Perform the following:
6. Remove the front hex screw that secures the ex-
isting left battery tray bracket to the wheelchair
frame.
A. Disconnect the limit switch. Refer to DISCON-
NECTING/CONNECTING LIMIT SWITCH in
PROCEDURE 8 of this manual.
7. Remove the locknut that secures existing left battery
tray hanger bracket and MKIV controller from the
wheelchair.
B. Remove the phono jack nut that secures the
phono jack to the side shroud.
8. Remove the existing left battery tray hanger bracket
from the wheelchair.
4. Disconnect the wiring harness (BLUE) from the con-
troller connector (BLUE).
9. Line up the mounting holes in the new battery tray
hanger bracket with the front mounting hole and rear
stud on the wheelchair frame.
5. Remove the two (2) phillips screws and spacers that
secure the rear battery connector to the wheelchair
frame.
10. Reinstall the front hex screw that secures the new
left battery tray hanger bracket to the wheelchair
frame. Use Loctite 242 and torque to 156-in/lbs.
6. Remove the two (2) phillips bolts and locknuts that
securethefrontbatteryconnectortowheelchairframe.
Wheelchair
Battery Tray
7. Remove the two (2) phillips screws that secure the
wiring harness to the charger cable mounting bracket.
Frame
Hanger Bracket
8. Note the position of the tie wraps that secure the ex-
isting wiring harness and motor cables to the
crossbraces.
MKIV
Controller
9. Cut the tie wraps that secure the existing wiring har-
ness and motor cables to the crossbraces.
10. Remove the existing wiring harness from wheelchair.
11. Position the rear battery connector of the new wiring
harness on the wheelchair frame as shown in FIG-
URE 18 and secure with the two (2) phillips screws
and spacers.
Locknut
12. Position the front battery connector on the wheelchair
frame as shown in FIGURE 18 and secure with the
two (2) phillips bolts and locknuts.
Front Hex
Screw
Rear Locknut - Loosen,
but Do Not Remove
13. Secure the wiring harness to existing charger cable
mounting bracket on the seat frame with the two (2)
phillips screws.
FIGURE 17 - REPLACING LEFT BATTERY TRAY
HANGER BRACKET FOR MODEL R2JR
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PROCEDURE 13
FWD WHEELCHAIRS
C. Connectthelimitswitch. Referto DISCONNECT-
ING/CONNECTINGLIMITSWITCHinthisPRO-
CEDURE 8 of this manual.
14. Resecure the wiring harness and motor cables to the
crossbraces with new tie wraps at the positions noted
in STEP 8.
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17. Reinstall the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure of
the manual.
15. Connect the wiring harness (BLUE) to the controller
connector (BLUE).
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16. HIGH BACK CAPTAIN'S SEAT MODEL WHEEL-
CHAIRS ONLY - Perform the following:
18. If necessary, install the front and rear shrouds. Refer
toREMOVING/INSTALLINGSHROUDSinPROCE-
DURE 10 of this manual.
A. Position the new phono jack on the side shroud.
B. Reinstall the phono jack nut onto the new phono
jack and tighten securely.
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Phono Jack
Nut
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Side
Shroud
Phono Jack
Phillips Screws
(STEPS 5, 11)
Spacers
(STEPS 5, 11)
Wiring
Harness
Tie Wraps
(STEPS 8, 16)
Phillips Bolts
(STEPS 6, 12)
To Controller
(STEPS 4, 15)
Charger Cable Mounting Bracket
Locknuts (STEPS 6, 12)
Phillips Screws (STEPS 7, 13)
FIGURE 18 - REPLACING WIRING HARNESS - 16, 18, AND 20-INCH WIDE MODELS
56
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FWD WHEELCHAIRS
PROCEDURE 13
11. Secure the wiring harness to existing charger cable
mounting bracket on the seat frame with the two (2)
phillips screws.
14-inch Wide Models (FIGURE 19)
1. Removetheshrouds.RefertoREMOVING/INSTALL-
ING SHROUDS in PROCEDURE 10 of this manual.
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12. Connect the wiring harness (BLUE) to the controller
connector (BLUE).
2. Remove the battery boxes. Refer to REMOVING/IN-
STALLINGTHEBATTERYBOXES inPROCEDURE
12 of this manual.
NOTE: See FIGURE 19 for proper positioning of con-
nections on wire connector support.
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3. Cut the tie wrap that secure the following connections
to the wire connector support:
13. Postiontherighthandmotor/controllerconnectionand
the left hand motor/controller connection side by side
on the wire connector support.
A. The right hand motor and controller connection.
B. The left hand motor and controller connection.
14. Postion the battery wiring harness/controller con-
nection on top of the right/left hand motor/con-
troller connections.
C. Battery wiring harness and controller connection.
(BLUE)
4. Disconnect the battery wiring harness (BLUE) and
controller connector (BLUE).
NOTE: When securing the above connections to wire
connector support, make sure to wrap tie-wrap around
crossbrace and thread through slot in wire connector
support.
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S
5. Remove the two (2) phillips screws and spacers that
secure the rear battery connector to the wheelchair
frame.
15. Secure the connections stated in STEPS 13 and 14
to the wire connector support with a tie-wrap.
6. Remove the two (2) phillips bolts and locknuts that
securethefrontbatteryconnectortowheelchairframe.
16. Install the battery boxes. Refer to REMOVING/
INSTALLING THE BATTERY BOXES in PRO-
CEDURE 12 of this manual.
7. Remove the two (2) phillips screws that secure the
wiring harness to the charger cable mounting bracket.
8. Remove the existing wiring harness from wheelchair. 17. Install the shrouds. Refer to REMOVING/INSTALL-
ING SHROUDS in PROCEDURE 10 of this manual.
9. Position the rear battery connector of the new wiring
harness on the wheelchair frame as shown in FIG-
URE 19 and secure with the two (2) phillips screws
and spacers.
10. Position the front battery connector on the wheelchair
frame as shown in FIGURE 19 and secure with the
two (2) phillips bolts and locknuts.
57
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PROCEDURE 13
FWD WHEELCHAIRS
F
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MKIV
Controller
W
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C
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R
S
Tie-Wrap
Right Hand Motor and
Controller Connection
Battery Wiring Harness
and Controller Connection
(BLUE)
Left Hand Motor and
Controller Connection
Wire Connector Support
Slot
Wiring
Phillips Screws
Rear Battery
Connector
Harness
To Controller
Phillips Bolts
Spacer
Spacer
Phillips Screws
Front Battery
Connector
Charger Cable
Mounting Bracket
Locknuts
FIGURE 19 - REPLACING WIRING HARNESS - 14-INCH WIDE MODELS
58
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FWD WHEELCHAIRS
PROCEDURE 13
USERS' WEIGHT 201 TO 250 LBS -
MOTOR MOUNTING POSITIONS
REPOSITIONING MOTORS (FIGURE
20)
F
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D
SEAT
WIDTH
SEAT DEPTH
16
17
18
WARNING
N/A
N/A
N/A
The ove ra ll pe rforma nc e of the whe e lc ha ir WILL
be a ffe c te d by the front whe e l mounting posi-
tion. The following c ha rts show the mounting po-
sition of the motors for e a c h se a t width a nd de pth
de pe nding on the fa c tory se tting or use r's we ight.
*14
16
18
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
W
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C
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20
USERS' WEIGHT 251 TO 300 LBS
If the mounting position tha t c orre sponds to the
use r's we ight is diffe re nt tha n the fa c tory se tting,
the motors MUST BE re positione d to ma inta in
prope r sta bility a nd c ontrolla bility BEFORE using
the whe e lc ha ir. Othe rwise injury or da ma ge c a n
occur.
(FWD MOTORS WITH MOTOR LOCKS ONLY)-
MOTOR MOUNTING POSITIONS
SEAT
WIDTH
SEAT DEPTH
17
16
18
*14
16
18
N/A
N/A
N/A
FRONT
FRONT
FRONT
FRONT
FRONT
FRONT
FRONT
FRONT
FRONT
Pe riodic a lly re vie w the following c ha rts to ma ke
sure the motor mounting position still corresponds
to the use r's we ight to ma inta in the prope r sta bil-
ity a nd c ontrolla bility.
R
S
20
*NOTE: 14 wide is only for R2JR.
R2 ONLY - NEVER re position the motors. Re posi-
tioJnRing the motors forwa rd WILL re duc e the c on-
trolla bility of the whe e lc ha ir. This proc e dure MUST
be pe rforme d by a n Inva c a re De a le r.
1. Remove the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure of
the manual.
2. Perform one (1) of the following:
NOTE: If motors are repositioned, the front riggings may
needtoberepositioned. RefertoADJUSTING/REPLAC-
ING TELESCOPING FRONT RIGGING SUPPORT in
PROCEDURE 9 of the owner's manual, 1080722.
A. WHEELCHAIR EQUIPPED WITH FLIP-UP RE-
MOVABLE FOOTBOARD - Remove the hex
screws and spacers that secure the battery tray
hanger bracket and footboard mounting bracket
to the wheelchair frame.
FACTORY SETTINGS - MOTOR MOUNTING POSITIONS
B. WHEELCHAIRNOTEQUIPPEDWITHFLIP-UP
REMOVABLE FOOTBOARD - Remove the front
hex screw that secures the battery tray hanger
bracket to the wheelchair frame.
(R2 STANDARD
)
SEAT
WIDTH
SEAT DEPTH
17
16
18
*14
16
18
N/A
N/A
N/A
3. Rotate battery tray hanger bracket up.
FRONT
FRONT
FRONT
FRONT
FRONT
FRONT
FRONT
FRONT
FRONT
4. Left side of wheelchair only - Remove the front dust
cover from the end of the crossbrace.
