Home

Invacare Power 9000 & Excel Service Manual

1. life of the battery Bottom i Wid DO NOT tp the batteries Keep the ee UM batteries in an upright position FIGURE 1 INSIALLING REMOVING BATTERIES INTO FROM BATTERY BOXES 15 Qm 2m i 5U PROCEDURE 7 BATTERIES CONNECTING BATTERY CABLES When connecting the battery cables to the battery ies the battery cable s MUST be connected to the battery terminal s post s NEVER allow any of your tools and or battery cable s to contact BOTH battery terminal s post s at the same time An as shown in DETAIL A or DETAIL B of HGURE 3 depending on battery type otherwise damage to the battery cable may result when installing batiery terminal caps electrical short may occur and serious personal injury or damage may occur The use of rubber gloves and safety glasses is recommended when working 2 Connect battery cable s to battery ies terminal s with batteries post s as follows DETAIL or DETAIL Bof FIGURE 3 depending on battery type Dual U1 or Dual 22NF Battery Boxes NEGATIVE BLACK battery cable to NEGATIVE Perform one 1 of the following methods for connecting battery terminal post the battery cable s B POSITIVE RED battery cable to POSITIVE FOR DUAL U1 BATTERIES Use direct mount battery terminal post method Refer to FIGURES 2 and 3 3 Secure the battery cable s ring terminal s to the battery terminal s post s BLACK to NEGATIVE TTERIE
2. CONNECTING BATTERY CABLES BATTERY CLAMP METHOD 18 BATTERIES PROCEDURE 7 9 Installthe battery box es into the wheelchair Referto 10 If necessary charge the battery ies Refer to INSTALLING REMOVING BATTERY BOX ES in the CHARGING BATTERIES in the PROCEDURE PROCEDURE 8 FWD MODELS or PROCEDURE 8 FWD MODELS or PROCEDURE 9 RWD 9 RWD MODELS of this manual MODELS of this manual NOTE New Battery ies MUST be fully charged BEFORE using otherwise the life of the battery ies will be reduced B CONNECTING BATTERY CABLE S TO BATTERY IES TERMINAL S POST S a POSITIVE Battery Terminal T Post and Battery Clamp NEGATIVE Battery Terminal E Fuse Box placement Post and Battery Clamp R when box top Negative BLACK l is installed Battery Cable Positive 4 P Ae RED Battery TOP VIEW Cable Group 22NF Battery Fuse Box ETAIL A Positive RED AT Battery Midi 21 LT Hex Screw S Mounting Plate Battery Clam Negative BLACK Battery Cable ER TONED p VIEW P d POSITIVE 4 Battery PI Terminal Post 22NF Battery ie i due NEGATIVE Battery Terminal Post NOTE Battery clamps exploded away for clarification purposes only DETAIL RED Battery Clamp Cover POSITIVE 7 Banery Terminal Post NEGATIVE Battery Terminal Post Tie Wrap Tie Wrap 22NF Battery BLACK Battery Clamp Cover FIGURE 6 CONNECTING BATTERY CABLES BATTERY CL
3. Caster Head Tube Fork fp P Locknut Washer Hex Screw Washer Caster HGURE 3 REPLACING FORKS 14 BATTERIES PROCEDURE 7 This Procedure includes the following NOTE If there is battery acid in the bottom or on the sides of the battery box es or battery ies apply baking soda Installing Removing Batteries into From Battery 5 these areas to neutralize the battery acid Before Connecting Battery Cables reinstalling the NEW or existing battery ies clean the baking soda from the battery box es or battery ies B NOTE When securing battery lifting strap to battery 2 observe polarity markings located on the ends of the battery boe pon o 5 big 2 r pom lifting strap side to POSITIVE battery terminalpost MET side to NEGATIVE battery terminal post The use of rubber gloves and safetyglasses R is recommended when working with 1 If necessary remove the battery boxes from the l batteries wheelchair Refer to INSTALLING REMOVING E BATTERY BOXES in PROCEDURE 8 FWD or Invacare stongly recommends that battery PROCEDURE 9 RWD of this manual S installation and battery replacement a AIMAYS be done by a qualified technician 2 Secure the battery lifting strap to battery terminal s After ANY adjustments repair or service POSG FIGURE T and BEFORE use make sure all attaching hardware is tightened securely otherwise injury or damage may resul
4. 12 Line up the mounting holes in the armrest insert armrest plate and armrest pad 13 Reinstall rear phillips screw through the armrest insert armrest plate and armrest pad and tighten securely 14 Reinstall the front phillips screw into the armrest plate and armrest pad and tighten securely 15 Repeat STEPS 11 14 for opposite side of wheelchair 16 Install Loctite 242 onto the three 3 hex bolts Armrest Plate Armrest Pad Lug Bolt STEPS 7 9 7 Locknuts STEPS 3 17 Armrest Insert Phillps Screw STEPS 5 13 Locknuts lu M STEPS 7 9 Ob Washers du STEPS 7 9 Hex Bolts STEPS 3 16 482 gt Phillps Screw STEPS 4 14 Adjustment Lock Lever GN Ss Washers STEPS 7 9 Spacers Seat Frame Assembly STEPS 3 17 FIGURE 9 REPOSTIONING MKIV J OYSTICK CAPIAIN SSEAT 24 FWD WHEELCHAIRS 17 Install the three 3 hex bolts spacers and locknuts that secure joystick mounting bracket to armrest plate 18 Slide the joystick mounting tube through the joystick mounting bracket to the desired position 19 Secure adjustment lock to joystick mounting tube by turning lever on adjustment lock REMOVING INSTALLING MKIV CONTROLLER FIGURE 10 Replacement controller MUST be same part numberasfactory installed c ontoller Otherwise injury ordamage may result Removing 1 If necessary remove the rear shroud and rear compartment if equipped R
5. MIDDLE 18 MIDDLE MIDDLE MIDDLE 20 MIDDLE MIDDLE MIDDLE USERS WEIGHT 200 LBS AND UNDER MOTOR MOUNTING POSITIONS SEAT DEPTH MIDDLE REAR REAR USERS WHGHT201 TO 250 LBS MOTOR MOUNTING POSITIONS SEAT SEAT DEPTH WIDTH 16 17 18 16 MIDDLE MIDDLE MIDDLE MIDDLE MIDDLE MIDDLE MIDDLE MIDDLE MIDDLE NOTE The front motor mounting position is reserved for future applications 1 Remove the battery boxes Refer to INSTALLING REMOVING BATTERY BOXES in this procedure of the manual 2 Perform one 1 of the following A WHEELCHAIR EQUIPPED WITH FLIP UP REMOVABLE FOOTBOARD Remove the hex screws and spacers that secure the battery tray hanger bracket and footboard mounting bracket to the wheelchair frame B WHEELCHAIR NOT EQUIPPED WITH FLIP UP REMOVABLE FOOTBOARD Remove the front hex screw that secures the battery tray hanger bracket to the wheelchair frame 3 Rotate battery tray hanger bracket up 4 Leftside of wheelchair only Remove the front dust cover from the end of the crossbrace NOTE Left is determined by sitting in the wheelchair 5 Refer to charts in this procedure to determine the proper mounting position that corresponds to the user s weight 6 Remove the six 6 socket screws that secure the motor to the wheelchair frame 7T Position the motor on the wheelchair frame at the position noted in STEP 5 as shown in FIGURE 26 37 A N w lt PROCEDUR
6. NOTE Make sure the detent ball on the pin is fully visible 11 Repeat STEPS 2 10 for the opposite side of the wheelchair if necessary 12 Reinstall the battery boxes Refer to INSTALLING REMOVING BATTERY BOXES in this procedure of the manual Clutch Handle l STEPS 4 5 7 Tip STEPS 2 6 8 Ir Outside of Wheelchair Motor 2 Gearbox i upu Pin STEPS 3 10 DETAIL A MEL Motor Gearbox Clutch Handle STEPS 9 10 Detent Ball FIG URE 27 REPLACING CLUTCH HANDLES REPLACING MOTOR GEARBOX FIGURE 28 1 Remove the battery boxes Refer to INSTALLING REMOVING BATTERY BOXES in this procedure of the manual 2 Disconnect the right and or left motor connector from the controller 3 Remove the drive wheels from the wheelchair Refer to REMOVING INSTALLING DRIVE WHEELS in PROCEDURE 6 of this manual 4 Perform one 1 of the following A WHEELCHAIR EQUIPPED WITH FLIP UP REMOVABLE FOOTBOARD Remove the hex screws and spacers that secure the battery tray hanger bracket and footboard mounting bracket to the wheelchair frame B WHEELCHAIR NOT EQUIPPED WITH FLIP UP REMOVABLE FOOTBOARD Remove the front hex screw that secures the battery tray hanger bracket to the wheelchair frame FWD WHEELCHAIRS 5 Rotate battery tray hanger bracket up 6 Leftside of wheelchair only Remove the front dust cover from the end of the cross
7. RII electronics it may be necessary to tum battery tray slightly away from controller to install the battery tray 4 Attach the hanger brackets to the support tubes on the wheelchair frame CHANGING SEAT WIDTH FIGURE 8 1 Remove the battery boxes and battery tray from the wheelchair Refer to INSTALLING REMOVING BATTERY BOXES and INSTALLING REMOVING BATTERY TRAY in this procedure of the manual 2 Remove the existing back and seat upholstery from the wheelchair Refer to REPLACING BACK UPHOLSTERY in PROCEDURE 3 of this manual and REPLACING SEAT UPHOLSTERY in PROCEDURE 5 of the owners manual part number 1080737 NOTE If adjusting the seat width of the wheelchair the back and seat upholstery MUST be changed as well 3 Remove the hex screws and locknuts that secure the two 2 pivot links to the wheelchair frame and cross braces Refer to the following chart to determine if new pivot links will be needed PIVOTLINK SEATWDTH RANGE IN INCHES 14 15 16 18 and 19 20 4 Remove dust covers from bottom of crossbraces 5 Remove the hex screws washers and locknuts that secure the bottom of the two 2 crossbraces to the wheelchair frame 6 Remove the hex screw coved spacers washers and locknut that secure the two 2 existing crossbraces together NOTE Note coved spacer washer and locknut order for reinstallation 7 Remove the four 4 pivot tube plug pins from the bottom of the two 2 exi
8. 0 volts under load 2 0 for a pair replace the batteries Testing under load is the only way to spot this problem While special battery load testing equipment is available itis costly and difficult to transport Use a digital voltmeter to check battery charge level at the charger connector It is located on the base of the wheelchair frame NOTE READ the instructions CAREFULLY before us ing the digital voltmeter NOTE Invacare recommends that ONLY qualified ser vice personnel perform this lest Ensure that power is OFF 2 Make sure battery is fully charged An extremely discharged battery will exhibit the same symptoms as a bad one 3 Place a one 1 piece of wood taller than the axle of the drive wheels between the wheelchair and a wall workbench or other stationary object 4 Removethe footrests from the wheelchair and place the stabilizer wheels or the front of the wheelchair against the piece of wood 5 Placethe voltmeter leads into the charger plug on the wheelchair Most digital voltmeters are not affected by polarity however analog meters meters with swinging needles can be and should be used carefully A good meter reading should be 25 5 to 26 VDC 6 Havetwo 2 individuals one 1 on each arm apply as much downward pressure as possible on the arms of the wheelchair PROCEDURE 2 7 Tumthe wheelchair ON and push the joystick forward trying to drive the wheelchair through the stationary
9. CANES 11 PROCEDURE 5 ELECTRONICS PREPARING MKIV JOYSTICK FORUSE 12 REPOSITIONING MKIV JOYSTICK 12 PROCEDURE 6 WHEELS REPLACING PNEUMATIC TIRES TUBES DRIVE WHEELS CASTERS 18 REMOVING INSTALLING DRIVE WHEELS 13 REPLACING CASTERS 14 REPLACING FORKS 14 PROCEDURE 7 BATTERIES INSTALLING REMOVING BATTERIES INTO FROM BATTERY BOXES 15 CONNECTING BATTERY CABLES 16 PROCEDURE 8 FWD WHEELCHAIRS 20 ASSEMBLING EXCEL 20 ADJUSTING FLIP UP REMOVABLE 21 REPLACING ARMREST PADS 22 REPLACING ARMREST PLATE 22 REPLACING SEAT POSITIONING STRAP 23 REPLACING CAPTAIN S SEAT 23 REPOSITIONING MKIV JOYSTICK CAPTAIN S SEAT 23 REMOVING INSTALLING MKIV CONTROLLER 24 REPLACING WIRING HARNESS 25 DISCONNECTING CONNECTING 5 26 ADJUSTING LIMIT SWITCH 26 REMOVING INSTALLING SHROUDS 27 CHANGING SEAT WIDTH INTEGRATED SLING SEATS 29 REPLACING CROSSBRACES CAPTAIN
