CONTROL SYSTEM FOR THE PHYSICALLY DISABLED

Transcription

1 INSTALLATION Push/Rock HAND CONTROL SYSTEM FOR THE PHYSICALLY DISABLED With Howell Ventures Ltd

2 Sure Grip Hand Control Systems and Accessories are warranted against manufacturing or material defects for a period of 48 months from date of purchase. This warranty covers replacement of parts and materials only, labour is not covered. Warranty valid only upon receipt of the completed Warranty Registration Form Sure Grip serial number: Installation Date: Owner Name: Address: City: Installation Details Province /State Postal Code /Zip Dealer Name: Address: City: Province /State Postal Code /Zip X Signature of Owner: X Signature of Dealer: March 20092

3 TABLE OF CONTENTS 1.0 Purpose Introduction Instructions Precautions Sure Grip Parts List & Diagram Sure Grip Components and Parts Tools For Installation Pre-Installation Checks Installation Procedure Determine Best Location for Clamping Block & Support Rod Install Mounting Bracket & Clamping Block Install Support Rod Install Gas Rod Install Brake Rod Install Main Body Install Gas & Brake Tubes Make Final Adjustments Perform Final Sure Grip Checks Post-Installation Checks Miscellaneous 11.1 Hand Control Maintenance AutoLock System Maintenance Log

4 1.0 PURPOSE The purpose of the Installer s Guide is to: provide the Sure Grip Trained Installer with reference information and instruction (supplemental to the Training Program) during the installation of the Sure Grip 2.0 INTRODUCTION The Sure Grip allows those who cannot use the foot pedals of a vehicle, the opportunity to operate the gas and brake by means of a hand control. Through an innovative design, Sure Grip provides users with a better overall way of driving; push forward to brake, rock back to accelerate. This unique rocking motion allows full range braking and acceleration with minimal distance of hand travel. The Sure Grip hand control includes the following ergonomic features: easiest gas operation in the industry thus reducing forearm fatigue comfortable arm position ability to operate the vehicle with two hands easy access of signals and other auxiliary functions smooth transition from gas to brake and back again. The Sure Grip is a very accommodating hand control that is able to meet almost any installation challenge. The performance of the Sure Grip depends completely on how well the installation is performed. Because all vehicles are different, the installer needs to be creative. Please closely follow this manual and do the best possible job while being mindful of your client; give them the driving experience they deserve! 4

5 3.0 INSTRUCTIONS a. Prior to installing the Sure Grip, READ all sections. b. RE-FAMILIARIZE yourself with the Sure Grip components, parts terminology and relationship of the parts, and how the Sure Grip is assembled. c. Upon completion of the Sure Grip installation, please COMPLETE and RETURN the Warranty Card and pictures of the installation to Howell Ventures Ltd. 4.0 PRECAUTIONS WARNING Improper installation may cause system failure, which may lead to fatal accidents. CAUTION Sure Grip components, Gas and Brake Tubes, can only support a bend of 15 degrees or less. Most vehicles today contain decorative panels and trim around the dashboard area and standard equipment such as air conditioning. Therefore, it is often necessary to remove and/or trim these panels and ducts to obtain the necessary clearances. For this reason it is imperative that the installer be technically skilled to successfully perform any vehiclespecific fabrication. The Guide s purpose is to assist the Installer during an installation. More in depth instruction is obtained through the Training Program and direct consultation with the manufacturer. Phone: Fax: suregrip@suregrip-hvl.com 5