20
NOTE: Left is determined by sitting in the wheelchair.
FACTORY SETTINGS - MOTOR MOUNTING POSITIONS
(R2 BASIC AND R2JR)
5. Refer to the charts in this procedure to determine
propermountingpositionthatcorrespondstotheuser's
weight.
SEAT
WIDTH
SEAT DEPTH
17
16
18
6. Removethesix(6)socketscrewsthatsecurethe mo-
tor to the wheelchair frame.
*14
16
18
REAR
REAR
REAR
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
7. Position the motor on the wheelchair frame at the po-
sition noted in STEP 5 as shown in FIGURE 20.
20
CAUTION
USERS' WEIGHT 200 LBS AND UNDER -
MOTOR MOUNTING POSITIONS
The longer socket screws must be positioned in
the mounting holes on the OUTSIDE of the wheel-
cha ir fra me a nd the short socket screws must be
in the mounting holes on the INSIDE of the wheel-
cha ir fra me. Otherwise da ma ge to the gea rbox
ma y result.
SEAT
WIDTH
SEAT DEPTH
17
16
18
*14
16
18
REAR
REAR
REAR
REAR
REAR
REAR
REAR
REAR
REAR
REAR
REAR
REAR
20
59
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PROCEDURE 13
FWD WHEELCHAIRS
8. Use Loctite 242 and tighten the motor to the wheel-
chair frame securely with the six (6) socket screws.
Torque to 60-inch pounds.
STEPS 2, 4, 10, 11, 12
Spacers
Dust Cover (Not Shown)
Battery Tray
Hanger
F
W
D
9. Repeat STEPS 2-8 for the opposite side of the wheel-
chair, if necessary.
Bracket
10. Line up the mounting hole in the battery tray hanger
bracketwiththemountingholeinthewheelchairframe.
W
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L
Hex Screws
11. Left side of wheelchair only - Reinstall the front dust
cover onto the end of the crossbrace.
Footboard
Mounting
Bracket
12. Perform one (1) of the following:
A. WHEELCHAIR EQUIPPED WITH FLIP-UP RE-
MOVABLE FOOTBOARD - Reinstall the hex
screws and spacers that secure the battery tray
hanger bracket and footboard mounting bracket
to the wheelchair frame. Use Loctite 242 and
torque to 156-in/lbs.
C
H
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R
S
LONG Socket Screws (Apply Loctite 242 and
torque to 60-inch pounds) (STEPS 6, 8)
B. WHEELCHAIR NOT EQUIPPED WITH FLIP-UP
REMOVABLE FOOTBOARD - Reinstall the front
hex screw that secures the battery tray hanger
bracket to the wheelchair frame. Use Loctite 242
and torque to 156-in/lbs.
Wheelchair
Frame
13. Reinstall the battery boxes. Refer to INSTALLING/RE-
MOVING BATTERY BOXES in this procedure of the
manual.
SHORT Socket
Screws (Apply
Loctite 242 and
torque to 60-
REPLACING CLUTCH HANDLES -
R2BASIC AND R2J R (FIGURE 21)
inch pounds)
(STEPS 6, 8)
1. Remove the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure of
the manual.
Motor/
Gearbox
2. Remove the tip from the existing clutch handle.
3. Remove the pin that secures the existing clutch
handle to the motor/gearbox.
NOTE: Basic motor/gearbox shown only for clarity. Stan-
dard motor gearbox reposition the same way.
4. Disconnect the existing clutch handle from the mo-
tor/gearbox.
NOTE: Basic motor/gearbox - It is not necessary to dis-
connect clutch handle from the motor/gearbox.
5. Feed existing clutch handle through wheelchair
frame.
6. Remove the rubber tip from the new clutch handle.
7. Install the new clutch handle onto the wheelchair.
FRONT MOTOR
MOUNTING POSITION
NOTE: Make sure the new clutch handle is pointing to-
wards the outside of the wheelchair.
MIDDLE MOTOR
MOUNTING POSITION
8. Install the rubber tip onto the new clutch handle.
9. Connect the clutch handle to the motor/gearbox and
line up the mounting holes in the clutch handle and
motor/gearbox.
10. Insert the pin through the clutch handle and motor/
gearbox as shown in DETAIL "A" in FIGURE 21.
REAR MOTOR
MOUNTING POSITION
NOTE: Make sure the detent ball on the pin is fully vis-
ible.
FIGURE 20 - REPOSITIONING MOTORS
60
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FWD WHEELCHAIRS
PROCEDURE 13
11. Repeat STEPS 2-10 for the opposite side of the 5. Perform one (1) of the following:
wheelchair, if necessary.
A. WHEELCHAIR EQUIPPED WITH FLIP-UP RE-
F
W
D
12. Reinstall the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure
of the manual.
MOVABLE FOOTBOARD - Remove the hex
screws and spacers that secure the battery tray
hanger bracket and footboard mounting bracket
to the wheelchair frame.
W
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Tip (STEPS 2, 6, 8)
Clutch Handle
B. WHEELCHAIRNOTEQUIPPEDWITHFLIP-UP
REMOVABLE FOOTBOARD - Remove the front
hex screw that secures the battery tray hanger
bracket to the wheelchair frame.
(STEPS 4, 7)
Outside of
Wheelchair
5. Rotate battery tray hanger bracket up.
6. Left side of wheelchair only - Remove the front dust
cover from the end of the crossbrace.
NOTE: Left is determined by sitting in the wheelchair.
R
S
7. Remove the pin that secures the clutch handle to the
existing motor/gearbox.
Motor/
Gearbox
8. Disconnect clutch handle from existing motor/gear-
box.
Pin (STEPS 3, 10)
9. Notemountingpositionofmotor/gearboxonthewheel-
chair frame for installation of the new motor/gearbox.
DETAIL "A"
Motor/Gearbox
Detent Ball
10. Remove the six (6) socket screws that secure the ex-
isting motor/gearbox to the wheelchair frame.
Clutch Handle (STEP 9)
11. Position the new motor/gearbox on the wheelchair
frame at the position noted in STEP 9 as shown in
FIGURE 22.
FIGURE 21 - REPLACING CLUTCH HANDLES -
RANGER II FWD BASIC
CAUTION
REPLACING MOTOR/ GEARBOX -
R2BASIC AND R2J R (FIGURE 22)
The longer socket screws must be positioned in
the mounting holes on the OUTSIDE of the wheel-
cha ir fra me a nd the short socket screws must be
in the mounting holes on the INSIDE of the wheel-
cha ir fra me. Otherwise da ma ge to the gea rbox
ma y result.
1. Remove the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure of
the manual.
2. Perform one (1) of the following:
A. For R2BASIC - Proceed to STEP 3
B. FOR R2JR
12. Use Loctite 242 and tighten the motor/gearbox to the
wheelchair frame securely with the six (6) socket
screws. Torque to 60-inch pounds.
Cut the tie wrap that secures the following con-
nections to the wire connector support:
13. Connect the clutch handle to the new motor/gearbox
and line up the mounting holes.
l The right hand motor and controller con- 14. Insert the pin through clutch handle and new motor/
gearbox as shown in DETAIL "B" in FIGURE 22.
nection.
l The left hand motor and controller con- NOTE: Make sure the detent ball on the pin is fully visible.
nection.
15. RepeatSTEPS6-13fortheoppositesideofthewheel-
chair, if necessary.
l Battery wiring harness (BLUE)and control-
ler connector (BLUE).
16. Reinstall the drive wheels onto the wheelchair. Refer
to REMOVING/INSTALLING DRIVE WHEELS in
PROCEDURE 9 of this manual.
3. Disconnect the right and left motor connector from
the controller.
17. Left side of wheelchair only - Reinstall the front dust
4. Remove the drive wheels from the wheelchair. Re-
fer to REMOVING/INSTALLING DRIVE WHEELS
in PROCEDURE 9 of this manual.
cover onto the end of the crossbrace.
18. Line up the mounting hole in the battery tray hanger
bracketwiththemountingholeinthewheelchairframe.
61
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PROCEDURE 13
FWD WHEELCHAIRS
19. Perform one (1) of the following:
5. Rotate battery tray hanger bracket up.
A. WHEELCHAIR EQUIPPED WITH FLIP-UP RE-
MOVABLE FOOTBOARD - Reinstall the hex
screws and spacers that secure the battery tray
hanger bracket and footboard mounting bracket
to the wheelchair frame. Use Loctite 242 and
torque to 156-in/lbs.
6. Left side of wheelchair only - Remove the front
dust cover from the end of the crossbrace.
F
W
D
NOTE: left is determined by sitting in the wheelchair.
7. Note the mounting position of the motor/gearbox on
the wheelchair frame for installation of new motor/
gearbox.
W
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C
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B. WHEELCHAIR NOT EQUIPPED WITH FLIP-UP
REMOVABLE FOOTBOARD - Reinstall the front
hex screw that secures the battery tray hanger
bracket to the wheelchair frame. Use Loctite 242
and torque to 156-in/lbs.
8. Remove the six (6) socket screws that secure the
existing motor/gearbox to the wheelchair frame.
9. Position the new motor/gearbox on the wheelchair
frame at the position noted in STEP 6 as shown in
FIGURE 23.
20. Reconnect the right and left motor connector to the
controller.
CAUTION
21. FOR R2JR ONLY -
The longe r soc ke t sc re ws must be positione d in
the mounting hole s on the OUTSIDE of the whe e l-
c ha ir fra me a nd the short soc ke t sc re ws must be
in the mounting hole s on the INSIDE of the whe e l-
c ha ir fra me . Othe rwise da ma ge to the ge a rbox
c a sting c a n re sult.
