Invacare Formula PTO Plus Service Manual Download Page 35

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SECTION 10—SAFETY INSPECTION/TROUBLESHOOTING

Part No 1125031

Formula

™

PTO Plus Powered Seating

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

Battery failure.

Malfunctioning battery charger.

Electrical malfunction.

Check batteries for shorted cell.
Replace if necessary.

Replace charger.

Contact Invacare.

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

Batteries not charged.

Weak batteries.

Have charger checked.

Replace batteries if necessary.Refer to
Installing/Removing the Batteries on
page 150, Rem oving/Installing Batteries
from/into Battery Tray on page 160 or
Replacing Batteries on page 173.

Motor “chatters” or runs irregular.

Electrical malfunction.

Contact Invacare.

Joystick erratic or does not respond
as desired.

Damaged motor coupling.

Electrical malfunction.

Controller programmed
improperly.

Inspect motor coupling. See service
manual for wheelchair base.

Contact Invacare for Service.

Check programming. See electronics
manual.

Wheelchair does not respond to
commands.

Poor battery terminal
connection.

Have terminals cleaned.

Power indicator off - even after
recharging.

Electrical malfunction.

Contact Invacare.

SYMPTOM

PROBABLE CAUSE

SOLUTIONS

Summary of Contents for Formula PTO Plus

Page 1: ...in this manual MUST be performed by a qualified technician For more information regarding Invacare products parts and services please visit www invacare com Formula PTO Plus Powered Seating on TDX Whe...

Page 2: ...TECHNICAL SUPPORT BEFORE ATTEMPTING TO SERVICE OR OPERATE THIS EQUIPMENT OTHERWISE INJURY OR DAMAGE MAY RESULT USEFUL TERMS The following acronyms are used throughout this manual ACRONYM DEFINITION TR...

Page 3: ...nto M71 Wheelchairs 13 Pronto M91 Wheelchairs 14 SECTION 7 GENERAL GUIDELINES 15 Accessories 15 Batteries 15 Electrical Grounding Instructions 16 Operation Information 17 Repair or Service 19 Tire Pre...

Page 4: ...enter Mount Footrest 54 Adjusting the Angle of the Center Mount Footrest 55 Adjusting the Center Mount Footplate Angle 55 Adjusting the Tension of the Center Mount Footplate 56 SECTION 13 POWER ELEVAT...

Page 5: ...03 Removing Installing the Actuator Shroud 107 Replacing the Tilt Actuator 108 Removing Installing the Cam Switch Cover 112 Removing Installing the Cam Harness Cable 114 Removing Installing the Spring...

Page 6: ...150 Connecting Disconnecting the Battery Wiring Harness 153 Charging Batteries 155 Battery Charger Operation 156 SECTION 21 M71 BATTERIES 159 Warnings For Handling and Replacing Batteries 159 Using t...

Page 7: ...are s position that users of wheelchairs should be transferred into appropriate seating in vehicles for transportation and use be made of the restraints made available by the auto industry Invacare ca...

Page 8: ...r s TDX MK5 1114809 TDX Base Only MK6i 1143150 Pronto M71 MK5 before 1 24 06 1106631 Pronto M71 MK5 after 1 23 06 1141449 Pronto M71 Base Only MK6i 1143240 Pronto M91 MK5 before 1 24 06 1110560 Pronto...

Page 9: ...EV B REFER TO OWNER S MANUAL WEIGHT CAPACITY 375 LBS 170 kgs P N 1125066 Rev B If tilt function is not operating and is in the down seated position PRIOR to servicing the device contact Invacare Techn...

Page 10: ...assist module Call 800 832 4707 WARNING WARNING ALWAYS reinstall the spring safety bracket AND tether when servicing the PTO Plus seating system These safety devices MUST be in place at all times Othe...

Page 11: ...25062 Rev B P N 1111014 REV B REFER TO OWNER S MANUAL WEIGHT CAPACITY 275 LBS 125 kgs P N 1126990 REV B REFER TO OWNER S MANUAL WEIGHT CAPACITY 375 LBS 170 kgs P N 1125066 Rev B If tilt function is no...

Page 12: ...BACK HEIGHT RANGE 16 24 inches SEAT TO FLOOR HEIGHT ADJUSTABLE IN 1 INCH INCREMENTS 18 to 20 inches inch OVERALL WIDTH WITH JOYSTICK AND TRSS 27 inches OVERALL HEIGHT 37 45 inches OVERALL LENGTH WITH...

Page 13: ...air with a weight limitation of 300 lbs then the power wheelchair is restricted to a 275 lb weight limitation SEAT WIDTH RANGE 16 20 inches SEAT DEPTH RANGE 1 INCH INCREMENTS 16 20 inches BACK HEIGHT...

Page 14: ...en the power wheelchair is restricted to a 275 lb weight limitation SEAT WIDTH RANGE 16 22 inches SEAT DEPTH RANGE 1 INCH INCREMENTS 16 22 inches BACK HEIGHT RANGE 16 24 inches BACK ANGLE RANGE ASBA 8...

Page 15: ...manuals or instruction sheets supplied with this product or optional equipment Accessories WARNING Risk of Serious Injury or Damage Use of non Invacare accessories may result in serious injury or dama...