6 5.0 SURE GRIP PARTS LIST AND DIAGRAM Item Qty Part # Description Item Qty Part # Description Control Tube Assembly ¼ x ¼ Setscrew Gas Lever Assembly ¼ NC Nylon Lock Nut Ball Joint - Gas Tube ¼ Vinyl Nut Cap Ball Joint Brake Rod Brake Rod Gas Tube /8 Vinyl Nut Cap Control Arm Large Brake Block Brake Tube Small Brake Block Tension Spring Washer /8 High Collar Lock Washer Gas Block Bracket /16 x 2 ½ UNC Bolt ¼ x ¾ Setscrew /16 Lock Washer ¼ Lock Washer /16 UNC Nut ¼ Ball Joint Gas Rod /16 Ball Joint - Brake Tube ¼ UNF Nut /16 Stover Nut Threaded Gas Rod Operating Handle /16 Flat Washer Tension Spring Support Rod Brake Rod Package (Includes Items 4, 25, 32, 36, 39, 40, 41, 42, 43, 44) Support Tube Main Body Assy (Includes Items 1, 2, 8,11, 28, 29, 30, 31, 33, 34, 35, 37, ) /8 Setscrew ¼ Expansion Pin Gas Tube Assy (Includes Items 3 & 6) /8 UNF Nylon Nut Brake Tube Assy (Includes Items 9, 45, 46) /8 UNC Hex Nut Gas Rod Package (Includes Items 15, 16, 18, 19, 20, 21, 32) 6

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8 6.0 SURE GRIP COMPONENTS AND PARTS The Sure Grip Hand Control system consists of the following eight (8) key components: 1. Mounting Bracket 2. Clamping Block 3. Support Rod 4. Gas Rod Assembly 5. Brake Rod Assembly 6. Main Body 7. Gas Tube 8. Brake Tube 7.0 TOOLS FOR INSTALLATION The tools necessary for the Sure Grip installation are as follows: Sure Grip Jack Press (For bending tubes and Support rod) Electric drill - 3/8 capacity with drill bits Allen wrenches 1 Countersink Permanent strength lock thread Torque wrench Standard Shop Tools 8

9 8.0 PRE-INSTALLATION CHECKS Prior to installing the Sure Grip, ENSURE the following: a. Vehicle equipped with power steering, power brakes and automatic transmission ONLY. b. Vehicle meets all motor vehicle safety standards. c. Brakes operate satisfactory. d. IF brakes are worn, THEN POSTPONE Sure Grip installation until brakes repaired. e. Gas pedal is in good working order. f. Steering wheel tilted to the client s preference. (Often after an installation, the tilt can only be moved upward without interfering with the hand control.) g. Power adjustable pedals disengaged. h. Battery disconnected (if vehicle equipped with air bag). i. Vehicle is ready for Sure Grip installation. j. All sections of the Installation and Owner s Guide have been read as stated per Section 3.0 Instructions. 9

10 WARNING Vehicle must meet all motor vehicle safety standards. Installation of the Sure Grip on modified vehicles is not authorized. Modified is defined as changes not made or authorized by the vehicle s manufacturer. These changes include: oversized, undersized or un-treaded tires modified suspension systems additional or modified carburetors or linkages small steering wheels not supplied by the vehicle s manufacturer any change that tends to make the vehicle difficult or dangerous to drive. 10

11 9.0 INSTALLATION PROCEDURE Upon successful completion of Section 8 PRE-INSTALLATION CHECKS, the vehicle should be ready for the installation of the Sure Grip. There are eight (9) major steps to Installing the Sure Grip. These major steps are: 9.1 Determine Best Location for Clamping Block & Support Rod 9.2 Install Mounting Bracket & Clamping Block 9.3 Install Support Rod 9.4 Install Gas Rod 9.5 Install Brake Rod 9.6 Install Main Body 9.7 Install Gas and Brake Tubes 9.8 Make Final Adjustments Remember, upon completion of the Sure Grip installation, please COMPLETE Section 10 Post-Installation Checks. 11

12 9.1 Determine Best Location for Clamping Block & Support Rod a. IF the vehicle is equipped with air bags, THEN ENSURE negative side of battery disconnected. b. REMOVE the knee bolster and lower dash panel to examine the steering column. Figure Clamping Block & Support Rod Combinations c. DETERMINE where the Support Rod should exit the dash and where the Clamping Block should be mounted as follows: 1. Refer To Figure Clamping Block & Support Rod Combinations. 2. ATTACH the Clamping Block to the Support Rod. 3. SIMULATE the final install by sliding the Main Body onto the Support Rod and holding the Operating Handle beside the steering wheel. 4. NOTICE where the Support Rod will exit the dash (preferably through the hole provided). 5. DETERMINE where the Clamping Block should be mounted (preferably the steering column studs). 12

