44
REPLACING THE WIRING HARNESS
MKIV CONTROLLER ONLY (FIGURE 1)
1. If necessary, remove the front and rear shrouds. Refer to
REMOVING/INSTALLING SHROUDS in PROCEDURE
10 of this manual.
2. Remove the battery boxes. Refer to INSTALLING/RE-
MOVING BATTERY BOXES in PROCEDURE 11 of this
manual.
NOTE: Before removing the tie-wraps, note the tie-wraps po-
sition on the base frame and the components that they se-
cure.
3. Remove the tie-wrap “A” and “B” that secure the following
components to the base frame:
A. The connection between the left motor/gearbox lead
and left controller lead.
B. Right controller lead.
C. The connection between the controller connector
(BLUE) and the wiring harness (BLUE) connector.
D. The coil wrapped battery lead.
4. Remove tie-wrap “C” that secures the following to the
base frame:
A. The connection between the right motor/gearbox lead
and right controller lead.
B. The cable extending out from the blue connector of
the wiring harness for the power take-off.
C. Power take-off cable and lead for battery charger port
5. Remove tie-wrap “D”.
PROCEDURE 12
BASE FRAME
B
A
S
E
F
R
A
M
E
This Procedure includes the following:
Replacing the Wiring Harness MKIV Controller Only
Adjusting Stabilizer Assembly for User Preference
Replacing Stabilizer Cylinders
Replacing Stabilizer Wheel
Replacing Clutch Handles
Replacing Motor/Gearbox - Basic Motors
Replacing Motor/Gearbox - Standard Motors
Replacing Seat Mounting Plates
Replacing Seat Support Brackets
Replacing Seat Support Bracket T-Nuts
Replacing Battery Charger Bracket and T-Nut
Adjusting Weight Distribution
6. Remove the two (2) phillips bolts and locknuts that se-
cures the battery charger port to the mounting bracket.
7. Remove the battery charger port from the mounting
bracket.
8. HIGH BACK CAPTAIN'S SEAT MODEL WHEEL-
CHAIRS ONLY (DETAIL "A") - Unplug the power take-off
of the Captain’s Van Seat from the power take-off of the
wiring harness.
9. Disconnect the the connection between the controller
connector (BLUE) and the wiring harness (BLUE) con-
nector.
10. Remove the existing wiring harness from wheelchair.
11. Connect the controller connector (BLUE) and the new
wiring harness (BLUE) connector.
12. Install the battery charger port into the mounting bracket.
13. Secure the battery charger port to the mounting bracket
with the existing two (2) phillips bolts and locknuts. Se-
curely tighten.
14. HIGH BACK CAPTAIN'S SEAT MODEL WHEEL-
CHAIRS ONLY - Plug the power take-off of the captain’s
van seat into the power take-off of the wiring harness.
15. Perform the following steps for tie-wrap installation:
A. Position the connection between left controller lead
and the left motor/gearbox lead below the
crossmember with the left controller lead furthest
out on the crossmember and then fold cable lead
back in the opposite direction.
B. Position the connection between the controller con-
nector (BLUE) and the wiring harness (BLUE) con-
nector on top of the crossmember with the coil
wrapped battery lead extending out toward the right
hand side of the chair then fold back in opposite
direction and positioned on top of the two (2) blue
connectors. The cable for the PTO extending from
the BLUE connector is to run along crossmember
to the right hand side of the chair
C. Position the connection of the right controller lead
and the right motor/gearbox lead on top of the
crossmember so that the right controller lead is routed
on top of the blue connectors.
D. Install tie-wrap “A” and “B” to secure all components
and cables noted in STEPS 1-3 to the base frame.
E. With the connection of the right controller lead and
the right motor/gearbox lead on top of the
crossmember, fold the power take-off leads under-
neath crossmember and secure with tie wrap “C”.
F. Install tie-wrap “D”.
16. Reassemble wheelchair by reversing STEPS 1-2.
WARNING
After ANY adjustments, repair or service
and BEFORE use, make sure all attaching
hardware is tightened securely - other-
wise injury or damage may result.