Page 16: ...arger plugged into the joystick charger port at the same time Doing so will reduce the life of the batteries READ and CAREFULLY follow the manufacturer s instructions for each charger supplied or purc...

Page 17: ...k of Death or Serious Injury Traveling on inclines with wet slippery icy or oily surfaces could cause loss of traction resulting in death or serious injury DO NOT use on inclines with wet slippery icy...

Page 18: ...which to drive the wheelchair If a clear line of sight is not present have the back angle repositioned or readjust the lockout angle such that safe driving with a clear line of sight is achieved WARN...

Page 19: ...around children Keep hands and feet out from underneath tilt seat otherwise serious injury may result DO NOT tip the wheelchair without assistance DO NOT store items under the seat DO NOT leave eleva...

Page 20: ...efore use make sure that all attaching hardware is tightened securely WARNING Risk of Death Serious Injury or Damage Improperly connected joystick could cause loss of power resulting in death serious...

Page 21: ...base with tie wraps after servicing is complete Failure to follow the warnings and instructions listed below will result in injury to the users attendants and or bystanders and or damage to the wheel...

Page 22: ...se the tire to explode and cause bodily harm The recommended tire pressure is listed on the side wall of the tire Weight Limitation WARNING Refer to specifications on page 12 to determine the weight l...

Page 23: ...ed seat to the full upright position Make sure the hands and body of both the occupant and attendants bystanders are clear of all pinch points before returning the tilted seat to the full upright posi...

Page 24: ...eful protection from the more common sources of radiated EMI There are a number of sources of relatively intense electromagnetic fields in the everyday environment Some of these sources are obvious an...

Page 25: ...NOT operate hand held transceivers transmitters receivers such as citizens band CB radios or turn ON personal communication devices such as cellular phones while the powered wheelchair is turned ON 2...

Page 26: ...and properly Make sure actuator mechanism and tilt tracks are clean Ensure all fasteners are secure on clothing guards Ensure arms are secure but easy to release Ensure arm adjustment levers operate...

Page 27: ...functions after securing the cables to be sure cables do not get pinched or crushed during operation of the wheelchair Cables MUST be secured to the wheelchair frame and or base with tie wraps after s...

Page 28: ...TY INSPECTION TROUBLESHOOTING Formula PTO Plus Powered Seating 28 Part No 1125031 Verify front casters will not collide with legrests when fully swiveled Verify easy removal of arms and legrests Insta...

Page 29: ...m not functioning or working intermittently Low batteries Faulty electrical connection Blown fuse Seat has been driven under a heavy load for an extended period of time Charge batteries Check all conn...

Page 30: ...r lock levers are disengaged Speed set too low Battery charger connected Return to neutral position upright and completely lowered Refer to Operating the Powered Tilt System on page 103 Contact Invaca...

Page 31: ...DIAGNOSTICS CODE ERROR CODE DESCRIPTION SUB CODE DETAILS OF ERROR CODE POSSIBLE SOLUTION 1 E 01 User Fault 00 Stall Timeout or user error Release joystick to neutral and try again 2 E02 Battery Fault...

Page 32: ...e left park brake connections and cable 01 Left Park Brake Output Enabled When Wheelchair Idle 02 Left Park Brake Output Did not Enable When Entering Drive Mode 03 Left Park Brake fault during power u...

Page 33: ...re fault 08 Power up testing fault 09 Relay fault or precharge fault 10 Bridge fault or disable all fault 11 Electronics fault Thermistor 12 Calibration setting fault 9 E09 Communications Fault 00 Rem...

Page 34: ...LARGE displays and the wheelchair does not drive The joystick or input device is sending a value outside of the reverse forward left or right limits Error codes E01 E02 E03 or E04 Replace joystick or...

Page 35: ...y Refer to Installing Removing the Batteries on page 150 Removing Installing Batteries from into Battery Tray on page 160 or Replacing Batteries on page 173 Motor chatters or runs irregular Electrical...

Page 36: ...INGS Risk of Death Serious Injury or Property Damage Failure to observe the following transport warnings may result in death serious injury or property damage TRRO includes four factory installed tran...

Page 37: ...list on page 27 TDX Wheelchairs with TRRO Only Install the TRRO non compliance label and inform the wheelchair user of the change in transport ready status to TRBKTS Pronto Wheelchairs with TRRO or TR...

Page 38: ...crews securing the seat pan to the seat frame 3 Remove the seat pan from the seat frame 4 Remove the batteries Refer to one of the following sections of the manual Refer to TDX Batteries on page 171 R...

Page 39: ...ONTAL position 2 Remove the quick release pin that secures the flip back armrest to the wheelchair frame 3 Pull UP on the flip back armrest and remove the armrest from the arm sockets 4 Repeat STEPS 1...

Page 40: ...re refer to FIGURE 11 4 on page 41 1 Disconnect the joystick from the controller 2 Perform one of the following Low Seat to Floor Height Detail A i Remove the two hex screws that secure the seat frame...

Page 41: ...ith ASBA Seats Hex Screws Flat Washer Locknut Front Upper Seat Bracket Seat Frame Low Seat To Floor Rear Mounting Plate Flat Washer Locknut DETAIL A LOW SEAT TO FLOOR Hex Screws Flat Washers Locknuts...