10. Limit Switch Phono Jack FIGURE 12 DISCONNECTING CONNECTING LIMIT SWITCH 26 FWD WHEELCHAIRS ADJ USTING LIMIT SWITCH FIGURE 13 NOTE The following procedure is for High Back Captain s seat model wheelchairs only NEVER operate the wheelchair while in any re cline position over 114 RELATIVE TO THE SEAT FRAME Ifthe limitswitc hdoesnotstop the wheel chairfiom operating in a recline position greater than 114 RELATIVE TO THE SEATFRAME DO qualified technician otherwise injury ordamage may occur 1 Place the wheelchair on a level surface 2 Recline the captain s seat back to a 24 to achieve the 114 angle relative to the seat frame Refer to AD JUSTING CAPTAIN S SEAT in PROCEDURE 9 of the owners manual part number 1080737 NOTE The captain s seat frame is at a 5 angle relative to the ground When the back angle is adjusted to 114 rela tive to the seat it wil measure 61 relative to the ground NOTE To determine 114 back angle relative to the seat frame place a magnetic protractor available at any hard ware store on the back as shown in FIGURE 13 and adjust the back until the magnetic protractor reads 61 3 Turn the wheelchair power switch on the joystick to the ON position NOTE The wheelchair should not operate 4 IF wheelchair operates proceed to the following steps to adjustthe actuator on the upper limit switch bracket A Fully recline the back Refer to ADJUSTIN
11. Retaining Strap Clip Strap Hear _ Front Battery Battery Box Box Gu Front of the Battery Cable L P d Wheelchair Wires NEVER amp pull to unplug Connector E VN Battery Connections on ESN Side of Wheelchair Frame c NOTE Wheelchair Frame not shown for clarity FIG URE 19 INSIALLING REMOVING BATIERY BOXES BATTERY TRAY Folding Battery Tray for Transport FIGURE 20 1 Remove the battery boxes from the wheelchair Refer to INSTALLING REMOVING BATTERY BOXES in this procedure of the manual FIGURE 20 BATIERY TRAY FOLDING BATIERY TRAY FOR TRANSPORT 34 FWD WHEELCHAIRS 2 Lift up on the pin side of the battery tray and rotate UP towards the battery tray pivot 3 Fold the wheelchair Refer to ASSEMBLING EXCEL in this procedure of the manual Unfolding Battery Tray for Use FIGURE 21 1 Unfold the wheelchair Refer to ASSEMBLING EXCEL in this procedure of the manual 2 Rotate the pin side of the battery tray DOWN towards the mounting slots on the hanger bracket Make sure pins of battery tray are secure in the mounting slots ofthe hangerbrac ket otherwise in jury ordamage may result 3 Install the battery boxes Refer to INSTALLING REMOVING BATTERY BOXES in this procedure of the manual Hanger Bracket Battery Tray x Mounting Slots FIGURE 21 BATIERY TRAY UNFOLDING BATIERY TRAY FOR USE Changing Width of Battery Tray FI
12. S SEAT 30 WHEN TO CHARGE BATTERIES 32 CHARGING BATTERIES 32 REPLACING BATTERIES 33 INSTALLING REMOVING BATTERY BOXES 33 BATTERY TRAY fep 34 REPOSITIONING MOTORS 36 REPLACING CLUTCH HANDLES 38 REPLACING MOTOR GEARBOX 38 PROCEDURE 9 RWD WHEELCHAIRS 40 ASSEMBLING POWER 9000 40 WHEN TO CHARGE BATTERIES 41 CHARGING BATTERIES 41 REPLACING BATTERIES 42 INSTALLING REMOVING BATTERY BOXES 42 43 CHANGING SEAT WIDTH 43 ADJUSTING SEAT TO FLOOR HEIGHT 44 DISCONNECTING CONNECTING MKIV CONTROLLER MOTOR AND BATTERY LEADS 44 REMOVING INSTALLING MKIV CONTROLLER erui cmm 45 REPLACING WIRING HARNESS 45 REPLACING MOTOR GEARBOX 46 LIMITED WARRANTY 0 N T E N 5 SPECIFICATIONS NOTE All specifications are S approximate P INTEGRATED SLING SEAT CAPTAIN S SEAT F BACKTYPE C LOW LOW SOLID SEAT HIGH LOB LOBSS HIB F Seat Width Range 16 18
13. STEP 2 for the opposite front hex screw and caplug washer Move the footboard mounting brackets to one 1 of three 3 positions NOTE To ensure the existing hex screws tighten securely apply Loctite 242 onto the threads 5 Reinstall the two 2 hex screws and caplug washers through the two 2 footboard mounting brackets and bushings and into the wheelchair Refer to INSTALLING REMOVING FOOTRESTS or INSTALLING ELEVATING LEGRESTS PROCEDURE 3 of the owner s manual part number 1080737 Refer to BATTERY TRAY in this procedure of the manual Refer to INSTALLING REMOVING BATTERY BOXES in this procedure of the manual FIGURE 2 ASSEMBLING EXCEL UNFOLDING FOLDING CAPTAIN S SEAT 21 F W D W H E E L H R S W D W H E E L ie H R S PROCEDURE 8 6 Torque the two 2 hex screws to 156 in lbs 7 Reinstall the two 2 caplug caps Wheelchair Frame Bushing ete Footboard N Mounting Washer v f Bracket 2 Caplug Sorew PM Cap FIG URE 3 ADJ USIING FLIP UP REMOVABLE FOOTBOARD ANGLE Height FIGURE 4 1 If necessary remove the four 4 caplug caps 2 Remove the hex screw two 2 spacers washers and locknut that secure one 1 of the footboard pivots to the footboard mounting bracket 3 Repeat STEP 2 for opposite side of the wheelchair 4 Move the footboard pivots to one 1 of five 5 positions 5 Resecure the t
14. W D W H E E L ie H R S ve Captain s Seat if mt 4 N N 1 Seat Frame Seat Frame Assembly p Assembly Hex Screws Apply Loctite _ Washers 242 l FIG URE 8 REPLACING CAPTAIN S SEAT REPOSITIONING MKIV J OYSTICK CAPTAIN S SEAT FIGURE 9 1 Tum the lever on the adjustment lock to release the adjustment lock from joystick mounting tube 2 Remove the joystick from the wheelchair 23 W D W H E E L ie H R S PROCEDURE 8 3 Removethe three 3 hex bolts spacers and locknuts that secure joystick mounting bracket to armrest plate 4 Remove the phillips screw that secures the front of the armrest pad to the armrest plate 5 Remove the phillips screw that secures the rear of the armrest pad and armrest insert to the armrest plate 6 Remove the armrest pad from the armrest plate 7 Remove the lug bolt washers and locknut that secure the existing armrest plate to the seat frame assembly 8 Repeat STEPS 4 7 for opposite side of wheelchair 9 Position armrest plate with joystick mounting holes on desired side of seat frame assembly and secure with lug bolt washers and locknut Refer to FIGURE 9 10 Position armrest plate without joystick mounting holes on opposite side of seat frame assembly and secure with lug bolt washers and locknut Refer to FIGURE 9 11 Position the armrest pad on the armrest plate
15. has the proper tire pressure p s i DO NO overinflate the tires Failure to follow these suggestions may cause the tire to explode and cause bodily harm If tres are pneumatic replacement of or tube MUST be performed by Invacare dealer or qualified technician NOTE If drive wheels or casters are pneumatic under inflation causes excessive wear which results in poor performance of the tires REMOVING INSTALLING DRIVE WHEELS FIGURE 1 NEVER use a locking tab washer more than once ALWAYS use a NEW locking tab washer when installing the drive wheels Otherwise injury or damage may result Removing 1 Remove the hex screw locking tab washer and washer that secure the existing drive wheel to the wheel hub 2 Useawheelpullerto remove the existing drive wheel from the motor drive shaft Loctite Registered trademark of Loctite Corporation 13 PROCEDURE 6 Installing NOTE The keystock in the wheel hub MUST lineup with the cutout in the gearbox drive shaft 1 Install new existing drive wheel onto the motor drive shaft Make sure the chamfered angled in side of the wheel hub is pointing away from the wheelchair Install washer onto motor drive shaft Install the NEW locking tab washer onto the motor drive shaft Make sure the locking tab is in line with the keyway ofthe front wheel Apply Loctite 242 to the hex screw Install the hex screw Use a torque wrench only and torque to 90 inc
16. not to let them run low at any time Cleaning Battery Terminals DO NOTallow the liquid in the battery tb come incontactwith skin clothes orother possessions It is a form of acid and harmful or damaging bums result Should the liquid touch your skin washthe area immediately and thoroughly with cool water Inseriouscasesorifeye contact ismade seek medical atiention IMMEDIATHY The use of safety glassesisrecommended when cleaning the battery terminals NEVER smoke orstike a match nearbatieries If the capsofthe battery cellsare removed NEVER look directly into them while charging batteries 1 Examine battery clamps and terminals for corrosion 2 Verify that the plastic caps are in place over the battery cell holes 42 RWD WHEELCHAIRS 3 Clean the terminals and inside the battery clamps by using a battery cleaning tool wire brush or medium grade sand paper NOTE When done these areas should be shiny not dull 4 Carefully dust off all metal particles INSTALLING REMOVING BATTERY BOXES FIGURE 6 NOTE To remove the battery boxes from the wheelchair reverse the following procedure 1 Verify that the ON OFF switch on the joystick is in the OFF position 2 Position battery boxes onto battery tray Make sure battery cables on battery boxes are on the same side as the battery connectors on the wheelchair frame 3 Connect the battery cables from the battery boxes to the battery connector
17. AME 20 1 4 in ADULT FRAME 21 3 4 to 27 3 4 in With MKIV Joystick 33 1 4 to 37 1 4 in LOW SEAT FRAME 35 1 4 to 39 1 4 in ADULT FRAME 36 1 2 to 47 1 4 in NA 82 Ibs 145 lbs 157 lbs 110 lbs 12 1 2x2 1 4 in 8x 1 3 4 in Semi Pneumatic Standard 8x 2 in Pneumatic Optional Rotating Removable Standard Swingaway Removable Fixed Height Desk and Full Length Standard Adjustable Height Desk and Full Length Optional Black Nylon U1 Gel Cell 14 in chairs Dual Group 22NF Gel Cell 16 18 or 20 in chairs NOTE 18 inch wide x 16 inch deep wheelchair with MKIV RII electronics Speed M P H Turning Radius Range variable Weight Limitation 0to4 35 inches 12 14 miles with U1 batteries 18 22 miles with 22NF batteries 250 Ibs NOTE Range will vary with battery conditions surface terrain and operators weight NOTE Includes seating systems and accessories ozo 2 o m om uo gt omz mrmo co PROCEDURE 1 GENERAL GUIDELINES This Procedure Includes the Following Repair or Service Information Operating Information REPAIR OR SERVICE INFORMATION Set up of the Electronic Control Unit is to be performed ONLY by individuals certified by Invacare The final tuning adjustments of the controller may affect other activities of the wheelchair Damage to the equipment could occur under these circumstances If non certified ind
18. AMP METHOD 19 W D W H E E L ie H R S PROCEDURE 8 This Procedure Includes the Following Assembling Excel Adjusting Flip Up Removable Footboard Replacing Armrest Pads Replacing Armrest Plate Replacing Seat Positioning Strap Replacing Captain s Seat Repositioning MKIV Joystick Captain s Seat Removing Installing MKIV Controller Replacing Wiring Harness Disconnecting Connecting Limit Switch Adjusting Limit Switch Removing Installing Shrouds Changing Seat Width Integrated Sling Seats Replacing Crossbraces Captain s Seat When to Charge Batteries Charging Batteries Replacing Batteries Installing Hemoving Battery Boxes Battery Tray Repositioning Motors Replacing Clutch Handles Replacing Motor Gearbox Refer to PREPARING MKIV JOYSTICK FOR USE in PROCEDURE 5 of this manual Refer to REPOSITIONING MOTORS in this procedure of the manual Seat Guides S FWD WHEELCHAIRS After ANY adjustments repairorservice and FORE use make sure all attaching hardware is tightened securely otherwise injury ordamage may result ASSEMBLING EXCEL The weightofthe wheel hairwithoutthe userand batieriesisstill between 90and 127 65 Use proper lifting techniques lift with your legs to avoid jury Extreme caution isadvised when itisneces sary to move an UNOCCUPIED power wheel chair Invacare recommendsusing two 2 assis tants and making thorough