R
S
A. Position the right hand motor/controller con-
nection and the left hand motor/controller con-
nection side by side on the wire connector
support.
B. Position the battery wiring harness/controller
connection on top of the right/left hand mo-
tor/controller connections.
10. Use Loctite 242 and tighten battery tray mounting
bracket and motor/gearbox to the wheelchair frame
securely with the six (6) socket screws. Torque to
60-inch pounds.
NOTE: When securing the above connections to
wire connector support, make sure to wrap tie-
wrap around crossbrace and thread through slot
in wire connector support.
11. RepeatSTEPS2-10fortheoppositesideofthewheel-
chair, if necessary.
12. Reinstall the drive wheels onto the wheelchair. Refer
to REMOVING/INSTALLING DRIVE WHEELS in
PROCEDURE 9 of this manual.
C. Secure the above connections to the wire con-
nector support with a tie-wrap.
13. Line up the mounting hole in the battery tray hanger
bracket with the mounting hole in the wheelchair
frame.
22. Reinstall the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure of
the manual.
14. Left side of wheelchair only - Reinstall the front dust
cover onto the end of the crossbrace.
REPLACING MOTOR/ GEARBOX -
R2STANDARD (FIGURE 23)
15. Perform one (1) of the following:
A. WHEELCHAIREQUIPPEDWITHFLIP-UPRE-
MOVABLE FOOTBOARD - Reinstall the hex
screws and spacers that secure the battery tray
hanger bracket and footboard mounting bracket
to the wheelchair frame. Use Loctite 242 and
torque to 156-in/lbs.
1. Remove the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure of
the manual.
2. Disconnect the right and/or left motor connector from
the controller.
3. Remove the drive wheels from the wheelchair. Re-
fer to REMOVING/INSTALLING DRIVE WHEELS
in PROCEDURE 9 of this manual.
B. WHEELCHAIR NOT EQUIPPED WITH FLIP-
UP REMOVABLE FOOTBOARD - Reinstall the
front hex screw that secures the battery tray
hanger bracket to the wheelchair frame. Use
Loctite 242 and torque to 156-in/lbs.
4. Perform one (1) of the following:
A. WHEELCHAIREQUIPPEDWITHFLIP-UPRE-
MOVABLE FOOTBOARD - Remove the hex
screw and washer that secure the battery tray
hanger bracket to the wheelchair frame.
16. Reconnect the right and/or left motor connector to the
controller.
17. Reinstall the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure of
the manual.
B. WHEELCHAIR NOT EQUIPPED WITH FLIP-
UP REMOVABLE FOOTBOARD - Proceed to
STEP 6.
62
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FWD WHEELCHAIRS
PROCEDURE 13
LONG Socket
Screws (Apply Loctite
242 and torque to 60-
inch pounds) (STEPS
8, 10)
SHORT Socket
Screws (Apply
Loctite 242 and
torque to 60-
inch pounds)
(STEPS 8, 10)
F
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W
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Battery Motor Connectors
(STEPS 2, 16)
Dust Cover (Not Shown)
STEPS 4, 6,
13,14,15
C
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S
Spacers
Battery Tray
Hanger
Wheelchair
Frame
Bracket
Hex Screws
Footboard
Mounting
Bracket
Motor/
Gearbox
FIGURE 23 - REPLACING MOTOR/GEARBOX - RANGER II FWD - STANDARD
63
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PROCEDURE 14
MWD WHEELCHAIRS
WARNING
Afte r ANY a djustme nts, re pa ir or se rvic e a nd BE-
FORE use , ma ke sure tha t a ll a tta c hing ha rdwa re
is tighte ne d se c ure ly - othe rwise injury or da m-
a ge ma y re sult.
This Procedure Includes the Following:
Assembling Ranger II MWD
M
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When to Charge Batteries
Charging Batteries
Replacing Batteries
W
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ASSEMBLING RANGER II MWD
Installing/Removing Battery Boxes
Battery Tray
WARNING
The weight of the wheelcha ir without the user a nd
ba tte rie s is still be twe e n 100 a nd 116 lbs. Use
prope r lifting te c hnique s (lift with your le gs) to
a void injury. Extre me c a ution is a dvise d whe n it is
ne c e ssa ry to move a n UNOCCUPIED powe r
whe e lc ha ir. Inva c a re re c omme nds using two (2)
a ssista nts a nd ma king thorough pre pa ra tions.
Ma ke sure to use ONLY se c ure , non-de ta c ha ble
pa rts for ha nd-hold supports.
Replacing Wiring Harness
Stabilizer Identification
Adjusting Stabilizer Springs
Adjusting Stabilizer for User Preference
Replacing Stabilizer Cylinders
Replacing Stabilizer Wheels
Replacing Stabilizer Cylinder Springs
Repositioning Motors
R
S
Ke e p ha nds a nd finge rs c le a r of moving pa rts to
a void injury.
Replacing Clutch Handles - R2BASIC AND R2250 SERIES
Replacing Motor/Gearbox - R2BASIC AND R2250 SERIES
Replacing Motor/Gearbox - R2STANDARD
Unfolding/ Folding Integrated Sling Seats
(FIGURE 1)
UNFOLDING.
1. Push down on the seat rails until the seat rails are
positioned in the seat guides.
2. Assemble the wheelchair. Refer to FIGURE 1.
Install the electronics. Refer to REPOSITIONING MKIV
JOYSTICK in PROCEDURE 7 of this manual.
3. If necessary, install the shrouds. Refer to REMOV-
ING/INSTALLING SHROUDS in PROCEDURE 10
of this manual.
Seat Rails
Seat Guides
Install the footrests/legrests. Refer to INSTALLING/RE-
MOVING FOOTRESTS or INSTALLING ELEVATING
LEGRESTS in PROCEDURE 3 of the owner's manual,
part number 1080722.
Adjust the stabilizers. Refer to ADJUSTING STABILIZ-
ERS in this procedure of the manual.
Install the battery tray and batteries. Refer to INSTALL-
ING/REMOVING BATTERY TRAY and INSTALLING/
REMOVING BATTERY BOXES in this procedure of the
manual.
FIGURE 1 - ASSEMBLING RANGER II MWD - INTEGRATED SLING SEATS
64
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MWD WHEELCHAIRS
PROCEDURE 14
FOLDING.
FOLDING.
1. If necessary, remove the shrouds. Refer to REMOV- 1. HIGHBACKCAPTAIN'SSEATSONLY-Disconnect
M
W
D
ING/INSTALLING SHROUDS in PROCEDURE 10
of this manual.
the limit switch. Refer to DISCONNECTING/CON-
NECTING LIMIT SWITCH in PROCEDURE 8 of this
manual.
2. Remove the batteries, battery tray and footrests/
legrests from the wheelchair. Refer to FIGURE 1.
2. Remove captain's seat. Refer to REMOVING/IN-
STALLING CAPTAIN'S SEAT in PROCEDURE 5 of
the owner's manual, part number 1080722.
W
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C
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3. Lift up on the seat rails of the wheelchair.
Unfolding/ Folding Captain's Seats (FIGURE 2) 3. Removetheshrouds.RefertoREMOVING/INSTALL-
ING SHROUDS in PROCEDURE 10 of this manual.
UNFOLDING.
1. Push down on the push brackets until they are flush
with the pivot links on the crossbraces.
4. Remove the batteries, battery tray and footrests/
legrests from the wheelchair. Refer to FIGURE 2.
5. Lift up on push brackets located on the crossbraces.
2. Assemble the wheelchair. Refer to FIGURE 2.
3. Install the shrouds. Refer to REMOVING/INSTALL-
ING SHROUDS in PROCEDURE 10 of this manual.
R
S
4. Install the captain's seat. Refer to REMOVING/IN-
STALLING CAPTAIN'S SEAT in PROCEDURE 5 of
the owner's manual, part number 1080722.
5. HIGH BACK CAPTAIN'S SEATS ONLY - Connect
the limit switch. Refer to DISCONNECTING/CON-
NECTING LIMIT SWITCH in PROCEDURE 8 of this
manual.
Install the electronics. Refer to
REPOSITIONING MKIV JOY-
STICK in PROCEDURE 7 of this
manual.
Install the battery tray and batteries.
Refer to INSTALLING/REMOVING
BATTERY TRAY and INSTALLING/
REMOVING BATTERY BOXES in
this procedure of the manual.
Adjust the stabilizers. Refer
to ADJUSTING STABILIZ-
ERS in this procedure of the
manual.
Push Brackets
Install the footrests/legrests. Refer to IN-
STALLING/REMOVINGFOOTRESTSor
INSTALLING/REMOVING ELEVATING
LEGRESTS in PROCEDURE 3 of the
owner's manual, part number 1080722.
Crossbraces
FIGURE 2 - ASSEMBLING RANGER II MWD - CAPTAIN'S SEATS
65
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PROCEDURE 14
MWD WHEELCHAIRS
WHEN TO CHARGE BATTERIES
(FIGURE 5)
CHARGING BATTERIES (FIGURE 6)
WARNING
M
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D
Never a ttempt to recha rge the ba tteries by a tta ch-
ing c a ble s dire c tly to the ba tte ry te rmina ls or
cla mps. Alwa ys use the recha rging plug loca ted
on the side/rea r of the wheelcha ir fra me.
It is advantageous to recharge daily rather than only when
necessary. In fact, a battery’s life is extended if the charge
level is maintained well above a low condition.
W
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NOTE: As a general rule, batteries should be recharged
daily to assure longest possible life and minimize required
charging time. Plan to recharge batteries when it is antici-
pated wheelchair will not be used for a long period of time.