Page 42: ...ardware on page 44 FIGURE 11 5 Removing the Existing Seat Assembly TDX Wheelchairs with Adjustable ASBA Seats M71 and M91 Wheelchairs NOTE For this procedure refer to FIGURE 11 6 on page 43 1 Disconne...

Page 43: ...Seat Assembly M71 and M91 Wheelchairs Latch Bar is located under the front of the seat Rear Pivot Brackets Seat Clevis Pins Latch Bar located under the front of the seat NOTE Van Seat model shown ASBA...

Page 44: ...the four hex screws that secure the front lower seat brackets and front upper seat brackets to the support beam tube 6 Remove the front upper seat brackets and front lower seat brackets 7 Install the...

Page 45: ...t mounting hardware Refer to Installing New Seat Mounting Hardware on M71 and M91 on page 47 FIGURE 11 8 Removing the Existing Seat Frame Mounting Hardware M71 and M91 Wheelchairs Installing the New S...

Page 46: ...for the remaining front seat bracket 6 Install the seat assembly Refer to Installing the Seat Assembly on page 48 FIGURE 11 9 Installing the New Seat Mounting Hardware Installing New Seat Mounting Ha...

Page 47: ...or M91 users under 250 lbs NOTE For this procedure refer to FIGURE 11 10 1 Install the seat post to desired mounting position FIGURE 11 10 2 Install mounting screw and locknut Torque locknuts to 13 ft...

Page 48: ...ckets or seat posts for the desired seat dump NOTE Seat dump is the seat angle relative to the ground when the seating system is not tilted upright position The seat dump can be 0 3 or 5 4 Align the f...

Page 49: ...fer to Connecting Cables on page 50 FIGURE 11 11 Installing the Seat Assembly TDX Wheelchairs M91 and M71 Wheelchairs Seat Brackets Stationary Link Shoulder Screws Washer Cap Screw Stationary Link Was...

Page 50: ...number 1118231 5 Connect the joystick WARNING Cables MUST be secured to the wheelchair frame and or base with tie wraps after servicing is complete Failure to follow the warnings and instructions bel...

Page 51: ...ctor Drive Lock Out Sensor Molex Connector Left Power Elevating Legrest Actuator Connector Auxiliary Power Connector 5 Pin Connector To Controller TRECM or TAC Tilt Actuator Connector Right Power Elev...

Page 52: ...only to secure an unoccupied wheelchair during transport TDX Wheelchairs with TRRO Only The installation of this kit will void TRRO compliance DO NOT transport an occupied wheelchair in a motor vehicl...

Page 53: ...injury or damage may result NOTE For complete operating information on Invacare footrests refer to the appropriate Owner s Manual listed in Reference Documents on page 8 Removing Installing the Cente...

Page 54: ...g 2 Adjust the footrest extension tube to the desired height and align the corresponding holes to the extension tube mounting holes 3 Reinstall the two mounting screws to secure the footrest extension...

Page 55: ...ever to lock the center mount footrest in the new position FIGURE 12 3 Adjusting the Angle of the Center Mount Footrest Adjusting the Center Mount Footplate Angle After 2 14 07 NOTE For this procedure...

Page 56: ...ocedure refer to FIGURE 12 6 NOTE The tension can be adjusted to increase or decrease the rotation effort of the flip up footplates 1 Loosen the mounting screw on the footrest angle hinge to decrease...

Page 57: ...wner s Manual listed in Reference Documents on page 8 Installing Removing the Power Elevating Legrests WARNING To prevent personal injury always verify proper positioning of legs and feet prior to use...

Page 58: ...s Detail B 6 If necessary adjust powered legs Refer to Adjusting the Power Elevating Legrests on page 59 Removing the Power Elevating Legrests 1 Disconnect power legrests from the harness 2 Push power...

Page 59: ...ts 2 Loosen but DO NOT remove the two exterior button screws that secure the footplate assembly to the T nuts 3 Loosen but DO NOT remove the two button screws that secure the heel loop to the T nuts 4...

Page 60: ...nuts 7 Repeat STEPS 1 6 for opposite footplate if necessary Adjusting the Footplate Angle NOTE For this procedure refer to FIGURE 13 4 on page 61 1 Loosen but DO NOT remove the two flat head screws a...

Page 61: ...No 1125031 61 Formula PTO Plus Powered Seating FIGURE 13 4 Adjusting the Footplate Angle DETAIL A DETAIL B Direction of Rotation Set Screw Barrel Nuts Footplate Clamp Footplate Flat Head Screws Footpl...

Page 62: ...h adjustment bracket hex head screws and slide calf pad assembly up and out of the mounting channel 2 Remove the flat head socket screw and locking hex nut that secure the calf bracket to the depth ad...

Page 63: ...o desired position 3 Holding the calf pad assembly in position tightly secure the hex screws to the T nuts 4 Repeat STEPS 1 3 for opposite side if necessary FIGURE 13 7 Adjusting the Calf Pad Height A...

Page 64: ...ss wire bracket Installing 1 If power legrests were not previously installed perform the following steps A Remove the hex screw and washer securing the front of the rear arm socket to the seat frame B...

Page 65: ...ing legrest actuator to the power legrest bracket 3 Remove the short shoulder screw and locknut securing the actuator rod to the actuator bracket 4 Remove the power elevating legrest actuator from the...