19. APD Reinstall the front hex screw that secures the new left battery tray hanger bracket to the wheelchair frame Use Loctite 242 and torque to 156 in bs Reinstall the locknut Use Loctite 242 and torque to 156 in Ibs Torque the rear locknut that secures MKIV controller to the wheelchair to 156 in Ibs Wheelchair Battery Tray Hanger Bracket Frame Wa aA Footboard Hear Locknut Loosen but Mounting Do Not Hemove Bracket FIGURE 25 BATIERY TRAY REPLACING LEFT BATIERY TRAY HANGER BRAC KET REPOSITIONING MOTORS FIGURE 26 be affected by the front wheel mounting position The following c harts show the mounting position of the motors for each seat width and depth depending on the factory setting oruser s weight ifthe mounting position thatcomesponds to the user s weight is different than the factory setting the motors MUST BE repositioned to maintain propersiability BEFOREusing the wheel chair Otherwise injury ordamage may occur Periodically review the following charts to make sure the motor mounting position sill conesponds ip the user s weightto maintain the piopersiabiity FWD WHEELCHAIRS NOTE If motors are repositioned the front riggings may need to be repositioned Refer to ADJUSTING REPLAC ING TELESCOPING FRONT RIGGING SUPPORT in PROCEDURE 9 of the owner s manual 1080737 FACTORY SETTINGS MOTOR MOUNTING POSITIONS SEAT SEAT DEPTH WIDTH 16 17 18 16 MIDDLE
20. ATTERY BOXES in this procedure of the manual procedure of the manual 2 Remove the battery tray Refer to REMOVING 2 Remove the two 2 hex bolts and locknuts that secure BATTERY TRAY in this procedure of the manual the existing battery tray and washers to the battery tray 3 Perform one 1 of the following Range DACKE A WHEELCHAIR EQUIPPED WITH FLIP UP 3 Remove the existing battery tray from the wheelchair REMOVABLE FOOTBOARD Remove the hex screw and spacer that secures the existing right Installing Battery Tray FIGURE 23 battery tray hanger bracket and footboard 1 Line up the mounting holes in the new existing mounting DCRERGERS ihe wheelchair rame battery tray with the mounting holes in the battery B WHEELCHAIR NOT EQUIPPED WITH FLIP UP tray hanger bracket REMOVABLE FOOTBOARD Remove the front hex screw that secures the existing right battery 2 Position one 1 of the washers between the battery tray hanger bracket to the wheelchair frame hanger bracket and the new existing battery tray ow 3 Reinstall one 1 of the hex bolts and washers through 4 Remove the rear hex bolt that secures the existing right the new existing battery tray washer and battery tray patery tray hanger Hacka n ng nesena hanger bracket and loosely tighten with one 1 of NOTE NOTE hex screw size for reinstallation the locknuts 5 Remove the existing right battery tray hanger bracket 4 Repeat STEPS 2 3 for the remaining washers hex from
21. D BY CIRCUMSTANCES BEYOND INVACARES CONTROL AND SUCH EVALUATON WILLBE SOLELY DETERMINED BY INVACARE THE WARRANTY SHALLNOT APPLY TO PROBLEMS ARISING FROM NORMAL WEAR OR FAILURE TO ADHERE TO THESE INSTRUC TIONS A CHANGE IN OPERATING NOISE PARTICULARLY RELATIVE TO MOTORS AND GEARBOXES DOES NOT FAILURE ALLSUC H DEVIC ESWLLEXHIBITA C HANG EIN OPERATING NOISE DUETO AGING THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS WARRANTIES IMPLIED WARRANTIES IF ANY INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND HTNESS FOR A PARTIC ULAR PURPOSE SHALL NOT EXTEND BEYOND THE DURATION OF THE EXPRESSED WARRANTY PROVIDED HEREIN AND THE REMEDY FOR VIOLATIONS OF ANY IMPLIED WARRANTY SHALL BE LIMITED TO REPAIR OR REPLACEMENT OF THE DEFECTIVE PRODUCT PURSUANT TO THE TERMS CONTAINED HEREIN INVACARE SHALLNOTBE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES WHATSOEVER THIS WARRANTY SHALL EXTENDED TO COMPLY WIH SATE PROVINCIAL LAWS AND REQUIREMENTS 47 lt 2 gt gt gt OMmMA Z2 r Yes you can Invacare Corporation www invacare com USA One Invacare Way Elyria Ohio USA 44036 2125 800 333 6900 Canada 5970 Chedworth Way Mississauga Ontario L5R 3T9 Canada 905 890 8838 Invacare and Yes you can are trademarks of Invacare Corporation 2000 Invacare Corporation Form No 98 271 Part No 1085397 Rev B 1 7 00
22. E 8 STEPS 2 4 10 11 12 Dust Cover Not Shown AW Battery Tray Hanger Bracket Spacers Hex Screws Footboard Mounting Bracket LONG Socket Screws Apply Loctite 242 and torque to 60 inch pounds STEPS 6 8 Wheelchair Frame SHORT Socket Screws Apply Loctite P 242and 3 torque to 60 gt inch pounds Motor STEPS 6 8 Gearbox 5 D NOTE It is not necessary to disconnect the clutch handle from the motor gearbox FRONT MOTOR MOUNTING POSITION MIDDLE MOTOR MOUNTING POSITION FIGURE 26 REPOSITIONING MOTORS F W D W H E E L Cc H A R S W D W H E E L H R S PROCEDURE 8 The longer socket screws must be positioned the mounting holes on the OUTSIDE of the wheelchair frame and the short socket screws must be in the mounting holes on the INSDE of the wheekc hairfiame Otherwise damage to the gearbox may result 8 Use Loctite 242 and tighten the motor to the wheelchair frame securely with the six 6 socket screws Torque to 60 inch pounds 9 Repeat STEPS 2 8 for the opposite side of the wheelchair if necessary 10 Line up the mounting hole in the battery tray hanger bracket with the mounting hole in the wheelchairframe 11 Left side of wheelchair only Reinstall the front dust cover onto the end of the crossbrace 12 Perform one 1 of the following A W
23. G CAPTAIN S SEAT in PROCEDURE 9 of the owner s manual part number 1080737 NOTE This will make access to limit switch easier B Loosen but do not remove the two 2 phillips screws washers and locknuts that secure the actuator to the upper limit switch bracket C Slide actuator UP towards top ofthe wheelchair CAUTION DO NOT over tighten the phillips screws that secure the actuator to the upper limit switch bracket Damage to the actuator may occur D Only tighten the two 2 phillips screws washers and locknuts that secure the actuator to the up per limit switch bracket until the actuator does not move E Repeat STEPS 1 3 until wheelchair does not operate when captain s seat back is at a 24 angle FWD WHEELCHAIRS PROCEDURE 8 24 Back 14 T Recline Angle ES 5 3 4 inches N Upper Limit Switch Bracket Phillips ner pam Screws m Washers Magnetic Protractor and Lock Will read 61 when back 5 Seat Angle nuts recline angle is at 114 Actuator relative to the seat frame FIGURE 13 ADJ USTING LIMITSWIITCH REMOVING INSTALLING SHROUDS FIGURE 14 Removing Front Shroud 1 the retaining strap securing the front shroud and battery box to the wheelchair 2 Feedthe retaining strap through the front shroud 3 Remove the front shroud from the wheelchair Installing Front Shroud 1 Feedthe retaining strap throu
24. GURE 22 NOTE This procedure is only necessary when changing the width of the wheelchair 1 Fold the battery tray Refer to FOLDING BATTERY TRAY FOR USE in this procedure of the manual 2 Removethe hex bolt and locknut that secure one 1 of the battery tray pins to the battery tray 3 Referto FIGURE 24 to determine mounting hole in the battery tray that corresponds to width of the wheelchair 4 Reposition the battery tray pin to the mounting hole determined in STEP 3 5 Secure the battery tray pin to the battery tray with the hex bolt and locknut 6 Repeat STEPS 2 5 for remaining battery tray pin and two battery tray pivots FWD WHEELCHAIRS PROCEDURE 8 Battery Tray Battery Tray Hanger Bracket Battery Tray x ETA Battery Tray Pivot lt MS Hex Bolts 16 inch Wheelchair 18 inch Wheelchair a 20 inch Wheelchair gu b rd N Battery Tray AGURE 23 BATIERY TRAY REMOVING A INSIALLING BATIERY TRAY F W D W H E E L ie H R S He Replacing Right Battery Tray Hanger Bracket FIG URE 22 BATIERY TRAY CHANGING WDIHOF FIGURE 24 BATEN RAX NOTE Right and left is determined by sitting in the wheel chair Removing Battery Tray FIGURE 23 1 Remove the battery boxes from the wheelchair Refer 1 Remove the battery boxes from the wheelchair Refer to INSTALLING REMOVING BATTERY BOXES in this toINSTALLING REMOVING B
25. HEELCHAIR EQUIPPED WITH FLIP UP RE MOVABLE FOOTBOARD Reinstall the hex screws and spacers that secure the battery tray hanger bracket and footboard mounting bracket to the wheelchair frame Use Loctite 242 and torque to 156 ir lbs B WHEELCHAIR NOT EQUIPPED WITH FLIP UP REMOVABLE FOOTBOARD Reinstall the front hex screw that secures the battery tray hanger bracket to the wheelchair frame Use Loctite 242 and torque to 156 in Ibs 13 Reinstall the battery boxes Refer to INSTALLING REMOVING BATTERY BOXES in this procedure of the manual REPLACING CLUTCH HANDLES FIGURE 27 1 Remove the battery boxes Refer to INSTALLING REMOVING BATTERY BOXES in this procedure of the manual 2 Remove the tip from the existing clutch handle Remove the pin that secures the existing clutch handle to the motor gearbox 4 Disconnect existing clutch handle from motor gearbox 5 Feed the existing clutch handle through the wheelchair frame 6 Remove the rubber tip from the new clutch handle 7 Install the new clutch handle onto the wheelchair NOTE Make sure the new clutch handle is pointing towards the outside of the wheelchair 8 Install the rubber tip onto the new clutch handle 38 FWD WHEELCHAIRS 9 Connect the clutch handle to the motor gearbox and line up the mounting holes in the clutch handle and motor gearbox 10 Insert the pin through the clutch handle and motor gearbox as shown in DETAIL A in FIGURE 27
26. POSITIVE Connect battery cable s to battery ies terminal s Securely tighten the hex nut that secures post s as follows DETAIL the battery clamp to the positive battery terminal post NEGATIVE BLACK battery cable ring terminal between the mounting plate and battery clamp of B If the battery clamp on the POSITIVE battery NEGATIVE battery terminal post terminal postis positioned as shown in FIGURE 4 proceed to STEP 2 B POSITIVE RED battery cable ring terminal be tween the mounting plate and battery clamp bat CORRECT ORIENTATION OF THE POSITIVE tery clamp of POSITIVE battery terminal post BATTERY TERMINAL POST BATIERY CLAMP 4 Secure the battery cable s ring terminal s to the bat tery clamp s BLACK to NEGATIVE and RED to POSITIVE Battery Terminal Post POSITIVE with exisitng hex screws Securely Note position of battery clamp Tighten DETAIL NEGATIVE Battery 5 Verify battery cable ring terminal s are correctly in Hex Nut Terminal Post and Battery Clamp stalled and securely tightened 6 Slide battery clamp covers down battery cables and onto battery terminals DETAIL 7 Secure each terminal cap in place with a tie wrap Use tie wraps 11 1 2 inches long DETAIL NOTE It will be necessary to trim excess tie wrap in order to install the battery box top s 8 Install the battery box top s 22NF Battery FIGURE 4
27. S THAT HAVE 2 E en Mie E BATTERY and RED to POSITIVE with the provided 1 4 20 x 7 8 inch hex flange screw and hex flange locknut method Refer to FIGURES 2 AND 3 FIGURE 3 depending on battery type C FOR DUAL 22NF BATTERIES THAT DO 4 Verify all battery cable s ring terminal s are correctly HAVE MOUNTING HOLES IN THE BATTERY installed and securely tightened TERMINAL S POST S Use battery clamp method Referto FIGURES 4 5 AND 6 5 Slide terminal cap s down battery cable s and onto battery clamps FIGURE 3 DIRECT MOUNT METHOD FIGURE 2 AND 3 6 Secure each terminal cap in place with a tie wrap 1 Install battery terminal cap s onto battery cable s as follows FIGURE 2 Use tie wraps 11 1 2 inches long FIGURE 3 DUAL U1 BATTERIES NOTE It will be necessary to trim excess tie wrap in or ORANGE battery terminal cap onto RED battery 4870 install the battery box top s cable 7 Install the battery box top s B GRAYbatteryterminalcapontoBLACKbatterycable 8 Install the battery box es into the wheelchair Refer to DUAL 22NF BATTERIES INSTALLING REMOVING BATTERY BOX ES in the PROCEDURE 8 FWD MODELS or PROCEDURE 9 RWD MODELS of this manual NOTE New Battery ies MUST be fully charged BEFORE REDbatteryterminal cap onto RED battery cable B BLACK battery terminal cap onto BLACK battery add using otherwise the life of the battery ies will be reduced 9 If necessary charge t