13 9.2 Install Mounting Bracket & Clamping Block CAUTION The Clamping Block and Support Rod should be mounted on the right side of the steering column. 9.3 Install Support Rod in Clamping Block Figure Support Rod & Clamping Block NOTE The Support Rod can be adjusted across or up/down in the Clamping Block. Offset and extra long Support Rods are also available. With the offset Support Rod, the 90 degree bend is made in the middle of an elongated Support Rod. Tips Support Rod The Support Rod comes at a standard length. However, either end can be cut to position the hand control in the desired location. To position the hand control closely to the steering wheel, a bend in the Support Rod is often needed. Mark the Support Rod where it comes through the dash and give it a slight bend. Often this is only a 2 to 5 degree bend. 13

14 9.4 Install Gas Rod Figure Gas Bracket Attached to Pedal Arm NOTE Whenever possible, the Threaded Gas Rod should be placed on the right side of the gas pedal arm. This will allow for added room for those who are using the existing foot pedals. When attaching the Gas Block Bracket to the pedal arm, it is recommended that mounting be done as high as possible (in most cases). The higher the bracket, the less distance a user s hand must travel. Adversely, more arm strength is required when the bracket is mounted higher on the pedal arm. After mounting, apply the gas hard making sure the gas rod does not come in contact with the dash. a. ALLIGN the bracket with the pedal arm. b. WHEN the final position is determined, OBSERVE where the setscrews make contact and DRILL two holes in the pedal arm (1/8 in diameter and 1/8 deep). c. TIGHTEN ¼ setscrews to 25 in/lbs. d. Go To Step 9.5 Install Brake Rod. 14

15 9.5 Install Brake Rod Tips Brake Rod When attaching the Threaded Brake Rod to the pedal arm, it is recommended that mounting be done as high as possible (in most cases). The higher the clamping bracket is mounted, the less distance a user s hand must travel. Adversely, more arm strength is required when the bracket is mounted higher on the pedal arm. When the bracket is mounted higher on the pedal arm, the chances of having it rub or come in contact with the dash is greater. Therefore, after mounting the bracket, apply the brakes hard, making sure the Brake Rod does not come in contact with the dash. If contact is made, then consider lowering the bracket or bending the tube. a. IF attaching Brake Rod to brake pedal arm, THEN INSTALL as follows: 1. PLACE Brake Rod on left side of brake pedal arm. 2. PLACE one clamping bracket on each side. 3. BOLT brackets together and TIGHTEN to 22 ft/lbs. b. IF attaching Brake Rod to brake pedal, THEN INSTALL as follows: 1. PLACE brake block on pedal and MARK two holes. 2. DRILL two 5/16 holes in pedal (some rubber may have to be cut). 3. BOLT to pedal and TIGHTEN to 60 in/lbs. 4. Go To Step 9.6 Install Main Body. 15

16 9.6 Install Main Body Figure Main Body a. SLIDE the Support Tube of the Main Body onto the Support Rod. b. SLIDE or ROTATE the Main Body to determine the best position, ensuring the Operating Handle is one hand width from the steering wheel. c. TIGHTEN one setscrew in the Support Tube to temporarily hold in place. NOTE For all setscrews, it is recommended that a permanent strength lock thread be applied when the final position of the hand control is determined. d. TIGHTEN the setscrews on the Support Tube to 25 ft/lbs. e. Go To Step 9.7 Install Gas and Brake Tubes. 16

17 9.7 Install Gas & Brake Tubes CAUTION The Gas and Brake Tubes can only support a maximum bend of 15 degrees. Figure Gas Tube a. To install the Gas Tube, PERFORM the following: 1. SLIDE the Gas Tube onto the threaded Gas Rod. 2. ATTACH the Gas Rod end to the Gas Lever of the Main Body with a ¼ locknut and TIGHTEN snugly. 3. HOLD the Operating Handle in the neutral position, and THREAD the nuts along the Gas Rod making contact with the Gas Tube. 17