Page 66: ...houlder screw should be on the inside of the legrest and the locknut should be toward the outside of the legrest 4 Install the power elevating legrest Refer to Installing Removing the Power Elevating...

Page 67: ...pan from the upper mounting brackets Installing the Curved Back Pan 1 If the fastening strips and upper curved back pan mounting screws have been removed from the curved back pan and or the upper mou...

Page 68: ...e 11 Tighten all locknuts NOTE If any locknuts cannot be tightened properly perform the following steps A Remove the fastening strip from the curved back pan B Use an allen wrench to hold the curved b...

Page 69: ...N DETAIL B INSTALLING THE CURVED BACK PAN ADJUSTING CURVED BACK PAN HEIGHT Curved Back Pan Upper Curved Back Pan Mounting Screw Upper Height Adjustment Mounting Holes Small Mounting Screw Locknut Lowe...

Page 70: ...our front mounting brackets using the four socket screws washers and locknuts not shown Torque to 75 in lbs 20 5 If necessary tighten the socket screws and locknuts securing the front mounting bracket...

Page 71: ...his procedure refer to FIGURE 14 3 on page 72 1 Remove the armrests from the wheelchair 2 Remove the mounting screw washer coved washer and locknut from the top mounting hole of back angle plate and b...

Page 72: ...d locknuts to secure the back cane with insert to the back angle plate 6 Torque mounting screws to 75 in lbs 20 7 Reinstall the flip back armrests onto the wheelchair FIGURE 14 3 Adjusting the Back An...

Page 73: ...ocknuts to secure the cane brackets to the back canes 5 Torque the locknuts on upper and lower hex screws to 13 ft lbs FIGURE 14 4 Adjusting the Back Angle Adjustable ASBA Seats Adjusting the Back Hei...

Page 74: ...s securing the upper mounting brackets to the back canes Wheelchairs with a Seating System Remove the seating system from the back canes Refer to the seating system owner s manual 4 To ensure the prop...

Page 75: ...to the seating system owner s manual 11 Install the seat cushion 12 Install the armrest Refer to the wheelchair owner s manual FIGURE 14 5 Removing Installing the Back Canes ASBA Seats Adjustable ASBA...

Page 76: ...r and locknut through the slot in the cane bracket to secure the cane bracket to the back cane NOTE The cane bracket should be positioned as shown in FIGURE 14 6 2 Install the upper hex screw washer a...

Page 77: ...mounting tubes NOTE The threaded half clamp should be towards the rear of the wheelchair 2 Position the half clamps with the push bar onto one back cane NOTE The push bar should be oriented with the...

Page 78: ...chair 4 Secure the half clamps to the back canes using the three hex screws 5 Secure the bracket with lateral support attached to the half clamp with threaded holes using two socket screws FIGURE 14 8...

Page 79: ...or this procedure refer to FIGURE 14 11 on page 80 NOTE To adjust lateral width a different size bracket must be installed 1 Note the depth mounting position of the lateral support pad 2 Remove the tw...

Page 80: ...N 14 BACK Formula PTO Plus Powered Seating 80 Part No 1125031 FIGURE 14 11 Adjusting Lateral Width Lateral Support Pad Flat Screws Socket Screws Bracket Hinge NOTE Only one size bracket is shown for c...

Page 81: ...ess the battery compartment on wheelchairs equipped with a Formula PTO Plus seating system The seat assembly with the Formula PTO Plus seating system tilts back and props into place to provide access...

Page 82: ...eat assembly in the up open position while performing any necessary procedures Always lower the seat assembly to the down closed position when not servicing the wheelchair Ensure the seat is locked in...

Page 83: ...Installing the Seat Pan ASBA Seats NOTE For this procedure refer to FIGURE 15 2 on page 84 NOTE The following tools are required to perform this procedure Two 7 16 inch Sockets with Ratchet Torque Wr...

Page 84: ...seat pan to the seat frame 3 Remove the seat pan from the seat frame Installing 1 Position the new seat pan onto the seat frame as shown 2 Secure the new seat pan to the seat frame using the two sock...

Page 85: ...ents on page 8 3 Remove the two cap screws securing the stationary link to the front seat bracket or the front seat post 4 Refer to the table Seat Dump Mounting Positions to determine the mounting pos...

Page 86: ...ont seat posts for proper reinstallation 3 Remove the two cap screws and washers securing the stationary link to the front seat brackets or the front seat posts 4 Remove the two locknuts washers and s...

Page 87: ...onary link to the rear seat brackets or the rear seat posts using the two locknuts washers and shoulder screws Torque locknuts to 23 ft lbs 20 NOTE Washers are present only on TDX wheelchairs 3 Align...

Page 88: ...at Brackets Stationary Link Shoulder Screws Washer Cap Screw Stationary Link Washer Stationary Link Cap Screw Cap Screw Stationary Link Washer NOTE Seat not shown for clarity NOTE M91 base frame shown...

Page 89: ...y box 4 Remove the four cap screws and locknuts securing the front seat brackets to the battery box 5 Position one rear seat bracket at the desired height 6 Secure the rear seat bracket to the battery...

Page 90: ...or damage may occur The M71 wheel chair seat should only be mounted in mounting hole B FIGURE 15 7 Rear Seat Bracket Rear Seat Bracket Locknuts Front Seat Bracket Hex Screws Strap Nuts Battery Box Hex...