28. Service Manual Excel and P9000 DEALER KEEP THIS MANUAL THE PROCEDURES IN THIS MANUAL MUST BE PERFORMED BY A QUALIFIED TECHNICIAN ONLY Yes you can WARNING SPECIAL NOTES THE PROCEDURES IN THIS MANUAL SHOULD ONLY BE PERFORMED BY A QUALIHED TECHNICIAN DO NOT SERVICE OR OPERATE THIS EQUIPMENT WTHOUT ARST READING AND UNDERSIANDING THIS MANUAL AND THE OWNERS MANUAL SUPPLIED WITH THE WHEELCHAIR IF YOU ARE UNABLE TO UNDERSIAND THE WARNINGS CAUTIONS AND INSTRUCTIONS CONTACT INVACARE TECHNICAL SUPPORT BEFORE ATIEMPTING TO SERVICE OR OPERATE THIS EQUIPMENT OTHERMSSE URY OR DAMAGE MAY RESULT 202 2 20 5 SPECIAL NOTES WARNING CAUTION notices as used in this manual apply to hazards or unsafe practices which could result in personal injury or property damage NOTICE THE INFORMATION CONTAINED IN THIS DOC UMENT IS SUBJ ECT TO CHANGE WITHOUT NOTICE r om uo WHEELC HAIR USER As a manufacturer of wheelchairs Invacare endeavors to supply a wide variety of wheelc hairs to meet many needs of the end user However final selection of the type of wheelchair to be used by an individual rests solely with the user and his her healthcare professional capable of making such a selection WHEELC HAIR TIE DOWN RESTRAINTS AND SEAT POSITIONING STRAPS Nu Ne Invacare recommends that wheelchair users NOT be transported in vehicles of any kind while in wheelchairs As of this date the Department of T
29. Wheels Tires 12 1 2 x2 1 4 in Flat Free or Pneumatic Casters w Precision Sealed Bearings 8 x 1 3 4 in Semi Pneumatic Std 8 x 2 in Pneumatic Opt 6x2 in Semi Pneumatic Opt Footrest Legrest Swingaway Removable Adjustable Flip Up Removable Footboard Battery Size Not Supplied Dual Group 22NF Gel Cell PERFORMANCE Speed M P H 0 to 3 8 Turning Radius gt 26 in Range variable 17 22 miles 4 Weight Limitation 250 Ibs Range will vary with battery conditions surface terrain and operators weight NOTE Includes seating systems and accessories lt NOTE Refer to REPOSITIONING MOTORS in PROCEDURE 8 of this manual 4 SPECIFICATIONS SPECIFICATIONS NOTE All specifications are approximate Seat Width Range Seat Depth Range Back Height Range Standard Seat to Floor Overall Width Overall Height Overall Length RWD Wheelchairs FWD with 93 Front Riggings FWD with no Front Riggings OWeight W O Batteries W Batteries and PW93 Front Riggings U1 Gel Cell 14 inch Chairs Dual Group 22NF Gel Cell 16 18 or 20 inch Chairs Shipping Drive Wheels Tires Flat Free or Pneumatic Casters w Precision Sealed Bearings Battery Size Not Supplied Two 2 Required PERFORMANCE 14 16 18 or 20 in ADULT FRAME 16 18 or 20 in LOW SEAT FRAME 16 170r 18 in 17 and 18 in by extension 16 17 18 19 or 20 in 18 1 2 in LOW SEAT FR
30. anual and locknut locations CR CORAM OP Eek e Reinstall the front shroud onto the wheelchair Refer 4 Repeat STEPS 1 3 for the opposite side of the 45 REMOVING INSTALLING FRONT SHROUD in wheelchair if necessary this procedure of the manual 5 HIGH BACK CAPTAIN S SEAT MODEL WHEEL CHAIRS ONLY If necessary perform the following A Position the phono jack on the side shroud Phillips Screws Locknut Phillips Screws F W D W H E E L ie H R S Side Shroud Retaining Strap Hear Shroud p Washers Frame Battery Charger Cover Phono Jack Front Shroud Nut Filler Side Shroud Battery Box Phono Jack FIGURE 14 SHROUDS WHEH C HAIRS 28 FWD WHEELCHAIRS PROCEDURE 8 Hex Bolt STEPS STEPS 8 13 5 14 e c Locknut 6 STEPS 5 14 CHANGING SEAT WIDTH 4 Remove the existing back and seat upholstery from the wheelchair Referto REPLACING BACK UPHOL IEEE SLING SEATS STERY in PROCEDURE 5 of this manual and REPLACING SEAT UPHOLSTERY in PROCEDURE W 1 If necessary remove the shrouds Refer to REMOV 5 of the owner s manual part number 1080737 ING INSTALLING SHROUDS this procedure of NOTE If adjusting the seat width of the wheelchair the the manual back and seat upholstery MUST be changed as well W 2 Remove the battery boxes from the wheelchair 5 Remove the hex b
31. arts to avoid injury UNFOLDING 1 Push down on the seat rails until the seat rails are positioned in the seat guides 2 Assemble the wheelchair Refer to FIGURE 1 FOLDING 1 Remove the batteries and footrests legrests from the wheelchair Refer to FIGURE 1 2 Lift the battery tray UP and out of the way Refer to FIGURE 1 3 Lift up on the seat rails of the wheelchair Refer to PREPARING MKIV JOYSTICK FOR USE in PROCEDURE 5 of this manual Refer to INSTALLING REMOV ING FOOTRESTS or INSTALL ING REMOVING ELEVATING LEGRESTS in PROCEDURE 3 of the owners manual part num ber 1080737 FIG URE 1 ASSEMBLING POWER 9000 40 RWD WHEELCHAIRS WHEN TO CHARGE BATTERIES FIGURE 4 NOTE As a general rule batteries should be recharged daily to assure the longest possible life and minimize the required charging time In fact a battery s life is extended if the charge level is maintained well above a low condition Plan to recharge the batteries when it is anticipated the wheelchair will not be used for a long period of time BATTERY DISCHARGE INDICATOR BDI is located at the rear of the joystick housing and provides information on the remaining charge in the batteries At FULL charge the BDI will be GREEN As the battery becomes discharged the BDI indicator will tum AMBER YELLOW then RED and finally FLASHING RED If the BDI is FLASHING RED the user should charge the batteries as soon as possibl
32. attery clamp covers onto battery cables as follows FIGURE 5 A REDbattery clamp cover onto RED battery cable The battery clamp of the POSITIVE battery terminal post MUST be mounted in B BLACK battery clamp cover onto BLACK battery the position shown in HGURE 5 otherwise or the battery box top cannot be installed NOTE Only one 1 battery cable and battery clamp cover propery are shown for clarity Both battery clamp covers install in the same manner 1 Perform one 1 of the following Ifthe battery clamp of the POSITIVE battery BATTERY CLAMP COVERS terminal post is NOT mounted in the orientation shown in FIGURE 5 perform the following Loosen thehexnutthat secures the battery clamp tothe POSITIVE battery terminal post Battery Clamp When tightening the clamps FIGURE 5 CONNECTING BATTERY always use a box wrench Pliers will CABLES BATTERY CLAMP METHOD round off the nuts NEVER wiggle the battery terminal s post s when tightening The battery may become damaged When connecting the battery cable ring terminal s to the battery ies clamp s the battery cable s MUSt be connected in the position shown in DETAIL A otherwise battery terminal post damage may occur to the battery cable Reposition the battery clamp onthe POSITIVE and or battery clamp covers battery terminal post as shown in FIGURE 4 Removethe battery clamp from the
33. attery clamps Most batteries are not sold with instructions by using a battery cleaning tool wire brush or However wamings are frequently noted on the medium grade sand paper cell caps Read them carefully otherwise injury ordamage can occur NOTE When done these areas should be shiny not dull 4 Carefully dust off all metal particles a m INSTALLING REMOVING BATTERY ecommen attery Types BOXES FIGURE 19 NOTE Invacare recommends that both batteries be replaced if one 1 battery is defective The warranty and performance specifications contained inthis manual are based onthe use of deep cycle gel cell or sealed lead acid batienes Invacare strongly recommends their use as the power source for this unit CAUTION NOTE To remove the battery boxes from the Failure to use the correct battery size and or wheelchair reverse the following procedure Maec ue De i Verify that the ON OFF switch on the joystick is in the OFF position CHAIR SEAT VOLTS BATTERY 2 f necessary remove the Captain s Seat Refer to WIDTH SIZE REMOVING INSTALLING CAPTAIN S SEAT in PROCEDURE 9 of the owner s manual part number 1 Remove the battery boxes from the wheelchair 3 If necessary remove the front and rear shrouds Refer to REMOVING INSTALLING BATTERY gt BOXES in this procedure of the manual Refer to REMOVING INSTALLING SHROUDS in es this procedure of the manual 2 Removethe existing batteries from th
34. brace NOTE Left is determined by sitting in the wheelchair 7 Remove the pin that secures the clutch handle to the existing motor gearbox 8 Disconnect clutch handle from existing motor gearbox 9 Note mounting position of motor gearbox on the wheel chair frame for installation of the new motor gearbox STEPS 4 6 Dust Cover Not Shown 17 18 19 dn ee Battery Tray Hanger Bracket Hex Screws 9 Footboard Mounting Bracket LONG Socket Screws Apply Loctite 242 and torque to 60 inch pounds STEPS 10 12 Wheelchair Frame n ET Clutch Handle STEP 8 Dust Cover STEPS 4B 19B SHORT Socket Screws Apply Loctite 242 and X torque to 60 Pa inch pounds STEPS 10 STEP 7 18 2 Motor Gearbox DETIL B Pin STEP 14 Motor Gearbox Clutch Handle 127 14 STEP 13 Detent Ball FIG URE 28 REPLACING MOTOR GEARBOX PROCEDURE 8 10 Remove the six 6 socket screws that secure the existing motor gearbox to the wheelchair frame 11 Position the new motor gearbox on the wheelchair frame at the position noted in STEP 7 as shown in FIGURE 28 The longer soc ket screws must be positioned in the mounting holes on the OUTSIDE of the wheekchair frame and the short socket screws must be in the mounting holes on the INSIDE of the wheekc hairfiame Otherwise damage to the gearbox may result 12 Us
35. care echnical Support 1 800 832 4707 Y p DISCONNECTING CONNECTING pK rm MKIV CONTROLLER MOTOR AND DE BATTERY LEADS FIGURE 9 SRI Oe SWS O Controller NOTE To connect MKIV controller motor and battery leads 14 ae reverse the following procedure Eds lt NE 5 1 Disconnect the fastening straps that secure the nylon Y P Left Right Motor iN boot around the connected motor and battery leads Leads 2 Disconnect controller left right motor and battery leads 9 DISCONNECTING CONNECTING MKIV fromthe leads secured to the wheelchair with tie wrap CONTROLLER MOTOR AND BATIERY LEADS 44 RWD WHEELCHAIRS REMOVING INSTALLING MKIV CONTROLLER FIGURE 10 1 Disconnect the left right motor leads and battery leads Refer to DISCONNECTING CONNECTING MKIV CONTROLLER MOTOR AND BATTERY LEADS in this procedure of the manual 2 Remove the two 2 hex screws that secure the MKIV controller onto the wheelchair NOTE When installing the MKIV controller onto the wheelchair use Loctite 242 on hex screws 3 Install the new existing MKIV controller onto the wheelchair by reversing STEPS 1 and 2 LE Wheelchair gt Frame PROCEDURE 9 REPLACING HARNESS FIGURE 11 Disassembly 1 Remove the battery boxes Refer to INSTALLING REMOVING BATTERY BOXES in this procedure of the manual 2 Disconnect the wiring harness BLUE from the contro
36. ck cane to the wheelchair frame with the existing hex screws washers and locknuts NOTE Make sure the back canes are mounted to the same height 10 Securely tighten the new back upholstery to the back canes with the two 2 phillips screws and washers 11 Secure the bottom of the new back upholstery to the wheelchair frame with tie wraps 12 Reinstall the armrest onto the wheelchair 10 UPHOLSTERY Back Upholstery Phillips Screw Tie Wrap Mounting Hole Locknuts Washer Hex Screws FIGURE 1 REPLACING BACK UPHOLSTERY SEAT FRAME This Procedure Includes the Following Adjusting Seat Depth Adjusting Back Height Replacing Back Canes After ANY adjustments repair or service and BEFORE use make sure that all attaching hardware is tightened securely otherwise injury or damage may result ADJ USTING SEAT DEPTH FIGURE 1 1 Remove the existing seat upholstery from the wheelchair Referto REPLACING SEAT UPHOLSTERY in PRO CEDURE5 ofthe Owners Manual part number 1080737 NOTE If adjusting seat depth of the wheelchair the seat upholstery MUST be changed as well 2 Remove the two 2 plug buttons from the ends of the crossbraces that are towards front of wheelchair NOTE The two 2 plug buttons will be used in the ends of the seat extensions 3 Install the two 2 seat extension tubes into the ends on the crossbraces Line up the second mounting hole fro
