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Hi Dave,
Yep those instructions were just recently updated! :-)
You should test the IKFast solution using the command line tool ikfastdemo.cpp or by compiling the inbuilt main() function as mentioned in the OpenRAVE documentation. This was written to check that your IK works before using it in ROS; if you don't get a solution using this test code, then it won't work in ROS either. However it hasn't been tested with 5 or 7 DOF arms, so if you think there's a bug then let me know.
The PR2 and WAM are 7 DOF, so there should be a little bit of documentation around. It seems that you create the IK solution by saying that the shoulder or wrist will be a "free parameter", then you call IK by specifying the known angle/pose of this joint (eg. horizontal) and therefore the solver only has 6 unknowns.
I would suggest that you first test generating an IKFast solution and using the demo program for a known redundant manipulator model eg. the WAM, then this might indicate where the problem is?
Regards, David.
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