Page 91: ...four height positions in 1 2 inch increments 1 Remove the tilt assembly Refer to Removing Installing the Tilt Assembly on page 86 2 Remove the mounting screw and locknut that secure the seat post to t...

Page 92: ...o the seat frame 3 Examine the Seat Width Adjustment Table to determine if the seat width adjustment is within or beyond the range of the existing seat frame 4 Perform one of the following Within the...

Page 93: ...and coved washer Torque the hex screw to 75 in lbs 8 BPO Option Only Install the new spreader bar Refer to Removing Installing the Spreader Bar on page 77 Seat Width Mounting Holes SEAT WIDTH SIDE RA...

Page 94: ...e seat frame must be replaced to change the seat depth Refer to Removing Installing the Seat Frame on page 99 Side Rail Crossbar Crossbar Mounting Holes Seat Frame Hex Screw Coved Washer Seat Frame Mo...

Page 95: ...g Seat Depth Adjustment Table to determine the distance required to obtain the desired seat depth NOTE Distance is between the rear of the rear arm socket and the rear of the side rail Detail A 6 Meas...

Page 96: ...Remove both armrests 2 Remove the two hex screws washer and lanyard securing the crossbars to the side rail 3 Loosen but DO NOT remove the four hex screws securing the cane brackets to the side rails...

Page 97: ...lbs 3 Slide cane brackets with T nuts and back assembly into the slots in the side rails 4 Slide front arm sockets with T nuts into the slots in the side rails 5 Use a rubber mallet to tap the two ro...

Page 98: ...g at desired depth with existing two mounting screws spacers and locknuts Torque locknuts to 75 in lbs 20 FIGURE 15 11 Adjusting Replacing Telescoping Front Rigging Support ASBA Seats Adjustable ASBA...

Page 99: ...eat Pan on page 83 2 Disconnect the joystick from the controller 3 If replacing the seat frame perform the following steps A Remove the back canes Refer to Removing Installing the Back Canes on page 7...

Page 100: ...the tilt assembly using the four locknuts washers and hex bolts Torque the locknuts to 13 ft lbs 20 ASBA Seat Frame Positions WHEELCHAIR BASE SEAT DEPTH POSITION PRONTO M71 16 17 inch B 18 20 inch D...

Page 101: ...sher Position A DO NOT USE Position B Position C Position D NOTE Position C is at the front end of the slot and Position D is at the rear Tilt Assembly DETAIL A ASBA SEATS DETAIL B ADJUSTABLE ASBA SEA...

Page 102: ...line the seat back to the farthest driving position IMME DIATELY before drive lock out engages and ensure there is a clear line of sight present in which to drive the wheelchair If a clear line of sig...

Page 103: ...iated wiring and could cause a fire death physical injury or property damage If such devices are used Invacare shall not be liable and the limited warranty is void MK6i Systems Use only the actuator c...

Page 104: ...hair until the desired angle is achieved Decreasing the Tilt Angle 1 Pull the single function toggle switch BACK towards the REAR of the wheelchair until the desired angle is achieved FIGURE 16 1 Usin...

Page 105: ...ake sure the wheelchair is on a level surface 2 Press the mode button to switch from driving mode to tilt mode NOTE The LED will light up with a circle around it 3 Move the joystick Forward Tilts the...

Page 106: ...en Actuator Control Switch Mode is selected NOTE The location of the icons indicates the joystick direction or quadrant Detail B 5 Select the desired operation using the joystick or an equivalent swit...

Page 107: ...seat pan Refer to Removing Installing the Seat Pan on page 83 2 Remove the two screws and washers securing the actuator shroud 3 Remove the actuator shroud NOTE Tilting the actuator shroud may be nece...

Page 108: ...bly Refer to Removing Installing the Spring Assist Assembly on page 115 Wheelchairs without Spring Assist Use the tilt function to tilt the seat assembly back 4 Turn the joystick off 5 Disconnect the...

Page 109: ...l the new actuator has the clevis pin and at least one threaded pivot pin installed Otherwise the seat assembly may fall backward and injury or damage may occur 3 Ensure the seat assembly is supported...

Page 110: ...tail C 4 Install the washer onto the clevis pin Detail C 5 Install the cotter pin through the clevis pin 6 Install one threaded pivot pin to secure the left side of the actuator to the front of the ti...

Page 111: ...Tilt Actuator NOTE Spring assist removed for clarity Cap Screws Cam Harness NOTE Cam harnesscable not shown for clarity Tilt Frame Mounting Holes CamSwitch Cover Threaded Pivot Pin Threaded Pivot Pin...

Page 112: ...nstalling the Seat Pan on page 83 9 Connect the joystick 10 Turn the joystick on 11 Test the operation of the tilt system to ensure no cables are being pulled crushed or damaged If necessary remove ti...

Page 113: ...rness cable mounting holes with the mounting holes in the tilt assembly Detail A 5 Secure the cam harness cable to the tilt assembly using the two cap screws 6 Tie wrap the cam switch cover to the act...

Page 114: ...Turn the joystick off 4 Disconnect the joystick 5 Remove the rear shroud from the wheelchair Refer to the owner s manual listed in Reference Documents on page 8 6 For proper installation note the loc...