37. d in STEP 8 F W D W H E E L H R S HIGH BACK CAPTAIN S SEAT MODEL WHEEL CHAIRS ONLY Perform the following A Position the new phono jack on the side shroud B Reinstall the phono jack nut onto the new phono jack and tighten securely Phillips Screws STEPS 5 11 Wiring Harness Phillips Bolts STEPS 6 12 To Controller STEPS 4 14 Phillips Screws STEPS 7 13 FIGURE 11 REPLACING WIRING HARNESS 25 W D W H E E L ie H R S PROCEDURE 8 C Connectthe limit switch Refer to DISCONNECT ING CONNECTING LIMIT SWITCH in this procedure of the manual 17 Reinstall the battery boxes Refer to INSTALLING REMOVING BATTERY BOXES in this procedure of the manual 18 If necessary install the front and rear shrouds Refer to REMOVING INSTALLING SHROUDS in this pro cedure of the manual DISCONNE CTING CONNECTING LIMIT SWITCH FIGURE 12 NOTE The following procedure is for High Back Captain s seat model wheelchairs only CAUTION Disc onnect limit switch BEFORE removing seator damage to switch may occur 1 Perform one 1 of the following DISCONNECTING While holding the body of the limit switch phono plug lift up gently NOTE When the limit switch is unplugged the wheel chair will NOT operate CONNECTING Plug limit switch plug into the limit switch phono jack Limit Switch Phono Plug Body
38. d locknut that secure the two 2 existing crossbraces together NOTE Note coved spacer washer and locknut order for reinstallation 11 Remove the four 4 pivot tube plug pins from the bottom of the two 2 existing crossbraces 12 Install the four 4 pivot tube plug pins into the bottom of the two 2 new crossbraces 13 Assemble the two 2 new crossbraces together Refer to DETAIL C in FIGURE 16 for hardware orientation 14 Reinstall the hex bolts washers and locknuts that secure the bottom of the two 2 new crossbraces to the wheelchair frame and tighten 15 Secure the wiring harness to the new crossbraces with new tie wraps 16 Reinstall the dust covers onto the bottom of the new crossbraces FWD WHEELCHAIRS 17 Reinstall the hex bolts spacers washers and locknuts that secure the 2 push brackets to the new crossbraces and tighten securely 18 Reinstall the hex bolts washers and locknuts that secure the pivot links to the crossbraces and tighten securely 19 Unfoldthe battery tray Referto FOLDING BATTERY TRAY FOR USE in this procedure of the manual Hex Bolt STEPS 5 18 Wheelchair Frame Washer STEPS 6 17 Hex Bolts STEPS 6 17 sw Hex Bolts STEPS 6 17 Pivot Link Push Bracket Crossbrace Spacer STEPS 6 17 STEPS 6 17 STEPS 5 18 Tie Wraps STEPS 8 15 PROCEDURE 8 20 Reinstall the battery boxes o
39. e Battery Discharge Indicator A N NOTE Accurate read X 2 ings are displayed when in neutral AGURE 4 WHEN TO CHARGE BATIERIES CHARGING BATTERIES FIGURE 5 NOTE New batteries MUST be fully charged prior to initial use of the wheelchair Neveratiemptip recharge the batieriesby attach ing cables directly to the batiery terminals or clamps Always use the rechaiging plug located on sde ofthe wheelchairframe DO NOT attempt recharge batteries and operate the power wheek hairat the same time During use and charging unsealed batteries wil vent hydiogen gas which is explosive in the right concentration wih air CAUTION Always charge new batteries before initial use or batiery life will be reduced NOTE As a general rule batteries should be recharged daily to assure the longest possible life and minimize the required charging time In fact a battery s life is extended if the charge level is maintained well above a low condition Plan to recharge the batteries when it is anticipated the wheelchair will not be used for a long period of time Range per battery charge using recommended batteries should be approximately 5 to 9 hours of typical operation Extensive use on inclines may substantially reduce per charge mileage 41 PROCEDURE 9 Description and Use of Battery Chargers The charger automatically reduces the charge from an initially high rate to a zero reading at a fully charged condi
40. e Loctite 242 and tighten the motor gearbox to the wheelchair frame securely with the six 6 socket screws Torque to 60 inch pounds 13 Connect the clutch handle to the new motor gearbox and line up the mounting holes 14 Insert the pin through clutch handle and new motor gearbox as shown in DETAIL B in FIGURE 28 NOTE Make sure the detent ball on the pin is fully visible 15 Repeat STEPS 2 13 for the opposite side of the wheelchair if necessary 16 Reinstall the drive wheels onto the wheelchair Refer to REMOVING INSTALLING DRIVE WHEELS in PROCEDURE 6 of this manual 17 Line up the mounting hole in the battery tray hanger bracket with the mounting hole in the wheelchairframe 18 Left side of wheelchair only Reinstall the front dust cover onto the end of the crossbrace 19 Perform one 1 of the following A WHEELCHAIR EQUIPPED WITH FLIP UP REMOVABLE Reinstall the hex screws and spacers that secure the battery tray hanger bracket and footboard mounting bracket to the wheelchair frame Use Loctite 242 and torque to 156 in Ibs B WHEELCHAIR NOT EQUIPPED WITH FLIP UP REMOVABLE FOOTBOAPD Reinstall the front hex screw that secures the battery tray hanger bracket to the wheelchair frame Use Loctite 242 and torque to 156 in lbs 20 Reconnect the right and or left motor connector to the controller 21 Reinstall the battery boxes Refer to INSTALLING REMOVING BATTERY BOXES in this proc
41. e battery boxes B Refer to INSTALLING REMOVING BATTERIES TO 4 Position the battery boxes onto the battery tray FROM BATTERY BOXES in PROCEDURE 7 ofthis NOTE Make sure the battery cables on the battery boxes manual are on the same side as the battery connectors on the 3 Clean the new battery terminals wheelchair frame 4 Install the new batteries into the battery boxes Refer 5 Connect the battery cables from the battery boxes to INSTALLING REMOVING BATTERIES TO FROM to the battery connectors on the wheelchair frame BATTERY BOXES in PROCEDURE 7 of this manual NEVER unplug the battery cables by pulling on the wires Unplug the battery cables by pulling on the connector ONLY Otherwise injury ordamage may result 33 W D W H E E L H R S PROCEDURE 8 WARNING Battery Box Retaining MUSTbe fastened securely and adjusted properly to hold batiery boxesin place before using the wheelchair 6 Position retaining straps around each battery box as shown in FIGURE 19 clip retaining strap together and adjust if necessary NOTE If wheelchair is equipped with shrouds refer to REMOVING INSTALLING SHROUDS in this procedure of the manual before connecting retaining strap together 7 f necessary install the Captain s Seat Refer to REMOVING INSTALLING CAPTAIN S SEAT in PROCEDURE 9 of the owner s manual part number 1080737 m B Retaining
42. e wiring harness BLUE from the controller connector BLUE 5 Remove the two 2 phillips screws and spacers that 14 secure the rear battery connector to the wheelchair frame 15 Phono Jack 2 16 Nut l Side Shroud Phono Jack ERA Spacers STEPS 5 11 Tie Wraps STEPS 8 15 Charger Cable Mounting Bracket Locknuts STEPS 6 12 necs Position the rear battery connector on the wheelchair PROCEDURE 8 Remove the two 2 phillips bolts and locknuts that secure the front battery connector to wheelchair frame Remove the two 2 phillips screws that secure the wiring hamess to the charger cable mounting bracket Note the position of the tie wraps that secure the exist ing wiring harness and motor cables to the crossbraces Cut the tie wraps that secure the existing wiring harness and motor cables to the crossbraces Remove the existing wiring hamess from wheelchair frame as shown in FIGURE 11 and secure with the two 2 phillips screws and spacers Position the front battery connector on the wheelchair frame as shown in FIGURE 11 and secure with the two 2 phillips bolts and locknuts Secure the wiring hamess to existing charger cable mounting bracket on the seat frame with the two 2 phillips screws Connect the wiring harness BLUE to the controller connector BLUE Resecure the wiring harness and motor cables to the crossbraces with new tie wraps at the positions note
43. ed If the charger operates for sixteen 16 hours and is unable to fully charge the batteries an internal timer turns the charger off and begins to fast blink the green light NOTE If the batteries need to be charged more often or take longer to charge than normal they may need to be replaced Contact an authorized dealer for service 5 f necessary install the rear shroud Refer to REMOVING INSTALLING SHROUDS in this proce dure of the manual 32 FWD WHEELCHAIRS PROCEDURE 8 Battery Charger ws Cleaning Battery Terminals Connector on side r of Wheelchai 7 DO NOTallow the liquid in the battery tb come incontactwith skin clothesorotherpossessions It is a form of acid and harmful or damaging bums may result Should the liquid touch your skin washthe area immediately and thoroughly with cool water In seriouscasesorifeye contact is made seek medical atiention IMMEDIATHY NEVER smoke orstike a match nearbatieries If NOTE Position of Battery Charger Connector the capsofthe battery cellsare removed NEVER vary depending on wheelchair options look directly into them while charging batteries FIG URE 18 CHARGING BATIERIES 1 Examine battery clamps and terminals for corrosion ify that the plasti in pl th REPLACING BATTERIES 2 Verify that the plastic caps are in place over the battery cell holes F W D W H E E L ie H R S 3 Clean the terminals and inside the b
44. edure of the manual W D W H E E L ie H R S R W D W H E E L ie H R S PROCEDURE 9 This Procedure Includes the Following Assembling Power 9000 When to Charge Batteries Charging Batteries Replacing Batteries Installing Removing Battery Boxes Battery Tray Changing Seat Width Adjusting Seat to Floor Height Disconnecting Connecting MKIV Controller Motor and Battery Leads Removing Installing MKIV Controller Replacing Wiring Harness Replacing Motor Gearbox After ANY adjustments repair or service and BEFORE use make sure all attaching hardware istightened securely otherwise injury or damage may result Refer to INSTALLING REMOVING BATTERY ES BOXES and BATTERY TRAY in this procedure of the manual Refer to INSTALLING ANTI TIPPERS in PROCEDURE 10 of the owners manual part number 1080737 RWD WHEELCHAIRS ASSEMBLING POWER 9000 FIGURE 1 The weight of the wheelc hair without the user and batteries is approximately 82 Ibs Use proper lifting tec hniques lift with your legs to avoid injury Extreme caution is advised when itis necessary to move an UNOCCUPIED power wheelchair Invac are recommendsusing two 2 assistants and making thorough preparations Make sure tp use ONLY secure non detachable parts for hand hold supports Unfolding Folding the Wheelchair WARNING Keep hands and fingers clear of moving p
45. efer to REMOVING INSTALLING SHROUDS in this procedure of the manual Disconnect the left right motor leads and battery leads 3 Remove the two 2 locknuts that secure the exist ing MKIV controller and washer s to the wheelchair 4 Remove existing MKIV controller from the wheelchair Installing Install washer s onto rear mounting stud 2 Install new existing MKIV controller onto wheelchair frame 3 Secure the new existing MKIV controller to the wheelchair with NEW locknuts Torque to 156 in lbs 4 f necessary install the rear shroud and rear compart ment if equipped Referto REMOVING INSTALLING SHROUDS in this procedure of the manual Mounting Studs on Wheelchair Frame AMOT Locknut Washer sa A MKIV Controller d FIG URE 10 REMOVING INSIALLING CONTROLLER FWD WHEELCHAIRS REPLACING MRING HARNESS 6 FIGURE 11 1 If necessary remove the front and rear shrouds Refer to REMOVING INSTALLING SHROUDS g this procedure of the manual 2 HIGH BACK CAPTAIN S SEAT MODEL WHEEL CHAIRS ONLY DETAIL A Perform the following A Disconnectthe limitswitch Referto DISCONNECT 10 ING CONNECTING LIMIT SWITCH in this proce dure of the manual 11 B Remove the phono jack nut that secures the phono jack to the side shroud i 3 Remove the battery boxes Refer to INSTALLING REMOVING BATTERY BOXES in this procedure of the manual 13 4 Disconnect th
