48
FIGURE 5 - REPLACING CLUTCH HANDLES
Tip
Outside of
Wheelchair
Motor/
Gearbox
Clutch Handle
Clutch
Handle
Pin
Motor/Gearbox
DETAIL "A"
NOTE: Battery tray not shown for clarity.
Pin
PROCEDURE 12
BASE FRAME
B
A
S
E
F
R
A
M
E
7. Remove the battery tray and both motor/gearboxes.
Refer to REMOVING/INSTALLING THE BATTERY
TRAY in PROCEDURE 11 in this manual.
8. Remove the controller. Refer ot REMOVING/INSTALL-
ING THE CONTROLLER in PROCEDURE 7 of this
manual.
9. Remove the tip from the existing clutch handle.
10. Feed the existing clutch handle through the wheelchair
frame.
11. Remove the rubber tip from the new clutch handle.
12. Install the NEW clutch handle onto the wheelchair.
NOTE: Make sure the NEW clutch handle is pointing to-
wards the outside of the wheelchair.
13. Install the rubber tip onto the new clutch handle.
14. Repeat STEPS 9-13 for the opposite side of the wheel-
chair, if necessary.
15. Install the controller. Refer ot REMOVING/INSTALL-
ING THE CONTROLLER in PROCEDURE 7 of this
manual.
16. Install the battery tray and both motor/gearboxes. Re-
fer to REMOVING/INSTALLING THE BATTERY TRAY
in PROCEDURE 11 in this manual.
17. Connect clutch handles to existing motor/gearboxes.
18. Install the pins that secure the clutch handles to the
existing motor/gearboxes.
19. Reassemble wheelchair by reversing STEPS 1-3.
REPLACING THE MOTOR/
GEARBOX (FIGURES 5 AND 6)
1. Remove the front and rear shrouds. Refer to RE-
MOVING/INSTALLING SHROUDS in PROCEDURE
10 of this manual.
2. Remove the front and rear battery boxes. Refer to
REMOVING/INSTALLING THE BATTERY BOXES in
PROCEDURE 11 of this manual.
3. Remove the seat. Refer to one (1) of the following:
A. REMOVING/INSTALLING THE STANDARD
SEAT FRAME in PROCEDURE 6 of this manual.
B. REMOVING/INSTALLING THE CAPTAIN’S VAN
SEAT in PROCEDURE 6 of this manual.
C. REMOVING/INSTALLING THE RECLINER SEAT
FRAME in PROCEDURE 13 of this manual.
4. Remove the drive wheels. Refer to REMOVING/IN-
STALLING THE DRIVE WHEELS in PROCEDURE
9 of this manual.
5. For wheelchairs equipped with motors that have clutches,
perform the following: Refer to FIGURE 5.
A. Remove the pin that secures the clutch handle to the
existing motor/gearbox.
B. Disconnect clutch handle from existing motor/gear-
box.
6. Note mounting position of motor/gearbox on the wheel-
chair frame for installation of the new motor/gearbox.
7. Remove the three (3) outside and two (2) inside mount-
ing screws that secure one (1) motor/gearbox and battery
tray to the base frame. Refer to FIGURE 6.
8. Remove the motor/gearbox from wheelchair frame.
9. Position the NEW motor/gearbox and align mounting holes
with the existing battery tray and wheelchair frame at the
position noted previously. Refer to FIGURE 6.
CAUTION
The three (3) OUTSIDE mounting screws that
secure the motor/gearbox to the base frame
MUST be M6 x 1 x 35-millimeters long and the
two (2) INSIDE mounting screws that secure
the motor/gearbox to the base frame MUST
be M6 x 1 x 20-millimeters long, otherwise
damage to the gearbox casting can result.