Page 115: ...tie wraps and reposition new tie wraps to secure the cables and prevent damage Removing Installing the Spring Assist Assembly WARNING DO NOT install the spring assist assembly onto M71 wheelchairs Th...

Page 116: ...rear of the spring assist assembly to the tilt frame Detail B 13 Remove the spring assist assembly from the tilt frame Installing 1 Position the spring assist assembly onto the tilt frame as shown in...

Page 117: ...moving Installing the Spring Assist Assembly Top View Cotter Pin Clevis Pin Washer Spring Assist Assembly Tilt Frame Mounting Screw Spring Retainer Threads Locknut Spring Assist Assembly Spring Thread...

Page 118: ...frame and or base ALWAYS test all wheelchair functions after securing the cables to be sure cables DO NOT get pinched crushed or pulled during operation of the wheelchair Connecting Disconnecting Net...

Page 119: ...r this procedure refer to FIGURE 17 2 on page 120 1 Loosen but DO NOT remove the mounting screw securing the drive lockout clamp to the tilt assembly 2 Remove the drive lockout sensor from the drive l...

Page 120: ...ng the Drive Lockout Sensor NOTE For this procedure refer to FIGURE 17 2 on page 120 1 Tilt the seating system until the joystick indicates drive lockout MK6i MPJ Joysticks TILT WARNING or SPM Inhibit...

Page 121: ...t present in which to drive the wheelchair If a clear line of sight is not present have the back angle repositioned or readjust the lockout angle such that safe driving with a clear line of sight is a...

Page 122: ...eds to be set to the desired actuator controls for each joystick direction FIGURE 17 3 Removing Installing the Sanode Removing Installing the 4 Way Switch Box 4WSB NOTE For this procedure refer to FIG...

Page 123: ...Test the seating system function to ensure the cable is not pulled crushed or pinched 7 If adding the 4 way switch box to the seating system further programming in the CALIBRATION menu is necessary t...

Page 124: ...the joystick mounting bracket to the half clamps and the half clamps to the joystick mounting tube not shown 3 Connect the connector to the 4 way switch box 4 Secure the cable to the powered seating...

Page 125: ...ble to the powered seating system using tie wraps 4 Test the seating system function to ensure the cable is not pulled crushed or pinched FIGURE 17 6 Removing Installing the Quad Push Button QPB Remov...

Page 126: ...network connector Refer to Connecting Disconnecting Network Connectors on page 118 4 Secure the cable to the powered seating system using tie wraps 5 Test the seating system function to ensure the cab...

Page 127: ...work Connectors on page 118 Installing 1 Secure the DLIAM to the seat pan using the two mounting screws 2 Connect the power elevating legrest harness connector 3 Connect the network connector Refer to...

Page 128: ...s Powered Seating 128 Part No 1125031 FIGURE 17 8 Removing Installing the Dual Leg Integrated Actuator Module DLIAM Network Connector Power Elevating Legrest Harness Connector Cables Dual Leg Integrat...

Page 129: ...oystick off 3 Disconnect the joystick 4 Tilt the PTO Plus back Refer to Tilting the Seat Assembly on page 81 5 Remove the shroud listed below from the wheelchair Refer to the owner s manual listed in...

Page 130: ...ted in Reference Documents on page 8 TDX Wheelchairs Remove the rear shroud M71 and M91 Wheelchairs Remove the front shroud 6 Disconnect the PTO Plus auxiliary power connector from the power take off...

Page 131: ...TAC must be programmed after installation Refer to Programming the TAC on page 142 1 Use the tilt function to tilt the seat back to 20 to 25 Refer to Operating the Powered Tilt System on page 103 2 Tu...

Page 132: ...CM or TAC to the mounting bracket FIGURE 18 3 14 Perform one of the following Systems Manufactured Before 1 17 2005 Loosen the two hex screws securing the controller bracket to the half clamps Systems...

Page 133: ...ontroller TAC Recline Sensor 3 pin Molex connector NOT USED Tilt Sensor 3 pin Molex connector Labeled Tilt Drive Lock Out Sensor 3 pin Molex connector Labeld D L Elevate Sensor Proximity Switch 3 pin...

Page 134: ...e repositioned or readjust the lockout angle such that safe driving with a clear line of sight is achieved Read and understand A Note About Drive Lock Out on page 102 BEFORE perform ing this procedure...

Page 135: ...tical position If the drive lock out does not stop the wheelchair from operating or the seat from elevating lowering in a tilt recline back angle position over 20 relative to vertical DO NOT operate t...

Page 136: ...ct the tilt actuator connector 2 pin Anderson from the SAC 5 Set up your digital multimeter for DC volts 6 Locate pins 2 and 3 on the charger port 7 Plug the negative BLACK lead into pin 2 8 Plug the...

Page 137: ...e position over 20 relative to vertical DO NOT operate the wheelchair or elevate lower the seat The wheelchair user MUST have a clear line of sight to drive safely On initial chair delivery and after...

Page 138: ...hten the mounting screw loosened in STEP 1 8 Plug the drive lockout sensor into the TRECM TAC SAC or TRSS drive lockout 3 pin Molex connector 9 Secure the drive lockout sensor cable to the wheelchair...

Page 139: ...the tilt sensor There is no adjustment to this switch Refer to Removing Installing the Cam Harness Cable on page 114 for replacement instructions Drive Lock Out Sensor 3 pin Molex Connector TRECM Moun...