46. er to contact a qualified electrician and have the two prong receptacle replaced with a property grounded three prong wall receptacle in accordance with the National Electrical Code If you must use an extension cord use ONLY a three wire extension cord having the same or higher electrical rating as the device being connected In addition Invacare has placed RED ORANGE WARNING TAGS on some equipment DO NOT remove these tags BATTERIES The warranty and performance specifications contained in this manual are based on the use of deep cycle gel cell or sealed lead acid batteries Invacare strongly recom mends their use as the power source for this unit TROUBLESHOOTING This Procedure Includes the Following Field Load Test Using Hydrometer To Check Battery Cells Lead Acid Motor Testing Motor Brush Inspection Electro Mechanical Parking Brake Test FIELD LOAD TEST FIGURE 1 NOTE The following test can also be performed through the controller of the wheelchair along with a remote programmer Refer to the individual CONTROLLER MANUAL supplied with each wheelchair Old batteries lose their ability to store and release power due to increased intemal resistance This means that as you try totake power from the battery some of that power is used up inthe process of passing through the battery resulting in less voltage at the posts The more power drawn the lower the voltage available When this lost voltage drops the output 1
47. ercentage of its rated Cap Motor load capacity until the NEW brush is burned in Cap Motor 4 Pin Motor Connector 4 Pin Motor Connector FIGURE 4 MOTOR BRUSH INSPECTION FIGURE 5 ELECTRO MECHANICAL PARKING BRAKE TEST Jaum oroirz uc PROCEDURE 3 This Procedure Includes the Following Replacing Back Upholstery After ANY adjustments repair or service and BEFORE use make sure that all attaching hardware is tightened securely otherwise injury or damage may result REPLACING BACK UPHOLSTERY FIGURE 1 1 Remove one 1 armrest from the wheelchair 2 Cutthe tie wraps that secure the bottom of the existing back upholstery to the wheelchair frame 3 Removethe two 2 phillips screws and washers that secure the existing back upholstery to the back canes 4 Removethe two 2 hex screws washers and locknuts that secure one 1 back cane to the wheelchair frame NOTE It is necessary to remove only one 1 back cane to replace the back upholstery 5 Pull the loose back cane out of the existing back upholstery 6 Pull the existing back upholstery up and over the mounted back cane 7 nstallthe new back upholstery over the mounted back cane 8 Slide the loose back cane through the new back up holstery The back canes MUST be securely fastened to the wheelchair frame BEFORE using the wheelchair 9 Using the mounted back cane as a guide reinstall the loose ba
48. et to the armrest plate 2 Remove armrest pad Refer to REPLACING ARMREST PADS in this procedure of the manual 3 Remove the lug bolt washers and locknut that secure the existing armrest plate to the seat frame assembly 4 Position the new armrest plate on the seat frame assembly and secure with the lug bolt washers and locknut Refer to FIGURE 2 for correct hardware orientation 5 Reinstall armrest pad Refer to REPLACING ARMREST PADS in this procedure of the manual 6 If necessary reinstall the three 3 hex bolts spacers and locknuts that secure the joystick mounting bracket to the armrest plate 7 Repeat STEPS 1 6 for the opposite armrest plate if necessary FWD WHEELCHAIRS Armrest Plate Armrest Pad Armrest Insert Lug Bolt Locknuts Phillips Screw gt p Locknuts i is Washers 8 A Phillips Screw Hex Bolts Washers E Spacers Seat Frame Joystick Mounting Bracket DPI RGURE 6 REPLACING ARMREST PLATE REPLACING SEAT POSITIONING STRAP FIGURE 7 NOTE The following procedure is for Captain s Seats only 1 Remove the Captain s seat from the wheelchair Refer to REMOVING INSTALLING CAPTAIN S SEAT in PROCEDURE 9 of the owner s manual part number 1080737 2 Remove the two 2 hex bolts washers and locknuts that secure the seat positioning strap to the seat frame assembly 3 Removethe two 2 halves of the seat positioning strap from the seat frame assembly 4 Pos
49. g i e MEG ohms or O L out of limit indicates a shorted brake or an open connection respectively If either condition exists send the motor to Invacare Technical Service for inspection repair NOTE It is very important to note which way the brush comes out of the motor The brush MUST be placed into the motor exactly the same way to ensure good contact With the commutator 1 Once the motor brush caps have been removed pull the brushes out of the motor The end of the brushes should be smooth and shiny and the spring should T R 0 U B L E S H 0 0 T l N G not be damaged or discolored If one or both of the brushes are damaged only the damaged or wom brushes need be replaced It is very important that any time a brush is replaced it must be burned in This is accomplished by running the motor for one hour in each direction with a half hour break in between A shorted electro mechanical brake will damage the brake output section in the controller DO NOT connect a shorted electro mechanical brake to a good controller module A shorted brake MUST be replaced This should also be done with little or no load on the motor i e put the wheelchair up on blocks so the drive large wheels do not contact the ground and run the wheelchair A motor with only one brush NOTE A bad motor can damage the controller module but a bad controller should NOT damage a motor replaced will only carry a small p
50. gh the front shroud as shown in FIGURE 14 2 Position the bottom of the front shroud between the battery box and the battery tray 3 Clip the retaining strap together Removing Rear Shroud 1 the retaining strap securing the rear shroud and battery box to the wheelchair 2 Feed the retaining strap through the rear shroud 3 Remove the rear shroud from the wheelchair Installing Rear Shroud 1 Feedthe retaining strap through the front shroud as shown in FIGURE 14 2 Clip the retaining strap together 3 Press down on the rear shroud until the two 2 clips secure the rear shroud to the two 2 side shrouds Removing Side Shrouds and Fillers 1 27 Remove the front shroud from the wheelchair Refer to REMOVING INSTALLING FRONT SHROUD in this procedure of the manual Remove the rear shroud from the wheelchair Refer to REMOVING INSTALLING REAR SHROUD in this procedure of the manual Perform one 1 of the following A INTEGRATED SLING SEAT MODELS Fold the wheelchair Referto TRANSPORTING EXCEL in this procedure of the manual B CAPTAIN S SEAT MODELS Remove the Captain s Seat from the wheelchair Refer to REMOVING INSTALLING CAPTAIN S SEAT in PROCEDURE 9 of the owner s manual part number 1080737 HIGH BACK CAPTAIN S SEAT MODEL WHEEL CHAIRS ONLY DETAIL A Remove the phono jack nutthat secures the phono jackto the side shroud Remove the phillips screws bolts washers and lock nu
51. h new tie wrap REMOVING BATTERY BOXES in this procedure 5 Reinstall the battery boxes Refer to INSTALLING of the manual REMOVING BATTERY BOXES in this procedure of MAN f a the manual DEAL 9 Underside of Motor 9P 9 REPLACING MOTOR GEARBOX Mount Plate 5 m FIGURE 12 i 1 Remove the battery boxes Refer to INSTALLING H REMOVING BATTERY BOXES in this procedureof ong Socket A Screws Apply ort ocket Screws Apply l 2 Disconnect the right and or left motor connector from Loctite 242 Loctite 242 and torque to 60 R the controller and torque to inch pounds S 3 Remove the drive wheels from the wheelchair Re 60 inch fer to REPLACING DRIVE WHEELS in PROCE pounds DURE 6 of this manual 4 Remove the six 6 socket screws that secure the mo tor gearbox and support tube to the wheelchair frame 5 Repositionnew motor gearbox on the wheelchair frame 6 Position the support tube between the wheelchair frame and the new motor gearbox Make sure the alignment hole in the support tube is positioned with Alignment the alignment pin on the motor mount plate Hole NOTE The alignment pin is the longest of the three 3 pins and is located in the center of the wheelchair frame motor mount plate Refer to DETAIL A in FIGURE 12 NOTE When the alignment hole in the support tube is positioned with the alignment pin on the wheelchair frame the anti tipper wheels should be pointing do
52. h pounds Examine the head of the hex screw and the locking tab washer Make sure one 1 of the tabs on the locking tab washer is parallel with one 1 of the flats on the head of the hex screw Chamfered Side of Wheel Hub Locking Tab Washer Hex Screw Apply Loctite 242 and use a Torque Wrench only to Torque to 90 inch pounds TIGHTEN Hex Screw if Locking Tab is not Parallel with Flat on Head STEP 7 Flat on Head Locking Tab Parallel of Hex Screw with Flat on Head of Hex Screw STEP 6 X Locking Tab M pi Bend Tab up tight against Flat on 55 4 Head of Hex Screw STEP 8 FIGURE 1 REMOVING INSTALLING DRIVE WHEELS PROCEDURE 6 7 1 of the tabs on the locking tab washer is NOT parallel with one 1 of the flats on the head of the hex screw FIGURE 1 TIGHTEN the hex screw until the closest flat and locking tab are parallel NOTE Tighten hex screw only DO NOT loosen hex screw to make one of the tabs on the locking washer parallel 8 Bend the parallel tab of locking tab washer up tight against flat of the hex screw FIGURE 1 REPLACING CASTERS FIGURE 2 1 Remove the hex screw washers and locknut that secure the caster to the fork Remove the caster from the fork Install Loctite 242 onto the hex screw Replace caster and reverse STEPS 1 3 Torque the locknut to 120 inch pounds Loosen the locknut 1 8 of a turn NO a F WD Move the ca
53. he Following REPOSITIONING MKIV J OYSTICK Preparing MKIV Joystick for Use FIGURE 2 Repositioning MKIV Joystick 1 Turn the lever on the adjustment lock to release the adjustment lock from joystick mounting tube tube 2 Remove the joystick from the wheelchair F 3 Removethe three 3 hex screws that secure joystick After ANY adjustments repair or service mounting bracket bracket the threaded hole half and BEFORE use make sure all attaching clamp and the opened hole half clamp to the arm tube hardware is tightened securely otherwise injury or damage may result 4 Reposition the threaded hole half clamp and opened hole half clamp on the opposite arm tube Make sure threaded hole half clamp is on the inside of arm tube PREPARING MKIV J OYSTICK FOR 5 While holding the two 2 half clamps install the front USE FIGURE 1 hex screw into the two 2 half clamps Securely tighten 6 Lineup mounting holes of the joystick mounting bracket with the mounting holes in the two 2 half clamps NOTE To reposition the MKIV joystick on a Captain s Seat refer to REPOSITIONING MKIV JOYSTICK CAPTAIN S WM SEAT in PROCEDURE 8 of this manual 7 Secure the joystick mounting bracket to the two 2 EE half clamps with the remaining two 2 hex screws NOTE joystick is factory installed on the right Slide tube through the bracketto the desired position side of the wheelchair To reposition the MKIV jo