18 4. ADJUST the nuts to stabilize the Operating Handle ensuring no play. 5. WHEN the final position is determined, TIGHTEN (or LOCK) the nuts back-to-back. Figure Brake Tube b. To install the Brake Tube, PERFORM the following: 1. THREAD the Brake Tube onto the Threaded Brake Rod. 2. INSERT the top portion of the Brake Tube (ball joint) into the bracket on the Control Tube of the Main Body and HOLD tube in place with 5/16 locknut (stover nut). 3. WHEN final position is determined, TIGHTEN the locknut (or bolt) to 60 in/lbs. 18

19 4. THREAD 3/8 hex nut up Threaded Brake Rod until it touches the Brake Tube. 5. TIGHTEN nuts located at top and bottom of Brake Tube. 6. CHECK angles to ensure both Gas and Brake Tubes do not bind. (Refer To Figure Assembly Pivot Points.) Figure Assembly Pivot Points c. IF either tube binds, THEN PERFORM the following: 1. LOCATE a pre-bent tube or BEND the tube but no more than 15 degrees, to conform to the dash. 2. INSTALL the bent tube in the same manner as the straight tube. 3. Go To Step 9.8 Make Final Adjustments 19

20 9.7.6 Setting the Spring Washer Tension Figure Tension Spring & Washer NOTE The tension spring and washer prevents the Operating Handle from turning when the brake or gas pedal is pushed by a foot, a. To set tension, TURN Tension Spring Washer and tighten setscrew. b. ENSURE tension is adequate by engaging the gas pedal and confirming Operating Handle returns to the neutral position. 20

21 9.8 Make Final Adjustments MAKE the following six (6) final adjustments: 1. Adjust Operating Handle Position 2. Adjust Neutral Position 3. Adjust Angle of Main Body 4. Adjust Location of the Main Body 5. Set The Spring Washer Tension 6. Perform Final Sure Grip Installation Checks Adjust Operating Handle Position Figure Operating Handle Position a. ENSURE Operating Handle as Close as possible to the turn signal handle while allowing for unobstructed activation. Approx. 2 inches from steering wheel. (continued) 21

22 Figure Operating Handle Position (Hand s Width) b. ENSURE Operating Handle is a hand s width away from the steering wheel. c. LOOSEN setscrew in Tension Spring washer. d. LOOSEN 3/8 lock nut on Gas Lever. e. ROTATE Operating Handle to desired location. f. ROTATE Gas Lever clockwise until it stops. g. HOLD Operating Handle in desired position and TIGHTEN 3/8 lock nut to 30 ft/lbs. h. TIGHTEN setscrew in Tension Spring washer. 22

23 9.8.2 Adjust Neutral Position Figure Operating Handle (Neutral Position) a. ENSURE neutral position of the Operating Handle is as tight as possible with very little back and forth movement. b. START the vehicle and ADJUST nuts on Gas Rod so engine does not rev. c. To adjust the neutral position of the Operating Handle, USE the nuts on the Gas Rod. d. BRING nuts to bottom of Gas Tube and LOCK back-to-back. (continued) 23

24 NOTE For the Operating Handle to return to the neutral position, the Gas and Brake Tubes may need a spring attached to their respective threaded rod. Figure Return to Neutral (Spring Attachment) e. IF either the Gas Tube or Brake Tube OR both need a spring attached to the threaded rod, THEN PERFORM the following: 1. INSERT looped end of spring into hose clamp placing it immediately above the ball joint. 2. ATTACH the straight end of return spring to the underside of dash by wrapping it around one of the screws in the dash. 3. CUT OFF any excess spring with pliers. 24

25 9.8.3 Adjust Angle of Main Body Figure Angle of Main Body NOTE The angle of the Main Body should be set so the Control Tube and the Support Tube have 100 to 120 degrees between them when the Hand Control is in the neutral position. When the brake is applied, there should be approximately 70 to 80 degrees between the tubes. a. To adjust the angle, MOVE the Support Tube on the Support Rod or MOVE the Brake Tube up or down the Threaded Rod. b. To lock the Brake Tube in place, HOLD the nut at top of the tube and TIGHTEN the nut on the Threaded Rod to the bottom of the tube. 25