DO NOT a ttempt to recha rge the ba tteries a nd
opera te the power wheelcha ir a t the sa me time.
During use a nd cha rging, unsea led ba tteries will
vent hydrogen ga s which is explosive in the right
concentra tion with a ir.
MKIV RII J oystick
BATTERY DISCHARGE INDICATOR (BDI) is located at
the rear of the 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 turn AMBER (YELLOW), then RED
and finally FLASHING RED. If the BDI is FLASHING RED,
the user should charge the batteries as soon as possible.
CAUTION
Alwa yscha rge new ba tteriesfully BEFOREinitia luse
or ba ttery 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
it is anticipated the wheelchair will not be used for a long
period of time.
R
S
NOTE: Accurate readings are displayed when in neutral.
MCC-MKIV X, A or A+ J oystick
The range per battery charge using recommended batter-
ies should be approximately 5 to 9 hours of typical opera-
tion. Extensive use on inclines may substantially reduce
per charge mileage.
BATTERYGAUGEDISPLAY(BGD)isthebargraphdisplay
located on the MKIV X, A or A+ joystick. It will keep you
informed as to power availability. A visual warning is given
beforethepowerbecomestoolowtooperatethewheelchair.
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 progressively 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 possi-
ble.
Description and Use of Battery Chargers
The charger automatically reduces the charge from an ini-
tially high rate to a zero reading at a fully charged condition.
SHUTOFF PROCEDURE.
A. For Models R2BASIC and R2STANDARD -If left unat-
tended, the charger should automatically shut-off
when full charge is obtained.
Battery Discharge
Battery Gauge
Indicator (BDI)
B. For R2250 SERIES -The Charger output and green
light will stay ON until the power switch on the bat-
tery charger is moved to the OFF position.
Display
There 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 MODELS R2BASIC and R2STANDARD - this is indi-
cated 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.)
MKIV X, A OR A+ JOYSTICK
NOTE: MKIV X Shown.
MKIV- RII JOYSTICK
FIGURE 5 - WHEN TO CHARGE BATTERIES
As a charge builds up, the charge rate is reduced, and the
following will occur:
A. ForModelsR2BASIC andR2STANDARD-thegreenlight
will stay illuminated for a longer period of time fol-
lowed by a shorter off time.
B. For Model R2250 SERIES - the battery charger rate
decreases to a "trickle charge".
66
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MWD WHEELCHAIRS
PROCEDURE 14
NOTE: If performing the charging procedures indepen-
dently, READ and CAREFULLY follow the individual in-
structions for each charger (supplied or purchased).
DETAIL "A"
Battery Charger Connector (on Side of Wheelchair)
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NOTE: If charging instructions are not supplied, consult
a qualified service technician for proper procedures.
WHEELCHAIRS
WITHOUT
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SHROUDS
Required Item s:
TOOL
QUANTITY
COMMENTS
From Battery
Charger
Battery Charger
✪ Extension Cord
1
1
Supplied
Not Supplied
✪ 3-prong plug, 15 ampere current rating; industrial type
Battery Charger
Connector (at
Rear of
Wheelchair)
Wheelchairs Equipped With MCC-Mark IV
J oystick (Detail "A" of FIGURE 6)
WHEELCHAIRS
WITH SHROUDS
1. If necessary, remove the rear shroud. Refer to RE-
MOVING/INSTALLINGSHROUDS-MWDWHEEL-
CHAIRS in PROCEDURE 9 of this manual.
R
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2. Attach the battery charger connector to the charger
cable/battery harness.
From Battery Charger
3. Plug the charger’s AC power cord, or extension, into
DETAIL "B"
the grounded 120 VAC wall outlet.
Three (3)
Pronged Plug
Battery Charger
4. Wait until charging is complete.
5. If necessary, install the rear shroud. Refer to RE-
MOVING/INSTALLINGSHROUDS-MWDWHEEL-
CHAIRS in PROCEDURE 9 of this manual.
From Battery
Charger
Front View of
Joystick
Wheelchairs Equipped With Mark IV RII
J oystick (Detail "B" of FIGURE 6)
Charger
Port
1. Attach the battery charger connector to the charger
port on the FRONT of the joystick.
Joystick
2. Plug the charger’s AC power cord, or extension, into
the grounded 120 VAC wall outlet.
Battery
Boxes
3. Wait until charging is complete.
Charger Port
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.
FIGURE 6 - CHARGING BATTERIES
REPLACING BATTERIES
NOTE: R2BASIC and R2STANDARD ONLY - If the charger
operates for sixteen (16) hours and is unable to fully
charge the batteries, an internal timer turns the charger
off and begins to fast blink the green light.
WARNING
The following proc e dure should be pe rforme d
only by a qua lified technicia n.
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.
Most ba tteries a re not sold with instructions. How-
ever, wa rnings a re frequently noted on the cell
c a ps. Re a d the m c a re fully, othe rwise injury or
da ma ge ca n occur.
NOTE: Invacare recommends that both batteries be re-
placed if one (1) battery is defective.
67
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PROCEDURE 14
MWD WHEELCHAIRS
Recom m ended Battery Types
INSTALLING/ REMOVING BATTERY
BOXES (FIGURE 7)
CAUTION
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Fa ilure to use the correct ba ttery size a nd/or volt-
a ge ma y ca use da ma ge to your wheelcha ir a nd
give you unsa tisfa ctory performa nce.
Installing
NOTE: To remove the battery boxes from the wheelchair,
reverse the following procedure.
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CHAIR
MODEL
QTY VOLTS BATTERY REMARKS
SIZE
WARNING
If the whe e lc ha ir is e quippe d with the re mova ble
footboa rd AND it is insta lle d in the he ighe st posi-
tion, it is ne c e ssa ry to re move the footboa rd pla te
BEFORE re moving the ba tte ry boxe s. Othe rwise ,
injury c a n oc c ur.
R2BASIC
2
2
2
12
12
12
22NF
22NF
U1
Deep Cycle
Deep Cycle
Deep Cycle
R2STANDARD
R2250 SERIES
1. Remove the battery boxes from the wheelchair. Refer to
REMOVING/INSTALLING BATTERY BOXES in this
procedure of the manual.
To remove the removable footboard, refer to REMOV-
ING THE REMOVABLE FOOTBOARD ASSEMBLY
FROM THE WHEELCHAIR in PROCEDURE 3 of this
Owner's Manual, part number 1080722.
2. Remove existing batteries from the battery boxes. Refer
to INSTALLING/REMOVING BATTERIES TO/FROM
BATTERY BOXES in this procedure of the manual.
R
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NOTE: Motors should be in the engaged position when
removing/installing batteries. Refer to ENGAGING/DIS-
ENGAGINGMOTORSinPROCEDURE8ofthismanual.
3. Clean the new battery terminals.
4. Install the new batteries into the battery boxes. Refer to
INSTALLING/REMOVING BATTERIES TO/FROM
BATTERY BOXES in this procedure of the manual.
1. Verify that the ON/OFF switch on the joystick is in the
OFF position.
2. If necessary, remove the front and rear shrouds. Re-
fer to REMOVING/INSTALLING SHROUDS in PRO-
CEDURE 9 of this manual.
Cleaning Battery Terminals
WARNING
DO NOT allow the liquid in the battery to come in
contact with skin, clothes or other possessions. It is a
form of acid and harmful or damaging burns may
result.Should the liquid touch yourskin,wash the area
immediately and thoroughly with cool water. In se-
rious cases or if eye contact is made, seek medical
attention IMMEDIATELY.
WARNING
Ba tte ry boxe s MUST be insta lle d/ re move d in
the ord e r sta te d b e low or the b a tte ry tra y
c ould rota te c a using the re a r ba tte ry box to
fa ll possibly c a using injury or da ma ge .
Use e xtre me c a re whe n insta lling/re moving the
ba tte ry boxe s.
NEVER smoke or strike a match near batteries. If the
caps of the battery cells are removed, NEVER look
directly into them while charging batteries.
NEVER unplug the ba tte ry c a ble s by pulling
on the wire s. Unplug the ba tte ry c a ble s by pull-
ing on the c onne c tor ONLY. Othe rwise injury
or da ma ge ma y re sult.
1. If applicable, verify that the plastic caps are in place over
the battery cell holes.
Whe n re m oving the b a tte ry b oxe s from the
whe e lc ha ir, re move the re a r ba tte ry box first.
2. Cut the tie wraps around the terminal caps/covers.
3. Slide the terminal cap/cover up the wire to expose the
battery terminal.
3. Position the battery boxes onto the battery tray in
the following order:
4. Examine battery clamps and terminals for corrosion.
A. FRONT Battery Box.
B. REAR Battery Box.
5. Clean terminals and inside the battery clamps by using a
battery cleaning tool, wire brush, or medium grade sand
paper.
4. Position retaining straps around each battery box
as shown in DETAIL "A" of FIGURE 7 and clip
retaining strap together.
NOTE: When done, these areas should be shiny, not dull.
6. Carefully dust off all metal particles.
NOTE: Make sure battery box leads are on the same
side as battery connectors on wheelchair frame.
7. Slide the terminal cap/cover back down the wire to cover
the battery terminal.
5. Connect the battery box leads to the battery con-
nectors on the wheelchair frame.
8. Secure the terminal cap/cover using NEW tie wraps.
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MWD WHEELCHAIRS
PROCEDURE 14
2. Turn the battery tray slightly to one (1) side.
6. If necessary, reinstall the removeable footboard.
Refer to REMOVING THE REMOVABLE
FOOTBOARD ASSEMBLY FROM THE WHEEL-
CHAIR in PROCEDURE 3 of this Owner's Manual,
part number 1080722.
3. Position the battery tray pins over the mounting slots
on the hanger brackets.