54. he battery ies Refer INSIALLING BATTERY TERMINAL CAPS to CHARGING BATTERIES in the PROCEDURE 8 FWD MODELS or PROCEDURE 9 RWD Battery Cable MODELS of this manual NOTE Only one 1 battery cable and terminal cap shown for clarity Both caps install in the same manner FIGURE 2 CONNECTING BATTERY CABLES DIRECT MOUNT METHOD 16 BATTERIES PROCEDURE 7 DETAIL A DETAIL B DUAL U1 BATTERIES DUAL 22NF BATTERIES E POSITIVE Battery Terminal Post 1 4 20 x 7 8 Inch y Hex Flange Screw Battery Terminal POSITIVE Red 1 4 20 x 7 8 Inch Post Battery Cable Hex Flange Screw 1 4 20 Hex 5 jew E R 5 1 4 20 Fl Locknut Positive Battery 22NF Battery Terminal Post NEGATIVE Black Battery Cable NEGATIVE Battery Terminal Post CONNECT BATTERY CABLE S RING TERMINAL S TO THIS SIDE OF BATTERY TERMINAL S POST S CONNECT BATTERY CABLE TO BATTERY TERMINAL AS SHOWN DUAL 01 BATTERIES DUAL 22NF BATTERIES Gray Battery RED POSITIVE Terminal Cap NEGATIVE NEGATIVE Battery Battery Terminal i POSITIVE Battery 2 o Terminal Post Cap ost U 1 Orange Battery Tie Wrap Batter y Terminal Cap 22NF Battery BLACK BatteryTerminal Cap HGURE 3 CONNECTING BATTERY CABLES DIRECT MOUNT METHOD 17 om um 2 Uu PROCEDURE 7 BATTERIES Battery Clamp Method FIGURES 4 5 and 6 2 Install b
55. ings are displayed when in neutral Battery Discharge Indicator FIGURE 17 WHEN TO CHARGE BATIERIES CHARGING BATTERIES FIGURE 18 Never attempt to recharge the batteries by attaching cables directly to the battery termi nalsorclamps Alwaysuse the recharging plug located on the side of the wheelchair frame DO recharge the batteries and operate the powerwheelc hairatthe same time During use and charging unsealed batteries will venthydrogen gas which is explosive in the right concentration with air CAUTION Always charge new batteries fully BEFORE initial use or battery life will be reduced NOTE As a general rule batteries should be recharged daily to assure the longest possible life and minimize the required charging time Plan to recharge the batteries when it is anticipated the wheelchair will not be used for a long period of time The range per battery charge using recommended batteries should be approximately 5 to 9 hours of typical operation Extensive use on inclines may substantially reduce per charge mileage FWD WHEELCHAIRS Description and Use of Battery Chargers The charger automatically reduces the charge from an initially high rate to a zero reading at a fully charged condition If left unattended the charger should automatically shut off when full charge is obtained There are some basic concepts which will help you understand this automatic process The amount of elec
56. iquid back into the same cell after reading the float Repeat this step until all cells have been ONLY use distilled water when topping off properly read A shorted or dead cell can be detected T the battery cells when it is the only cell that does not charge R Most batteries are not sold with instructions 9 Flush hydrometer in cold running water by allowing 0 However wamings are frequently noted the water to rise into hydrometer as far as possible T on the cell caps Read them carefully Dothis several times to guard against bum damage 1 Remove the battery box es Refer to one 1 of the 10 Replace the battery caps E following 11 Reinstall battery boxes Refer to one 1 of the following S A FWDWHEELCHAIRS INSTALLING REMOVING A FWDWHEELCHAIRS INSTALLING REMOVING H BATTERY BOXES in PROCEDURE 8 of this BATTERY BOXES in PROCEDURE 8 of this manual manual RWDWHEELCHAIRS INSTALLING REMOVING B RWDWHEELCHAIRS INSTALLING REMOVING l BATTERY BOXES in PROCEDURE 9 of this BATTERY BOXES in PROCEDURE 9 of this N manual manual G 2 Remove the battery caps from the battery 3 Squeeze the air from the hydrometer MOTOR TESTING FIGURE 3 4 Placethe hydrometer into a battery cell 1 On the 4 pin motor connector locate the two 2 contacts in the red and black housings NOF DO eta 2 Setthe digital multimeter to measure ohms 5 Draw up sufficient acid to cove
57. is procedure of the manual Install the Captain s Seat Refer to REMOVING INSTALLING CAPTAIN S SEAT in PROCEDURE 9 of the owner s manual part number 1080737 HIGH BACK CAPTAIN S SEATS ONLY Connect the limit switch Refer to DISCONNECTING CONNECTING LIMIT SWITCH in this procedure of the manual FOLDING 1 HIGH BACK CAPTAIN S SEATS ONLY Disconnect the limit switch Refer to DISCONNECTING CONNECTING LIMIT SWITCH in this procedure of the manual Refer to PREPARING MKIV JOYSTICK FOR USE in PRO CEDURE 5 of this manual y wt Refer to REPOSITIONING MOTORS in this procedure of the manual Push Brackets Crossbraces 6 PROCEDURE 8 Remove the Captain s Seat Refer to REMOVING INSTALLING CAPTAIN S SEAT in PROCEDURE 9 of the owner s manual part number 1080737 Remove the shrouds Refer to REMOVING INSTALL ING SHROUDS in this procedure of the manual Remove the batteries and footrests legrests from the wheelchair Refer to FIGURE 2 Lift the battery tray UP and out of the way Refer to FIGURE 2 Lift up on push brackets located on the crossbraces ADJ USTING FLIP UP REMOVABLE FOOTBOARD Angle FIGURE 3 NOTE Angle availability is limited when the motors are in the forward most position 1 2 3 4 Remove the caplug caps Remove the front hex screw and caplug washer that secure the footboard mounting bracket and bushing to the wheelchair Repeat
58. ischarged batteries may require up to sixteen 16 hours to be properly charged and equalized If the charger operates for sixteen 16 hours and is unable to fully charge the batteries an internal timer turns the charger off and begins to fast blink the green light NOTE If the batteries need to be charged more often or take longer to charge than normal they may need to be replaced Contact an authorized dealer for service Battery Charger Connector on Side of Wheelchair From Battery D Charger cu FIGURE 5 CHARGING BATIERIES R W D W H E E L ie H R S R W D W H E E L H R S PROCEDURE 9 REPLACING BATTERIES Most batteries are not sold with instructions However wamings are frequently noted on the cel caps Read them carefully otherwise injury or damage may occur NOTE Invacare recommends that both batteries be replaced if one 1 battery is defective Recommended Battery Types The warranty and performance specifications contained inthis manualare based on the use of deep cycle gel cell or sealed lead acid batteries Invacare strongly recommends their use as the power source for this unit CAUTION Failure to use the correct battery sze and or voltage may cause damage to yourwheel hair and give you unsatisfactory performance ec WIDTH NO 2 32 Ut Deep oye 16 18 20 inches 22NF Deep Cycle NOTE Charge batteries daily It is critical
59. ition the two 2 new seat positioning strap halves on the inside of the seat frame assembly as shown in FIGURE 7 Seat Positioning Strap Washer ibis d WV 2 Hex Bolt AGURE 7 REPLACING SEATPOSITIONING SIRAP Seat Frame Assembly PROCEDURE 8 5 Position the mounting holes in the two 2 new seat positioning strap halves with the mounting holes in the seat frame assembly Reinstall the two 2 hex bolts washers and locknuts that secure the seat positioning strap to the seat frame assembly and tighten securely 7 Install the captain s seat onto the wheelchair Refer to REMOVING INSTALLING CAPTAIN S SEAT in PROCEDURE 9 of the owner s manual part number 1080737 REPLACING CAPTAIN S SEAT FIGURE 8 1 Remove the Captain s seat from the wheelchair Refer to REMOVING INSTALLING CAPTAIN S SEAT in PROCEDURE 9 of the owner s manual part number 1080737 2 Remove four 4 hex screws and washers that se cure existing captain s seat to the seat frame assembly Line up mounting holes in the new captain s seat with mounting holes in the seat frame assembly 4 Apply Loctite 242 to the hex screws Install the four 4 hex screws and washers through the seat frame assembly and into the new captain s seat Tighten securely 6 Install the new captain s seat onto the wheelchair Refer to REMOVING INSTALLING CAPTAIN S SEAT in PROCEDURE 9 of the owner s manual part number 1080737 F
60. ividuals perform any work on these units the warranty is void OPERATING INFORMATION GENERAL WARNINGS Performance adjustments should only be made by professionals of the healthcare field or persons fully conversant with this process and the drivers capabilities Incorect settings could cause injury to the driver bystanders damage to the chair and to surrounding property After the wheelchair has been set up check to make sure that the wheelchair performs to the specifications entered during the set up procedure If the wheelchair does perform to specifications tum the wheelchair OFF immediately and reenter set up specifications Repeat this procedure until the wheelchair performs to specifications DO NOT use parts accessories or adapters other than those authorized by Invacare TIRE PRESSURE DO NOT use your wheelchair unless it has the proper tire pressure P S l DO NOT overin flate the tires Failure to follow these suggestions may cause the tire to explode and cause bodily ham The recommended tire pressure is listed on the side wall of the tire ELECTRICAL Grounding Instructions DO NOT under any circumstances cut or remove the round grounding prong from any plug used with or for Invacare products Some devices are equipped with three prong grounding plugs for protection against possible shock hazards Where a two prong wall receptacle is encountered it is the personal responsibility and obligation of the custom
61. ller connector BLUE 3 Remove the four 4 phillips screws that secure the battery connectors and battery connector spacers to the wheelchair frame 4 Remove the two 2 phillips screws washers and locknuts that secure the charger cable to the charger cable mounting bracket 5 Cut the tie wrap that secures the wiring harness and motor cables to the crossbraces 6 Remove the wiring hamess from the wheelchair Reassembly J fa 1 Secure the two 2 battery connectors of the new M battery harness and the battery connector spacers to Controller the wheelchair frame with the four 4 phillips screws FIG URE 10 REMOVING INSIALLING MKV 2 Secure charger cable to existing mounting bracket CONTROLLER on seat frame with two 2 phillips screws washers and locknuts A FQ E D Ons Battery Connector Spacer c Wiring Hamess Phillips fte Screws fi TO WES Charger Pf Cable Mounting Bracket em M1 Phillips Screws and Locknuts W D 2 74 Sa From Motors FIG URE 11 REPLACING WARING HARNESS 45 R W D W H E E L H R S RWD WHEELCHAIRS PROCEDURE 9 3 Connectthe wring harness BLUE to the controller 10 Repeat procedure for opposite side of the connector BLUE wheelchair if necessary R 4 Re secure the wiring harness and motor cables to the 11 Reinstall the battery boxes Refer to INSTALLING crossbraces wit
62. m the rear of the seat extension tube with the front mounting hole in the crossbrace 4 Install the new seat upholstery onto the wheelchair Refer to REPLACING SEAT UPHOLSTERY in PROCEDURE 5 of the Owners Manual part number 1080737 NOTE Make sure to line up the mounting holes in the seat extension tubes with the new seat upholstery 5 Install plug buttons into the ends ofthe seat extension tubes Washer Philips Screws Plug Button Crossbrac Seat Extension Tube a C FAAG URE 1 ADJUSTING SEAT DEPTH 11 PROCEDURE 4 USTING BACK HEIGHT REPLACING BACK CANES FIGURE 2 1 Remove the four 4 hex screws washers and locknuts that secure the two 2 back canes to the wheelchair frame 2 Reposition the back canes to one 1 of five 5 pairs of height adjustment holes ORIGINAL BACK HEIGHT IN INCHES OHOLEPAR 1 2 3 4 5 16 20 inches 16 17 18 19 20 Q Holes numbered from bottom to top for reference only There are no numbers on the back canes 3 Reinstallthe four 4 hex screws washers and locknuts that secure the back canes to the wheelchair frame 4 Securely tighten the hex screws and locknuts M Back Cane 5 4 3 2 Locknuts 1 Washers _ Hex serens T Wheelchair rm AS sS FIGURE 2 ADJUSTING BACK HEIGHT REPLACING BACK CANES mz umm A mo oOo zommaMomrm PROCEDURE 5 ELECTRONICS This Procedure Includes t