Page 140: ...elchair Decreases the tilt limit angle 8 Tighten the mounting screw to secure the tilt sensor clamp in the desired position Replacing 1 Loosen but DO NOT remove the mounting screw securing the tilt se...

Page 141: ...Seating FIGURE 18 8 Adjusting Replacing the Tilt Sensor TRECM or TAC Tilt Sensor 3 pin Molex Connector TRECM Drive Lockout Clamp Tilt Assembly Tilt Sensor Drive Lockout Cable DETAIL A TRECM Mounting S...

Page 142: ...press the Select button 4 Scroll to SYSTEM TYPE and select the appropriate standard program 5 Press the Save button 6 Press the Menu button 7 Scroll to ACTUATOR SELECTION and press the Select button 8...

Page 143: ...les MUST be secured to the wheelchair frame and or base with tie wraps after servicing is complete Failure to follow the warnings and instructions listed below will result in injury to the users atten...

Page 144: ...l MK6i Joystick MK6i Joystick Connection MK6i Wheelchair Controller Wheelchair Controller Programmer Port Battery Charging Port 3 Pin Circular DIN Socket Drive Lockout Mercury Switch Connector 3 pin M...

Page 145: ...oystick MK5 Joystick Connection 15 Pin D Sub for Control of Wheelchair and Actuators 24 VDC Auxiliary Power Connectors to AUX Output of Wheelchair Controller Custom 3 Pin Plug MK5 Wheelchair Controlle...

Page 146: ...or Control of Wheelchair and Actuators Network Connection to ACC Port of Wheelchair Control 5 Pin Circular DIN Plug 24 VDC Auxiliary Power Connectors to AUX Output of Wheelchair Controller Custom 3 Pi...

Page 147: ...tors to AUX Output of Wheelchair Controller Custom 3 Pin Plug Attendant User Switch Input 9 Pin D Sub To Right Legrest Actuator Limit Sensor Inputs 3 Pin Molex Amp Connectors To Recline Sensor Not Use...

Page 148: ...et MK5 Joystick MK5 Joystick Connection 15 Pin D Sub for Control of Wheelchair and Actuators Network Connection to ACC Port of Wheelchair Control 5 Pin Circular DIN Plug 24 VDC Auxiliary Power Connect...

Page 149: ...and negative battery terminals Replace cable s immediately if cable s insulation becomes damaged DO NOT remove fuse or mounting hardware from POSITIVE red battery cable mounting screw WARNING Make sur...

Page 150: ...the battery acid Before reinstalling the existing or new batteries clean the baking soda from the battery tray or batteries being sure to avoid contact with skin and eyes Determine source of contamina...

Page 151: ...FIGURE 20 1 B Batteries Without Built In Lifting Strap Use the battery lifting strap to position battery into the battery tray When battery is in proper position remove lifting strap Detail B of FIGU...

Page 152: ...r RED connector Refer to FIGURE 20 2 7 Move aside the motor leads and controller cable to allow unobstructed access to the front of the battery tray 8 Disconnect the rear battery from the front batter...

Page 153: ...battery cable and mounting screw connected Use the exposed threaded portion of the mounting screw to secure the POSITIVE RED cable to the POSITIVE terminal WARNING DO NOT remove fuse or mounting hardw...

Page 154: ...terminal cover from BLACK battery cable on front battery or GREY battery terminal cover from BLACK battery cable on rear battery 4 Remove the mounting screws and nuts that secure the POSITIVE RED batt...

Page 155: ...reduce the life of the batteries READ and CAREFULLY follow the manufactures instructions for each charger supplied or purchased If charging instructions are not supplied consult a qualified technicia...

Page 156: ...under any circumstances cut or remove the round grounding plug from the charger AC cable plug or the extension cord plug NOTE For this procedure refer to FIGURE 20 4 on page 157 NOTE Charge indicator...

Page 157: ...procedure refer to FIGURE 20 5 on page 158 NOTE The charger port located on the Front of the joystick requires the use of an independent charger The independent charger is NOT supplied with the wheelc...

Page 158: ...to the charger port on the front of the joystick 2 Plug the charger s AC power cord or extension into the grounded 110 volt wall outlet 3 Unplug the AC power cord or extension once charging is comple...

Page 159: ...jury or damage may result Make sure power to the wheelchair is OFF before performing this section The use of rubber gloves is recommended when working with batteries Invacare strongly recommends that...

Page 160: ...into Battery Tray WARNING Always use the battery handle or lifting strap when lifting the battery It is the most convenient method and assures that the battery acid will not spill It also helps to pro...

Page 161: ...t shown 4 Disconnect the front battery from the controller BLACK connector on the standard M71 OR RED connector on the M71 Formula PTO Plus 5 Disconnect the rear battery from the front battery GREY co...

Page 162: ...rking with batteries Battery terminal configuration as shown in FIGURE 21 3 DETAIL A MUST be used Batteries that have the terminal configuration reversed MUST NOT be used otherwise serious injury or d...

Page 163: ...es not tip when lifted by the handle E Repeat STEPS A D for the remaining battery 2 Secure the battery cables to the battery terminals as described below Securely tighten Refer to Detail A of FIGURE 2...