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WARNING
Ma ke sure pins of ba tte ry tra y a re se c ure in the
mounting slots of the ha nge r bra c ke t, othe rwise
injury or da ma ge ma y re sult.
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Retaining
Front Battery Box
Strap
Retaining
Strap Clip
Rear
Battery
Box
4. Push down on the battery tray to secure in place.
5. Install the battery boxes. Refer to INSTALLING/RE-
MOVING BATTERY BOXES in this procedure of the
manual.
Front of the
Wheelchair
6. If necessary, install the shrouds. Refer to REMOV-
ING/INSTALLING SHROUDS - MWD WHEEL-
CHAIRS in PROCEDURE 10 of this manual.
Battery Box
Leads
Battery Connections on
Side of Wheelchair Frame
R
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Rem oving
1. If necessary, remove the shrouds. Refer to REMOV-
ING/INSTALLING SHROUDS - MWD WHEEL-
CHAIRS in PROCEDURE 10 of this manual.
FIGURE 7 - INSTALLING/REMOVING BATTERY BOXES
BATTERY TRAY (FIGURE 8)
2. Remove the battery boxes from the wheelchair. Re-
fer to INSTALLING/REMOVING BATTERY BOXES
in this procedure of the manual.
Installing Battery Tray onto Wheelchair NOT
Equipped Weight Shift Basic Tilt
3. Lift up on the battery tray to release the battery tray
pins from the mounting slots on the hanger brack-
ets.
1. If necessary, remove the shrouds. Refer to REMOV-
ING/INSTALLING SHROUDS - MWD WHEEL-
CHAIRS in PROCEDURE 10 of this manual.
4. Turn the battery tray slightly to one (1) side.
5. Remove the battery tray from the wheelchair.
2. Turn the battery tray slightly to one (1) side.
NOTE: Make sure the end of the battery tray labeled
"FRONT" is towards the front of the wheelchair.
3. Position the battery tray pins over the mounting slots
on the hanger brackets.
WARNING
Ma ke sure pins of ba tte ry tra y a re se c ure in the
mounting slots of the ha nge r bra c ke t, othe rwise
injury or da ma ge ma y re sult.
4. Push down on the battery tray to secure in place.
5. Install the battery boxes. Refer to INSTALLING/RE-
MOVING BATTERY BOXES in this procedure of the
manual.
6. If necessary, install the shrouds. Refer to REMOV-
ING/INSTALLING SHROUDS - MWD WHEEL-
CHAIRS in PROCEDURE 10 of this manual.
Installing Battery Tray onto Wheelchair
Equipped Weight Shift Basic Tilt
1. If necessary, remove the shrouds. Refer to REMOV-
ING/INSTALLING SHROUDS - MWD WHEEL-
CHAIRS in PROCEDURE 10 of this manual.
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MWD WHEELCHAIRS
PROCEDURE 14
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BATTERY TRAY FOR WHEELCHAIRS NOT
EQUIPPED WITH WEIGHT SHIFT BASIC TILT
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"FRONT"
Label
Hanger
Bracket
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Battery Tray
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Mounting
Slots
Battery Tray Pins
BATTERY TRAY FOR WHEELCHAIRS
EQUIPPED WITH WEIGHT SHIFT BASIC TILT
Hanger
Bracket
Mounting
Battery Tray Pins
Battery Tray
Slots
FIGURE 8 - BATTERY TRAY
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MWD WHEELCHAIRS
PROCEDURE 14
Changing Width of Battery Tray (FIGURE 9)
REPLACING WIRING HARNESS
(FIGURE 10)
NOTE: This procedure is only necessary when changing
the width of the wheelchair.
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1. If necessary, remove the front and rear shrouds. Re-
fer to REMOVING/INSTALLING SHROUDS in PRO-
CEDURE 10 of this manual.
1. Remove the battery tray from the wheelchair. Refer to
INSTALLING/REMOVING BATTERY TRAY in this
procedure of the manual.
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2. Remove the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure of
manual.
2. Remove the hex bolt and locknut that secure one (1)
of the battery tray pins to the battery tray.
3. Disconnect the wiring harness (BLUE) from the con-
troller connector (BLUE).
3. Refer to FIGURE 9 to determine the mounting hole in
the battery tray that corresponds to the width of the
wheelchair.
4. Remove the two (2) phillips screws and spacers that
secure the rear battery connector to the wheelchair
frame.
4. Reposition the battery tray pin to the mounting hole
determined in STEP 3.
5. Remove the two (2) phillips bolts and locknuts that
securethefrontbatteryconnectortowheelchairframe.
5. Secure the battery tray pin to the battery tray with the
hex bolt and locknut.
R
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6. Remove the two (2) phillips bolts and locknuts that
secure the wiring harness to the charger cable mount-
ing bracket.
6. Repeat STEPS 2-5 for the other three (3) battery tray
pins.
7. Reinstall the battery tray onto the wheelchair. Refer to
INSTALLING/REMOVING BATTERY TRAY in this
procedure of the manual.
7. HIGH BACK CAPTAIN'S SEAT MODEL WHEEL-
CHAIRS ONLY (DETAIL "A") - Perform the following:
A. Disconnect the limit switch. Refer to DISCON-
NECTING/CONNECTINGLIMITSWITCHinthis
procedure of the manual.
Battery Tray Pins
Battery Tray
Hex Bolts
B. Remove the phono jack nut that secures the
phono jack to the limit switch bracket.
8. Note the position of the tie wraps that secure the ex-
isting wiring harness and motor cables to the cross-
braces.
16-inch Wheelchair
18-inch Wheelchair
20-inch Wheelchair
9. Cut the tie wraps that secure the existing wiring har-
ness and motor cables to the crossbraces.
Locknuts
10. Remove the existing wiring harness from wheelchair.
11. Position the rear battery connector of the new wiring
harness on the wheelchair frame as shown in FIG-
URE 10 and secure with the two (2) phillips screws
and spacers.
12. Position the front battery connector on the wheelchair
frame as shown in FIGURE 10 and secure with the
two (2) phillips bolts and locknuts.
13. Secure the wiring harness to existing charger cable
mounting bracket on the seat frame with the two (2)
phillips bolts and locknuts.
14. HIGH BACK CAPTAIN'S SEAT MODEL WHEEL-
CHAIRS ONLY - Perform the following:
FIGURE 9 - BATTERY TRAY - CHANGING WIDTH OF
BATTERY TRAY
A. Position the new phono jack on the limit switch
bracket.
B. Reinstall the phono jack nut onto the new phono
jack and tighten securely.
C. Connect the limit switch. Refer to DISCONNECT-
ING/CONNECTING LIMIT SWITCH in this pro-
cedure of the manual.
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PROCEDURE 14
MWD WHEELCHAIRS
15. Connect the wiring harness (BLUE) to the con-
troller connector (BLUE).
17. Reinstall the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure of
manual.
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16. Resecure the wiring harness and motor cables to
the crossbraces with new tie wraps at the posi-
tions noted in STEP 8.
18. If necessary, install the front and rear shrouds. Refer
to REMOVING/INSTALLING SHROUDS in PRO-
CEDURE 10 of this manual.
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(STEPS 7, 14)
DETAIL "A"
MKIV Joystick
NOTE: Position of Charger
CableMountingBracketmay
vary depending on wheel-
chair model and options.
Phono Jack Nut
Phillips Screws
(STEPS 4, 11)
Limit Switch Bracket
Phono Jack
Spacers
Controller
Wiring
Harness
(STEPS 4, 11)
Charger
Locknuts
(STEPS 6, 13)
Cable
Mounting
Bracket
R
S
To Controller
(STEPS 3, 15)
Phillips Bolts
(STEPS 5, 12)
Phillips Bolts
(STEPS 6, 13)
Tie Wraps
(STEPS 8, 16)
Locknuts
(STEPS 5, 12)
FIGURE 10 - REPLACING WIRING HARNESS
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MWD WHEELCHAIRS
PROCEDURE 14
STABILIZERS
STABILIZER IDENTIFICATION (FIGURE 11)
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NOTE: Depending on the date of manufacture, the wheelchair will have one (1) of the following types of
stabilizer assemblies. Refer to the chart below to determine the correct stabilizer assembly.
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TYPE A
Wheelchairs built
before 7/1/1999
TYPE B
Whelchairs built
between 7/1/1999 and 3/1/2000
TYPE C
Whelchairs built
after 3/1/2000
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FIGURE 11 -STABILIZER IDENTIFICATION
2. NEW STABILIZER SPRINGS ONLY - Rotate adjust-
ADJ USTING SPRINGS FOR TYPE A
STABILIZER ASSEMBLY (FIGURE 12)
ment nut DOWN until the 3-1/2-inch height is obtained.
3. Refer to FIGURE 12 to determine the height of the
stabilizer spring.
NOTE: Refer to STABILIZER INDENTIFICATION
above to determine correct stabilizer assembly.
4. Rotate the adjustment nut UP or DOWN to adjust the
stabilizer spring to the height determined in STEP 2.
WARNING
5. Adjust the for user preference. Refer to ADJUSTING
TYPEASTABILIZERASSEMBLYFORUSERPREF-
ERENCE in this procedure of the manual.
Injury or da ma ge ca n occur if the height of the
sta bilizer springs does not correspond to the a p-
proxima te weight of the user. If the height of the
sta bilizer springs does not correspond to the a p-
proxima te weight of the user, the wheelcha ir will
feel less sta ble a nd possibly ca use the footrests/
legrests to dra g the ground.
Stabilizer
Adjustment Nut
Measure This Height
If a djusting a new cylinder spring, it MUST be com-
pressed to the 3-1/2-inch height(FIGURE12)BEFORE
a djusting the sta bilizer spring to correspond to the
a pproxima te weight of the user. Otherwise the sta -
bilizer will not work properly.