26 9.8.4 Adjust Location of Main Body Figure Location of Main Body a. ENSURE the location of the Main Body is as close to the steering column as possible. b. ENSURE there is a least 2 of Support Rod in the Support Tube. c. WHEN the final position is found, ADD a permanent strength lock thread. d. Before tightening the setscrews to final the position, RE-INSTALL the vehicle s dash. e. TIGHTEN the setscrews to 25 ft/lbs. 26

27 9.9 Perform Final Sure Grip Installation Checks a. Physically CHECK tightness of all fasteners. b. OBSERVE all torque specifications. c. ENSURE brake lights only come on during braking. d. IF brake lights do not shut off, THEN Refer To Step Adjust Neutral Position. e. ENSURE vehicle idles properly. f. IF vehicle does not idle properly THEN Refer To Step Adjust Neutral Position. g. WHEN brake is fully applied, ENSURE the Gas Lever does not contact either the underside of the steering wheel or fingers. h. IF either occurs, THEN Refer To Step Adjust Location of Main Body. i. ENSURE the Operating Handle does not make contact with the door. j. IF contact occurs, THEN ADJUST the Operating Handle position. k. APPLY force (push hard) to both brake and gas to ensure the brackets do not touch the floor or firewall of the vehicle. l. IF contact occurs, THEN ADJUST brackets accordingly. m. TEST-DRIVE the vehicle to ensure the following: 1. Passing gear operates properly. 2. ABS braking system engages and the braking in general is in acceptable working order. 3. Everything else is operating properly. n. Prior to customer pick up, CLEAN (with a vinyl cleaner) all vinyl coated parts of the Sure grip. o. FAMILIARIZE the client with the Sure Grip hand control (continued) 27

28 p. INFORM the client to return the vehicle in one week for a final evaluation/adjustments. q. Go To Section 10.0 Post-Installation Checks POST-INSTALLATION CHECKS WHEN Step Perform Final Sure Grip Installation Checks has been completed, PERFORM the following: a. TAKE photos of the completed installation and if possible, photos to suregrip@suregrip-hvl.com b. COMPLETE the Sure Grip Warranty Card and MAIL to: Howell Ventures Ltd Rte. 102 Upper Kingsclear, NB E3E 1P8 For your Convenience Warranty Cards can now be filled out Suregrip-hvl.com (By Dealers, in the dealers lounge). Thank you! 28

29 11.0 Miscellaneous 11.1 user Maintenance Adjust the Neutral Position of the Operating Handle WARNING Except for the following maintenance tips, any other problems with the hand control should be directed towards your local mobility dealer. Do not attempt to repair this system on your own. a. LOCATE the two nuts at the bottom of the Gas Tube. NOTE Loosening the nuts will cause added slack in the Operating Handle. Tightening will eliminate slack. Over tightening the nuts will cause the vehicle to rev while idling. This situation should be avoided. b. TIGHTEN or LOOSEN the two nuts. c. WHEN the desired location is found, LOCK the two nuts back-to-back Check all Fasteners/Clean/Lubricate a. Every six (6) months, CHECK all fasteners. b. IF anything seems to be wearing, tearing or breaking, THEN immediately CONTACT your local dealer for maintenance. c. Clean all ball joints and pivot points. Lubricate all with light oil. d. Verify that the AutoLock system is operating properly. e. MAINTAIN the above information in the enclosed Installation and Maintenance Record. Remember, all Sure Grip parts are guaranteed for four(4) years. 29

30 11.3 AutoLock System 1. Each Sure Grip has a built in safety feature that allows the user to disable the accelerator function of the hand control when able bodied user are operating the vehicle. 2. It is the responsibility of the driver to always disable the accelerator function of the hand control via the AutoLock System anytime the vehicle is to be operated by able bodied users. 3. Failure to disable the acceleration function can result in severe injury, death, or property damage due to inadvertent and unwanted acceleration via the Hand Control. Operation of the System 1. Located on the right hand side of the operating handle is the AutoLock device. Simply push the knurled knob to the right to disable the accelerator of the hand control. 2. To enable the accelerator, pull the knurled knob to the left or press the locking pin from the opposite direction. Disabled Knurled Knob Push inward to disable. Knurled Knob Enabled Pull outward to enable accelerator 30

31 11.4 Installation/Maintenance Record Date Technician / Facility Comments 31

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