Page 164: ...nut U1 Battery DETAIL A DETAIL B POSITIVE Battery Terminal Cap NEGATIVE Battery Terminal Cap Tie wraps U1 Battery U1 Batteries GREY Connector BLACK Connector on M71 Standard OR RED Connector on M71 Fo...

Page 165: ...URE 21 3 7 Slide terminal cap s up on the battery cables 8 Disconnect POSITIVE RED battery cable from the POSITIVE battery terminal FIGURE 21 3 9 Disconnect NEGATIVE BLACK battery cable from NEGATIVE...

Page 166: ...charge rate is reduced and the battery charger rate decreases to a trickle charge NOTE If the batteries need to be charged more often or take longer to charge than normal they may need to be replaced...

Page 167: ...of the charger on the rear of the wheelchair Open rear shroud to view indicator lights 1 Plug the female connector of the AC power cord supplied to the AC receptacle on the charger and plug in the ma...

Page 168: ...RED Abnormal LED OFF Charger Off CHARGING INDICATOR STATUS YELLOW Charging BLINKING GREEN Output not connected SOLID GREEN Fully charged LED OFF Charger disconnected To Wall Outlet Female Connector on...

Page 169: ...l reduce the life of the batteries CAUTION Only use a charger approved by Invacare when charging through the joystick on this wheelchair model DO NOT use an independent charger with an output rating o...

Page 170: ...1 5 Charging Using an Independent Charger Plugged Into the Joystick DPJ Joystick SPJ 80 Joystick MPJ Joystick Charger Programming Port Charger Programming Port Charger Programming Port SPJ Joystick Ch...

Page 171: ...lation becomes damaged DO NOT remove fuse or mounting hardware from POSITIVE red battery cable mounting screw WARNING Make sure power to the wheelchair is OFF before performing these procedures The us...

Page 172: ...left and NEGATIVE on the right as shown below MUST be used Batteries that have the reverse terminal configuration MUST not be used otherwise injury and damage may occur Terminals MUST have a cross ho...

Page 173: ...ost s at the same time An electrical short may occur and serious personal injury or damage may occur 5 Remove the locknut that secures the bracket of the POSITIVE battery cable to the POSITIVE battery...

Page 174: ...NT BATTERY FOR REAR BATTERY Bracket of POSITIVE Battery Cable NEGATIVE Battery Cable BATTERY COVER AND TIE WRAP DETAIL RED Cover BLACK Cover GP24 Batteries 22NF Batteries Bracket of POSITIVE Battery C...

Page 175: ...4 TRRO and TRBKTS Options Only Perform the following steps A Remove two thumb screws that secure the top controller shroud FIGURE 22 4 to the battery box B Remove the top controller shroud from the b...

Page 176: ...the Battery Door and Rear Shrouds Wheelchairs without TRRO or TRBKTS Thumb Screws STEP 2 Disconnect Batteries from the controller here STEP 9 Mounting Screw STEP 6 GP24 Batteries with GP24 Battery Tr...

Page 177: ...GURE 22 5 A Disconnect ventilator battery from wiring harness B Disconnect the strap that secures the ventilator battery to the tray C Remove the ventilator battery Wheelchairs with TRRO or TRBKTS Bat...

Page 178: ...ar battery forward and remove it from the tray FIGURE 22 5 Removing the Batteries from the Wheelchair Disconnect front battery from rear battery here STEP 5 GP24 Batteries with GP24 Battery Tray DETAI...

Page 179: ...esignated by the battery stop Rear of the battery tray is the opposite end NOTE Orientation of the battery is critical otherwise batteries will not connect to the controller or each other 2 Position t...

Page 180: ...ll the battery support bracket onto the battery box FIGURE 22 4 on page 177 using the four hex screws and four locknuts if applicable Torque to 75 in lbs NOTE The installation of the battery support b...

Page 181: ...Assembly on page 81 8 If necessary charge the batteries Refer to Charging Batteries on page 184 Cleaning Battery Terminals WARNING Most batteries are not sold with instructions However warnings are f...

Page 182: ...p C RED LEDs indicate batteries are running out of charge Recharge batteries as soon as possible FIGURE 22 7 SPJ Joysticks MK6i MPJ Joystick NOTE For this procedure refer to FIGURE 22 8 The far right...

Page 183: ...this procedure refer to FIGURE 22 10 The left half of the second line is the Battery Gauge Display BGD It provides information on the remaining charge in the batteries At full charge solid blocks fil...

Page 184: ...urs of typical operation Extensive use on inclines may substantially reduce per charge mileage Description and Use of Battery Chargers The charger automatically reduces the charge from an initially hi...

Page 185: ...ire up to sixteen hours to be properly charged and equalized NOTE It is advantageous to recharge frequently rather than only when necessary In fact a battery s life is extended if the charge level is...

Page 186: ...NOTES Formula PTO Plus Powered Seating 186 Part No 1125031 NOTES...

Page 187: ...NOTES Part No 1125031 187 Formula PTO Plus Powered Seating NOTES...

Page 188: ...Canada 570 Matheson Blvd E Unit 8 Mississauga Ontario L4Z 4G4 Canada 800 668 5324 2016 Invacare Corporation All rights reserved Republication duplication or modification in whole or in part is prohibi...

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Invacare Formula PTO Plus, Service Manual

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