USER'S WEIGHT
HEIGHT
(APPROXIMATE MEASURED
- IN POUNDS) (APPROXIMATE
- IN INCHES)
100
150
200
250
300
4-3/16
4
3-7/8
3-11/16
3-1/2
NOTE: If the height of the stabilizer springs is less than the
height that corresponds to the approximate weight of the
user,thewheelchairwillnotbeabletoclear2-inchobstacles.
NOTE:Thestabilizerspringsarefactorysetforauserweigh-
ing approximately 300-pounds. Use FIGURE 12 as a start-
ing point when adjusting the stabilizer spring.
Spring
NOTE: The following adjustment should be made with an
unoccupied wheelchair.
NOTE: If the user's approximate weight is not listed above,
usetheHIGHESTlistedapproximateweightclosesttouser's
weight as a starting point to adjust the stabilizer spring.
1. Determine the approximate weight of the user.
FIGURE 12 - ADJUSTING STABILIZERS - SPRINGS
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PROCEDURE 14
MWD WHEELCHAIRS
Adjusting Type B Stabilizer Assem bly for User
Preference (FIGURE 14)
ADJ USTING STABILIZER FOR USER
PREFERENCE
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NOTE: Refer to STABILIZER INDENTIFICATION in
the beginning of this section to determine correct sta-
bilizer assembly.
Adjusting Type A Stabilizer Assem bly for User
Preference (FIGURE 13)
NOTE: Refer to STABILIZER INDENTIFICATION in
the beginning of this section to determine correct sta-
bilizer assembly.
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1. While the user is in the wheelchair, measure the dis-
tance between the bottom of the stabilizer wheel and
the ground/floor.
1. While the user is in the wheelchair, measure the dis-
tance between the bottom of the stabilizer wheel and
the ground/floor.
NOTE: The distance between the bottom of the stabilizer
wheel and the ground/floor is factory set at one (1) inch.
2. To increase obstacle climbing ability or stability per-
form the following:
NOTE: Measurement MUST be between 7/8 and 1-inch.
2. If the measurement taken in STEP 1IS NOT between
7/8 and 1-inch, perform the following procedure:
A. Loosen the jam nut on the stabilizer cylinder rod
and back the jamnut down until it is touching the
adjustment nut.
R
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A. Loosen the jam nut on the stabilizer cylinder rod
and back the jamnut down until it is touching the
adjustment nut.
B. Remove bottom hex bolt and locknut that secure
bottom of the stabilizer cylinder to the stabilizer
plates.
B. Remove bottom bolt and locknut that secure bot-
tomofthestabilizercylindertothestabilizerplates.
C. Perform one (1) of the following:
Increase obstacle climbing ability - Turn the
C. Perform one (1) of the following:
MEASUREMENT GREATER THAN 1-INCH -
Turn the bottom of the stabilizer cylinder COUN-
TERCLOCKWISE.
bottom
of
the
stabilizer
cylinder
COUNTERCLOCKWISE.
Increase stability - Turn the bottom of the stabi-
lizer cylinder CLOCKWISE.
MEASUREMENT LESS THAN 7/8-INCH - Turn
thebottomofthestabilizercylinderCLOCKWISE.
D. Line up mounting holes in stabilizer cylinder and
the stabilizer plates and reinstall the bottom hex
bolt.
D. Line up mounting holes in stabilizer cylinder and
the stabilizer plates and reinstall the bottom bolt.
E. Check performance of the wheelchair. Repeat
STEPS A-D if necessary.
E. Perform one (1) of the following:
DISTANCE IS BETWEEN 7/8 AND 1-INCH -
Reinstall the locknut tighten securely.
F. Tighten the jamnut on the stabilizer cylinder.
Locknut
DISTANCEISNOTBETWEEN7/8AND1-INCH
- Repeat STEPS B-E until the measurement is
between 7/8 and 1-inch.
Jam Nut
Adjustment Nut
Stabilizer
F. Tighten the jamnut on the stabilizer cylinder.
Plates
Locknut
Jam Nut
Stabilizer
Cylinder
Adjustment Nut
Stabilizer
Plates
BOTTOM
Hex Bolt
Stabilizer
Cylinder
Bottom of Stabilizer
Cylinder
BOTTOM
Hex Bolt
FIGURE 14 - ADJUSTING TYPE B STABILIZER ASSEMBLY
FOR USER PREFERENCE
Bottom of Stabilizer
Cylinder
FIGURE 13 - ADJUSTING TYPE A STABILIZER
ASSEMBLY FOR USER PREFERENCE
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MWD WHEELCHAIRS
PROCEDURE 14
5. Position the new stabilizer cylinder on the wheelchair
as shown in FIGURE 16.
Adjusting Type C Stabilizer Assem bly for User
Preference (FIGURE 15)
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NOTE: Refer to STABILIZER INDENTIFICATION in
the beginning of this section to determine correct sta-
bilizer assembly.
6. Secure the top of the new stabilizer cylinder to the
wheelchair frame with the hex bolt and locknut.
WARNING
DO NOT ove rtighte n. Sta bilize r c ylinde r will not
opera te properly.
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1. Rotating the locknut that is located on top of the lower
spring provides one (1) of the following:
A. Rotating the locknut CLOCKWISE - provides
more resistance of the stabilizer when stopping
and increases stability.
7. Secure the bottom of the new stabilizer cylinder to the
stabilizer plates with the hex bolt and locknut.
8. Repeat STEPS 2-7 for the opposite side of the wheel-
chair, if necessary.
B. RotatingthelocknutCOUNTER-CLOCKWISE
- provides less resistance of the stabilizer when
stopping and improves obstacle climbing ability.
9. Tighten the jam nut on the stabilizer cylinder.
10. Adjust the front stabilizer(s). Refer to ADJUSTING
STABILIZERS in this procedure of the manual.
R
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11. Ifnecessary, installthefrontshroud. RefertoREMOV-
ING/INSTALLING SHROUDS in PROCEDURE 10
of this manual.
Stabilizer
Locknut
Wheelchair Frame
Jam Nut
Locknuts
Lower
Spring
TOP Hex
Bolt
FIGURE 15 - ADJUSTING TYPE C STABILIZER
ASSEMBLY FOR USER PREFERENCE
Stabilizer
REPLACING STABILIZER
CYLINDERS
BOTTOM
Cylinder
Hex Bolt
Stabilizer
Replacing Stabilizer Cylinders for Type A and
Type B Stabilizer Assem blies (FIGURE 16)
Plates
NOTE: Refer to STABILIZER INDENTIFICATION in
the beginning of this section to determine correct sta-
bilizer assembly.
NOTE: Only stabilizer cylinder for Type A stabilizer
assemlby shown. Stabilizer cylinder for Type B stabi-
lizer assembly removes/installs in the same manner.
1. If necessary, remove the front shroud. Refer to RE-
MOVING/INSTALLINGSHROUDSinPROCEDURE
10 of this manual.
FIGURE 16 - REPLACING STABILIZER CYLINDERS FOR
TYPE A AND TYPE B STABILIZER ASSEMBLIES
2. Remove the top hex bolt and locknut that secure the
existing stabilizer cylinder to the wheelchair frame.
3. Remove the bottom bolt and locknut that secure the
bottom of the existing stabilizer cylinder to the stabi-
lizer plates.
4. Remove existing stabilizer cylinder from the wheel-
chair.
75
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PROCEDURE 14
MWD WHEELCHAIRS
Replacing Stabilizer Cylinders for Type C
Stabilizer Assem blies (FIGURE 17)
5. 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.
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NOTE: Refer to STABILIZER INDENTIFICATION in the
beginning of this section to determine correct stabilizer
assembly.
6. Secure the top of the stabilizer cylinder to the wheel-
chair frame with the top mounting screw and locknut.
Loosely tighten.
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1. Place a 1/2-inch block underneath drive wheel.
2. Remove the top mounting screw and locknut that se-
cures the top of the stabilizer cylinder to the wheel-
chair frame.
7. Torque both mounting screws to 13 ft/lbs and then back
off 1/8 to 1/4 turn.
NOTE: The length of the new stabilizer cylinder must be
adjusted to match the length of the stabilizer cylinder just
removed.
2. Note the mounting position of the existing stabilizer
cylinder for proper installation of the new stabilizer cyl-
inder.
8. Measure the distance between the top mounting hole
and the bottom mounting hole on the existing stabilizer
cylinder. Note this distance as distance “A” . Refer to
DETAIL “A”
3. Remove the bottom mounting screw, washers and
locknut that secures the bottom of the stabilizer cylin-
der to the swing arm.
R
S
4. Remove the existing stabilizer cylinder.
9. Place the wheelchair on a flat surface so that the stabi-
lizer wheels can hang freely.
10. Loosen the jam nut, located underneath the hex nut
adjuster, by turning CLOCKWISE as viewed from the
top.
Top
Mounting
Screw
Top of
Stabilizer
Cylinder
zRight Hand side of
Wheelchair Frame
11. Rotate the hex nut adjuster in one (1) of the following
directions:
A. Rotating the hex nut adjuster CLOCKWISE, as
viewed from the top, will move the stabilizer wheel
up.
Bottom of
Stabilizer
Cyliner
B. RotatingthehexnutadjusterCOUNTER-CLOCK-
WISE, as viewed from the top, will move the stabi-
lizer wheel down.
Locknut
Washer
12. When distance “A” is achieved, noted from STEP 8,
retighten the jam nut by rotating COUNTER-CLOCK-
WISE to lock the hex nut adjuster in position.
13. Placethewheelchaironaflatsurfacewithallsixwheels
in contact with the surface.
There is no
need to remove
this mounting screw
and locknut
REPLACING STABILIZER WHEEL
Replacing Stabilizer Wheel for Type A and Type
B Stabilizer Assem blies (FIGURE 18)
Bottom
Mounting
Screw
Locknuts
Swing
Arm
NOTE: Refer to STABILIZER INDENTIFICATION in the
beginning of this section to determine correct stabilizer as-
sembly.
NOTE: Stabilizer assembly exploded away for clarity.
It is not necessary to remove the stabilizer assembly
from the wheelchair frame.
NOTE: Note the position of the stabilizer wheel for installa-
tion of the new stabilizer wheel.
1. Remove the hex bolt and locknut that secure the exist-
ing stabilizer wheel and spacers to the stabilizer plates.
FIGURE 17 - REPLACING STABILIZER CYLINDERS FOR
TYPE C STABILIZER ASSEMBLIES
76
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MWD WHEELCHAIRS
PROCEDURE 14
2. Remove existing stabilizer wheel from the wheelchair.
REPLACING STABILIZER CYLINDER
3. Positionthenewstabilizerwheelandspacersbetween SPRINGS (FIGURE 16)
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the stabilizer plates.
Replacing Stabilizer Cylinder Springs for
4. Reinstallthehexboltthroughthestabilizerplates,spac-
ers and new stabilizer wheel and tighten securely.
Type A Stabilizer Assem blies (FIGURE 14)
NOTE: Refer to STABILIZER INDENTIFICATION in
the beginning of this section to determine correct sta-
bilizer assembly.
5. Repeat STEPS 1-4 for opposite side of wheelchair.
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Mount
Stabilizer
Wheel in
TOP
Mounting
Hole
1. If necessary, remove the front shroud. Refer to RE-
MOVING/INSTALLINGSHROUDSinPROCEDURE
10 of this manual.
2. Loosen the jam nut on the stabilizer cylinder.
Only
Stabilizer
Plates
3. Remove the top hex bolt and locknut that secure the
stabilizer cylinder to the wheelchair frame.
Locknut
Hex Bolt
R
S
4. Remove the bottom bolt and locknut that secure the
bottom of the stabilizer cylinder to the stabilizer plates.
Spacers
Stabilizer Wheel
5. Remove the stabilizer cylinder from the wheelchair.
6. Unscrew the stabilizer cylinder pivot and jam nut from
the stabilizer cylinder.
FIGURE 18 - REPLACING STABILIZER WHEEL FOR
TYPE A AND TYPE B STABILIZER ASSEMBLIES
WARNING
The sta bilizer cylinder spring is under compression.
SLOWLY remove the a djustment nut while check-
ing to ma ke sure the cylinder spring is becoming
unc ompre sse d. If the spring is not be c oming
uncompressed, DO NOT remove the a djustment
nut, otherwise injury or da ma ge ca n occur. Con-
ta ct Inva ca re Technica l Service, 1-800-832-4707.
Replacing Stabilizer Wheel for Type C
Stabilizer Assem blies (FIGURE 19)
NOTE: Refer to STABILIZER INDENTIFICATION in the
beginning of this section to determine correct stabilizer
assembly.
1. Secure the fork to the caster with one (1) 7/16-20 x 3-
1/4-inch hex screw, washer, and locknut.
7. SLOWLY remove adjustment nut and plate from sta-
bilizer cylinder while checking to make sure existing
stabilizer cylinder spring is becoming uncompressed.
2. Torque the locknut to 120-in/lbs.
8. Remove the existing stabilizer cylinder spring from the
stabilizer cylinder.
3. Loosen the locknut 1/8 of a turn by turning the locknut
COUNTER-CLOCKWISE.
NOTE: Examine the stabilizer cylinder and replace if worn.
4. Move the caster side to side.
9. Install the new stabilizer cylinder spring onto the stabi-
lizer cylinder.
NOTE: If the caster moves side to side, tighten the locknut
slightly. Repeat STEP 3 until there is no side to side move-
ment.
10. Reinstall the plate and adjustment nut onto the stabi-
lizer cylinder as shown in FIGURE 16.
5. Repeat STEP 1 for other caster and fork.
11. Screw the jamnut and stabilizer cylinder pivot onto
the stabilizer cylinder.
Locknut
7/16-20x
12. Position the new stabilizer cylinder on the wheelchair
as shown in FIGURE 16.
3-1/4-inch
Hex Screw
Washer
13. Secure the top of the new stabilizer cylinder to the
wheelchair frame with the hex bolt and locknut.
WARNING
DO NOT ove rtighte n. Sta bilize r c ylinde r will not
opera te properly.
Caster
Washer
14. Secure the bottom of the new stabilizer cylinder to the
stabilizer plates with the hex bolt and locknut.
FIGURE 19 - REPLACING STABILIZER WHEEL FOR
TYPE A AND TYPE B STABILIZER ASSEMBLIES
77
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PROCEDURE 14
MWD WHEELCHAIRS
15. RepeatSTEPS2-14fortheoppositesideofthewheel-
chair, if necessary.
2. Remove the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure of
the manual.
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16. Tighten the jamnut on the stabilizer cylinder.
3. Remove the tip from the existing clutch handle.
WARNING
Sta bilize rs MUST be a djuste d BEFORE use , oth-
e rwise the y will NOT ope ra te prope rly.
4. Removethepinthatsecurestheexistingclutchhandle
to the motor/gearbox.
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17. Adjust the front stabilizer(s). Refer to ADJUSTING
STABILIZERS in this procedure of the manual.
5. Disconnect the existing clutch handle from the motor/
gearbox.
18. Ifnecessary, installthefrontshroud. RefertoREMOV-
ING/INSTALLING SHROUDS in PROCEDURE 10
of this manual.
6. Feed the existing clutch handle through the wheel-
chair frame.
7. Remove the rubber tip from the new clutch handle.
8. Install the new clutch handle onto the wheelchair.
Locknuts (STEPS 3,
13)
Wheelchair
NOTE: Make sure the new clutch handle is pointing to-
wards the outside of the wheelchair.
R
S
Frame
TOP Hex Bolt
(STEPS 3, 13)
9. Install the rubber tip onto the new clutch handle.
10. Connect the clutch handle to the motor/gearbox and
line up the mounting holes in the clutch handle and
motor/gearbox.
Stabilizer
Cylinder
BOTTOM Hex
Bolt (STEPS
4, 14)
11. Insert the pin through the clutch handle and motor/
gearbox as shown in DETAIL "A" in FIGURE 21.
Stabilizer Plates
NOTE: Make sure the detent ball on the pin is fully visible.
Stabilizer Cylinder Pivot (STEPS 6, 11)
Jam Nut (STEPS 2, 11, 16)
12. RepeatSTEPS3-11fortheoppositesideofthewheel-
chair, if necessary.
13. Reinstall the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure of
the manual.
Adjustment Nut (STEPS 7, 9)
Plate (STEPS 7, 10)
14. If necessary, install the shrouds. Refer to REMOV-
ING/INSTALLING SHROUDS in PROCEDURE 10
of this manual.
Stabilizer Cylinder Spring
(STEPS 8, 9)
Tip (STEPS 3, 7, 9)
Clutch Handle
(STEPS 5, 8)
Outside of
Wheelchair
Inspect for Wear
Stabilizer Cylinder
FIGURE 16 - REPLACING STABILIZER CYLINDER
SPRINGS
Motor/
Gearbox
REPOSITIONING MOTORS
WARNING
Repositioning the motors MUST be performed by an
authorized Invacare dealer or qualified technician.
Pin (STEPS 4, 11)
DETAIL "A"
REPLACING CLUTCH HANDLES -
R2BASIC AND R2250 SERIES (FIGURE 21)
Motor/Gearbox
Detent Ball
Clutch Handle (STEP 10)
1. If necessary, remove the shrouds. Refer to REMOV-
ING/INSTALLING SHROUDS in PROCEDURE 10
of this manual.
FIGURE 21 - REPLACING CLUTCH HANDLES -
RANGER II MWD BASIC
78
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MWD WHEELCHAIRS
PROCEDURE 14
Battery Motor
Connectors
(STEPS 4, 19)
REPLACING MOTOR/ GEARBOX -
R2BASIC AND R2250 SERIES(FIGURE 22)
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1. If necessary, remove the shrouds. Refer to REMOV-
ING/INSTALLING SHROUDS in PROCEDURE 10
of this manual.
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2. Remove the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure of
the manual.
STEPS 5, 6 AND 17
Locknut
3. Cut the tie wrap that secures the motor wire to the
battery tray mounting bracket.
Crossbrace
Washer
Hex Bolt
4. Disconnect the right and/or left motor connector from
the controller.
5. Remove the drive wheels from the wheelchair. Refer
to REMOVING/INSTALLING DRIVE WHEELS in
PROCEDURE 9 of this manual.
Dust Cover
R
S
LONG Socket Screws (Apply
Loctite 242 and torque to 60-inch
pounds) (STEPS 11, 13)
6. Remove the dust covers, hex bolt, washers and lock-
nut that secure the bottom of the crossbrace to the
wheelchair frame
Wheelchair Frame
7. Removethebottomofthecrossbracefromthemount-
ing bracket on the wheelchair frame.
SHORT Socket
Screws (Apply
Loctite 242 and
Pin
(STEP 8)
8. Remove the pin that secures the clutch handle to the
existing motor/gearbox.
torque to 60-inch
pounds)
9. Disconnect clutch handle from existing motor/gear-
box.
(STEPS 11, 13)
10. Notemountingpositionofmotor/gearboxonthewheel-
chair frame for installation of the new motor/gearbox.
Clutch Handle
(STEP 9)
11. Remove the six (6) socket screws that secure the ex-
istingmotor/gearboxandbatterytraymountingbracket
to the wheelchair frame.
12. Position the new motor/gearbox and existing battery
tray mounting bracket on the wheelchair frame at the
position noted in STEP 10 as shown in FIGURE 22.
CAUTION
Tie Wrap
(STEPS 3,
20)
The longer socket screws must be positioned in
the mounting holes on the OUTSIDE of the wheel-
cha ir fra me a nd the short socket screws must be
in the mounting holes on the INSIDE of the wheel-
cha ir fra me. Otherwise da ma ge to the gea rbox
ma y result.
Battery
Tray
Mounting
Bracket
13. Use Loctite 242 and tighten the battery tray mounting
bracket and motor/gearbox to the wheelchair frame
securely with the six (6) socket screws. Torque to 60-
inch pounds.
Motor/
Gearbox
14. Connect the clutch handle to the new motor/gearbox
and line up the mounting holes.
DETAIL "B"
Pin (STEP 14)
Motor/Gearbox
(STEP 14)
15. Insert the pin through clutch handle and new motor/
gearbox as shown in DETAIL "B" in FIGURE 22.
Clutch Handle
(STEP 14)
Detent Ball
FIGURE 22 - REPLACING MOTOR/ GEARBOX -
RANGER II MWD BASIC
79
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PROCEDURE 14
MWD WHEELCHAIRS
NOTE: Make sure the detent ball on the pin is fully visible.
10. Position the new motor/gearbox and existing battery
tray mounting bracket on the wheelchair frame at the
position noted in STEP 8 as shown in FIGURE 19.
16. RepeatSTEPS3-15fortheoppositesideofthewheel-
chair, if necessary.
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17. Reinstall the drive wheels onto the wheelchair. Refer
to REMOVING/INSTALLING DRIVE WHEELS in
PROCEDURE 9 of this manual.
CAUTION
The longer socket screws must be positioned in the
mounting holes on the OUTSIDE of the wheelcha ir
fra me a nd the short socket screws must be in the
mounting holes on the INSIDE of the wheelcha ir
fra me. Otherwise da ma ge to the gea rbox ca sting
ma y result.
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18. Reinstall the hex bolt, washers, locknuts and covers
that secure the bottom of the crossbrace to the wheel-
chair frame.
19. Reconnect the right and/or left motor connector to the
controller.
11. Use Loctite 242 and tighten battery tray mounting
bracket and motor/gearbox to the wheelchair frame
securely with the six (6) socket screws. Torque to 60-
inch pounds.
20. Securemotorwiretothebatterytraymountingbracket
with a new tie wrap.
21. Reinstall the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure of
the manual.
R
S
12. Repeat STEPS 3-11 for the opposite side of the wheel-
chair, if necessary.
22. If necessary, install the shrouds. Refer to REMOV-
ING/INSTALLING SHROUDS in PROCEDURE 10
of this manual.
13. Reinstall the drive wheels onto the wheelchair. Refer to
REMOVING/INSTALLING DRIVE WHEELS in PRO-
CEDURE 9 of this manual.
14. Reinstall the hex bolt, washers, locknuts and dust cov-
ers that secure the bottom of the crossbrace to the
wheelchair frame.
REPLACING MOTOR/ GEARBOX -
R2STANDARD (FIGURE 23)
1. If necessary, remove the shrouds. Refer to REMOV-
ING/INSTALLING SHROUDS in PROCEDURE 10 of
this manual.
15. Reconnect the right and/or left motor connector to the
controller.
16. Secure the motor wire to the battery tray mounting
bracket with a new tie wrap.
2. Remove the battery boxes. Refer to INSTALLING/RE-
MOVING BATTERY BOXES in this procedure of the
manual.
17. Reinstall the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure of
the manual.
3. Cut the tie wrap that secures the motor wire to the bat-
tery tray mounting bracket.
18. If necessary, install the shrouds. Refer to REMOV-
ING/INSTALLING SHROUDS in PROCEDURE 10
of this manual.
4. Disconnect the right and/or left motor connector from
the controller.
5. Remove the dust covers, hex bolt, washers and lock-
nut that secure the bottom of the crossbrace to the
wheelchair frame
6. Remove the bottom of the crossbrace from the mount-
ing bracket on the wheelchair frame.
7. Remove the drive wheels from the wheelchair. Refer
to REMOVING/INSTALLING DRIVE WHEELS in
PROCEDURE 9 of this manual.
8. Note the mounting position of motor/gearbox on wheel-
chair frame for installation of new motor/gearbox.
9. Remove the six (6) socket screws that secure the exist-
ing motor/gearbox and battery tray mounting bracket
to the wheelchair frame.
80
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MWD WHEELCHAIRS
PROCEDURE 14
LONG Socket Screws
(Apply Loctite 242 and
torque to 60-inch pounds)
(STEPS 9, 11)
SHORT Socket Screws
(Apply Loctite 242 and
torque to 60-inch
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pounds) (STEPS 9, 11)
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Battery Motor Connectors
(STEPS 4, 15)
STEPS 5, 6 AND 14
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Locknut
Battery Tray
Mounting
Bracket
Crossbrace
Wheelchair
Frame
Washer
Tie Wrap
(STEPS 3,
16)
Hex Bolt
Dust Cover
Motor/Gearbox
FIGURE 23 - REPLACING MOTOR/ GEARBOX - RANGER II MWD STANDARD
81
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NOTES
NOTES
N
O
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E
S
82
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WARRANTY
LIMITED WARRANTY
PLEASE NOTE: THE WARRANTY BELOW HAS BEEN DRAFTED TO COMPLY WITH FEDERAL LAW APPLICABLE TO
PRODUCTS MANUFACTURED AFTER JULY 4, 1975.
This wa rra nty is extended only to the origina l purcha ser/user of our products.
W
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N
T
This wa rra nty gives you specific lega l rights a nd you ma y a lso ha ve other lega l rights which va ry from
sta te to sta te.
With rega rds to the origina l purcha ser/user only, Inva ca re wa rra nts the side fra mes a nd crossbra ces to be
free from defects in ma teria ls a nd workma nship for a period of five (5) yea rs from da te of purcha se;
electronics for a period of one (1) yea r from the da te of purcha se; motors a nd gea rboxes for a period of
e ighte e n (18) months for Ra nge r II mode ls with motors tha t ha ve motor loc ks a nd a period of twelve
(12) months for Ra nger II models with motors tha t ha ve clutches from the da te of purcha se; a ll rema in-
ing components (including ga s cylinders for recliners) for one (1) yea r from the da te of purcha se except
upholstered ma teria ls, pa dded ma teria ls a nd tires/wheels. If within such wa rra nty period a ny product
sha ll be proven to be defective, such product sha ll be repa ired or repla ced, a t Inva ca re's option. This
wa rra nty does not include a ny la bor or shipping cha rges incurred in repla cement pa rt insta lla tion or
repa ir of a ny such product. Inva ca re's sole obliga tion a nd your exclusive remedy under this wa rra nty
sha ll be limited to such repa ir a nd/or repla cement.
Y
For wa rra nty service, plea se conta ct the dea ler from whom you purcha sed your Inva ca re product. In
the event you do not receive sa tisfa ctory wa rra nty service, plea se write directly to Inva ca re a t the a d-
dre ss on the ba c k c ove r. Provide dea ler's na me a ddress, da te of purcha se, indica te na ture of the
defect a nd, if the product is seria lized, indica te the seria l number. Do not return products to our fa ctory
without our prior consent.
LIMITATIONS AND EXCLUSIONS: THE FOREGOING WARRANTY SHALL NOT APPLY TO SERIAL NUMBERED PROD-
UCTS IF THE SERIAL NUMBER HAS BEEN REMOVED OR DEFACED, PRODUCTS SUBJECT TO NEGLIGENCE,
ACCIDENT, IMPROPER OPERATION, MAINTENANCE OR STORAGE, COMMERCIAL OR INSTITUTIONAL USE,
PRODUCTS MODIFIED WITHOUT INVACARE'S EXPRESS WRITTEN CONSENT INCLUDING, BUT NOT LIMITED TO,
MODIFICATION THROUGH THE USE OF UNAUTHORIZED PARTS OR ATTACHMENTS; PRODUCTS DAMAGED BY
REASON OF REPAIRS MADE TO ANY COMPONENT WITHOUT THE SPECIFIC CONSENT OF INVACARE, OR TO
A PRODUCT DAMAGED BY CIRCUMSTANCES BEYOND INVACARE'S 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 OPERATING NOISE,
PARTICULARLY RELATIVE TO MOTORS AND GEARBOXES DOES NOT CONSTITUTE A FAILURE. ALL SUCH DE-
VICES 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 FITNESS FOR A
PARTICULAR PURPOSE, SHALL NOT EXTEND BEYOND THE DURATION OF THE EXPRESSED WARRANTY PRO-
VIDED HEREIN AND THE REMEDY FOR VIOLATIONS OF ANY IMPLIED WARRANTY SHALL BE LIMITED TO REPAIR
OR REPLACEMENT OF THE DEFECTIVE PRODUCT PURSUANT TO THE TERMS CONTAINED HEREIN. INVACARE
SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES WHATSOEVER.
THIS WARRANTY SHALL BE EXTENDED TO COMPLY WITH STATE/PROVINCIAL LAWS AND REQUIREMENTS.
83
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Invacare Corporation
USA
Canada
One Invacare Way
Elyria, Ohio USA
44036-2125
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. 98-273 Part No. 1085398 Rev B (1) 3/00
800-333-6900
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