63. nto the wheelchair Refer to INSTALLING REMOVING BATTERY BOXES in this procedure of the manual 21 Reinstall shrouds Referto REMOVING INSTALLING SHROUDS in this procedure of the manual 22 Reinstall the Captain s seat Refer to REMOVING INSTALLING CAPTAIN S SEAT in PROCEDURE 9 of the owner s manual part number 1080737 Dust Cover STEPS 7 16 Oa Locknut STEPS 8 14 Spacer STEPS 9 13 Hex Bolts STEPS 9 14 Pivot Tube Plug Pin STEPS 11 12 A DEMIL C SIEPS10 13 hp Front of Wheelchair Note orientation of hex bolt washers coved wash ers and locknut for installation of new crossbraces FIGURE 16 REPLACING CROSSBRACES CAPBIN S SEAT 31 F W D W H E E L ie H R S F W D W H E E L H R S PROCEDURE 8 WHEN TO CHARGE BATTERIES FIGURE 17 It is advantageous to recharge frequently rather than only when necessary In fact a battery s life is extended if the charge level is maintained well above a low condition BATTERY DISCHARGE INDICATOR BDI is located at the rear of the joystick housing and provides information on the remaining charge in the batteries At FULL charge the BDI will be GREEN As the battery becomes discharged the BDI indicator will AMBER YELLOW then RED and finally FLASHING RED If the BDI is FLASHING RED the user should charge the batteries as soon as possible NOTE Accurate read
64. object This puts a heavy load on the batteries as they try to push through the stationary object Read the meter while the motors are straining to determine the voltage under load NOTE If the voltage drops to less than 23 5 volts from a pairoffully charged batteries while under load they should be replaced regaraless of the unloaded voltages Battery Charger Connector ES Digital Voltmeter FIGURE 1 HELD LOAD TEST USING HYDROMETER TO CHECK BATTERY CELLS LEAD ACID FIGURE 2 NOTE Perform this procedure when a digital voltmeter is not available NEVER smoke or strike a match near the batteries If the caps of the battery cells are removed NEVER look directly into them when charging the battery The use of rubber gloves and safety glasses is recommended when testing the battery cells When reading a hydrometer DO NOT allow any liquid to come in contact with your eyes or skin It is a form of acid and can cause serious bums and in some cases blindness If you do get battery acid on you flush the exposed areas with cool water IMMEDIATELY If the acid comes into contact with eyes or causes serious bums get medical help IMMEDIATELY The battery acid can damage your wheelchair clothing and household items Therefore take readings cautiously and only designated areas T R 0 U B L E S H 0 0 T PROCEDURE 2 TROUBLESHOOTING 8 Flush the l
65. olts and locknuts that secure the two H Refer to INSTALLING REMOVING BATTERY 2 pivot links to the wheelchair frame and crossbraces E BOXES in this procedure of the manual Refer to the following chart to determine if new pivot E 3 Fold the battery tray Refer to FOLDING BATTERY __links will be needed L TRAY FOR TRANSPORT in this procedure of the PIVOTUNK SEATWDIH RANGE in inches ie manual 16 18 or 20 H Locknut Crossbrace S y 9 6 7 O Wheelchair Frame Washer STEPS 8 13 b Hex Bolts STEPS 8 13 a wee No Dust Cover STEPS 6 16 Pivot Link uM Pivot Tube Plug Pin STEPS 9 10 Locknut STEPS 5 14 Hex Bolts STEPS 5 14 DEAIL B RIGHT LEFT NOTE Right and left is determined by sit ting in the wheelchair Note orientation of hex bolt washers coved wash ers and locknut for installation of new crossbraces FIGURE 15 CHANGING SEATWDTH INTEGRATED SLING SEATS 29 W D W H E E L ie H R S PROCEDURE 8 6 Remove the dust covers from the bottom of the crossbraces NOTE Note position of the tie wraps that secure the wiring harness to the crossbraces 7 Cut the tie wraps that secure the wiring harness to the crossbrace 8 Remove the hex bolts washers and locknuts that secure the bottom of the two 2 crossbraces to the wheelchair frame 9 Remove the hex bolt coved spacers washers and locknut
66. or 20 in 19 19 19 Seat Depth Range 16 17 or 18 in In 1 in increments 17 in 17 in 17 17 18 in by extension A Back Height Range Std 16 17 18 19 or20 in In 1 in increments 16 in 18 in 22 in Opt Headrest N A N A N A 28 in Opt Backrest Ext N A 23 in N A N A Back Angle Range N A 55 114 98 35 170 S Seat to Floor 18 1 2 in 22 in 19 1 2 in 22 in Overall Width No Joystick 24 5 8 in 24 3 4 in 24 3 4 in 24 3 4 in Overall Height 34 3 8 in 16 in Back Height 35 in 35 in 39 in Weight W O Batteries 90 to 100 lbs 122 to 127 lbs WiBatteries Gel Cell 170 to 180 lbs 203 to 207 Ibs Shipping 105 to 115 lbs 153 to 157 lbs Armrests Removable Flip Back Fixed or Adjustable Flip Back Adjustable Height Full Length Std Height Desk and Full Length Upholstery Black Nylon Vinyl or Cloth with Vinyl NOTE 18 in wide x 16 deep wheelchair with MKIV electronics NOTE Low and High Back Types have an infinite adjustment Low Backs with Solid Seat have no adjustment INTEGRATED SLING SEAT AND CAPTAIN S SEAT DRIVE WHEEL POSITION Overall Length REAR POSITION MIDDLE POSITION FORWARD POSITION With 8 in Rear Casters and 93 Front Riggings 47 1 2 47 1 2 in N A With 8 in Rear Casters and no Front Riggings 32 1 2 in 33 1 2 in N A lt NOTE Refer to REPOSITIONING MOTORS in PROCEDURE 7 of this manual Drive
67. preparations Make sure tp use ONLY secure non detachable parts forhand hold supports Keep handsand fingers clearof moving avoid injury The overall performance of the wheelchair WILL be affected by the fiont wheel mounting pos tion Refer to REPOSITIONING MOTORS WHEELCHAIRS in this procedure of the manual BEFORE operating the wheelchair Unfolding Folding Integrated Sling Seat FIGURE 1 UNFOLDING 1 Push down on the seat rails until the seat rails are positioned in the seat guides 2 Assemble the wheelchair Refer to FIGURE 1 Seat Rails Refer to INSTALLING REMOVING FOOTRESTS or INSTALLING REMOV ING ELEVATING LEGRESTS in PROCE 2 DURE 3 of the owners manual part num 1080737 Referto INSTALLING REMOV ING BATTERY BOXES in this procedure of the manual dure of the manual FIGURE 1 ASSEMBLING EXCEL UNFOLDING FOLDING INTEGRATED SLING SEAT 20 FWD WHEELCHAIRS FOLDING 1 3 Remove the batteries and footrests legrests from the wheelchair Refer to FIGURE 1 Lift the battery tray UP and out of the way Refer to FIGURE 1 Lift up on the seat rails of the wheelchair Unfolding Folding Captain s Seat FIGURE 2 UNFOLDING 1 2 3 Push down on the push brackets until they are flush with the pivot links on the crossbraces Assemble the wheelchair Refer to FIGURE 2 Install the shrouds Refer to REMOVING INSTALLING SHROUDS in th
68. r float balls 3 Measure the resistance between the two 2 motor 6 Taplightly to remove air bubbles contacts 7 Number of floating balls indicates charge NOTE A normal reading is between 1 and 5 ohms 0 A reading of 0 ohms or in excess of 15 ohms Number of Floating Balls indicates a problem High readings are generally caused Discharged by bad connections and or damaged brushes Contact 25 Charged authorized dealer or Invacare 50 Charged 7596 Charged 100 Charged Overcharged Check charging system Number of Floating Balls Will Vary According to Charge Motor Connector HGURE 3 MOTOR TESTING HGURE 2 USING A HYDROMETER TO CHECK BATTERY CELLS LEAD ACID TROUBLESHOOTING PROCEDURE 2 MOTOR BRUSH INSPECTION ELECTRO MECHANICAL PARKING FIGURE 4 BRAKE TEST FIGURE 5 There are two 2 contact brushes on the motors located 1 under the brush caps on the motor housing If these caps are hard to remove they are either overtightened or the motor has become very hot Let motors cool If caps still 2 cannot be removed it is recommended that the motor be sent to Invacare Technical Services for inspection repair 3 On the four pin motor connector locate the side by side connectors in the black housings Set the digital multimeter to read ohms Measure the resistance between the two 2 brake contacts A normal reading is 100 ohms O A reading of 0 ohms W or a very high readin
69. ransportation has not approved any tie down systems for transportation of a user while in a wheelchair in a moving vehicle of any type It is Invacare s position that users of wheelchairs should be transferred into appropriate sealing in vehicles for transportation and use be made of the restraints made available by the auto industry Invacare cannot and does not recommend any wheelchair transportation systems AS REGARDS RESTRAINTS SEAT POSITIONING STRAPS IT IS THE OBLIGATION OF THE DME DEALER THERAPISTS AND OTHER HEALTHC ARE PROFESSIONALS TO DETERMINE IF A SEATING POSITIONING STRAP IS REQUIRED TO ENSURE THE SAFE OPERATION OF THIS EQUIPMENT BY THE USER SERIOUS INJ URY MAY OCCUR IN THE EVENT OF A FALL FROM A WHEELCHAIR SAVE THESE INSTRUCTIONS TABLE OF CONTENTS TABLE OF CONTENTS The following procedures refer to POWER 9000 and EXCEL wheelchairs except where specified SPECIAL NOTES SPECIFICATIONS REPAIR OR SERVICE INFORMATION 6 OPERATING INFORMATION 11 1 6 PROCEDURE 2 TROUBLESHOOTING 7 FIELD LOAD TEST n 7 USING HYDROMETER TO CHECK BATTERY CELLS LEAD ACID 7 MOTOR TESTING cene 8 MOTORBRUSHINSPECTION 9 ELECTRO MECHANICAL PARKING BRAKE TEST 9 PROCEDURE 3 UPHOLSTERY REPLACING BACK UPHOLSTERY 2 10 PROCEDURE 4 SEAT FRAME ADJUSTING SEAT DEPTH c 11 ADJUSTING BACKHEIGHT REPLACING BACK
70. s for one 1 year from the date of purchase except upholsiered materials padded materials and tires wheels If within such warranty period any product shall be proven to be defective such product shall be repaired or replaced atinvacare s option This warranty does notinclude any labororshipping charges incurred in replacemert part installation or repair of any such product Invacare s sole obligation and your exclusive remedy underthis warranty shall be limited to such repairand orreplacement Forwarnanty service please contactthe dealerfiom whom you purchased product In the event you do not receive satisfactory warranty service please wite directly to Invacare at the bottom of the back cover Provide dealer s name addiess date of purchase indicate nature of the defectand ifthe productis serialized indicate the serial number Do notretum products tp ourfactory without our prior consent LIMITATIONS AND EXCLUSIONS THE FOREGOING WARRANTY SHALL NOT APPLY TO SERIAL NUMBERED PRODUCTS IF THE SERIAL NUMBER HAS BEEN REMOVED OR DEFAC ED PRODUCTS SUBJ ECT TO NEGLIGENCE ACCIDENT IMPROPER OPERATION MAINTENANCE OR STORAGE COMMERCIAL OR INSTTUTIONALUSE PRODUCTS MODIFIED WTHOUTINVACARES EXPRESSWRITIEN CONSENTINC LUDING BUT NOT LIMITED TO MODIRCATION THROUGH THE USE OF UNAUTHORIZED PARIS OR ATIACHMENTS PRODUCTS DAMAGED BY REASON OF REPAIRS MADE TO ANY COMPONENT WITHOUT THE SPECIHC CONSENT OF INVACARE OR TO A PRODUCT DAMAGE
71. s on the wheelchair frame 4 Connectthe battery box retaining strap clip together Retaining Battery Boxes Battery Connections on Retaining Strap Clip Side of Wheelchair Frame FIG URE 6 INSIALLING REMOVING BATIERY BOXES The Battery Box Retaining Srap MUSTbe fastened securely and adjusted properly to hold battery boxes in place before using the wheelchair 5 Connect the battery box retaining strap clip together and adjust if necessary RWD WHEELCHAIRS BATTERY TRAY FIGURE 7 NOTE To remove the battery tray from the wheelchair reverse the following procedure 1 Remove the battery tray from the packaged container NOTE The hex socket screws will be positioned in the correct mounting holes for the corresponding width of the wheelchair Hex Screws Shown in 14 and 16 inch Wheelchair Width positions 18 inch Wheelchair Wiath Position 20 inch Wheelchair Width Position Key Slot Bracket i yf Crossbrace Bolt Bushing Key Slot Bracket put Battery Tray Hanger Bracket Battery Tray Support Tube FIG URE 7 BATIERY TRAY 43 PROCEDURE 9 2 Secure the hanger brackets to the battery tray in the mounting holes that the hex screws are mounted 3 Attach the key slot bracket located at the front of the battery tray over the crossbrace bolt bushing under the seat upholstery of the wheelchair NOTE If wheelchair is 14 inch wide and equipped with
72. ster side to side NOTE If the caster moves side to side tighten the locknut slightly Repeat STEP 7 until there is no side to side movement of the caster Fork Locknut Hex Screw D Washer Washer Caster FIGURE 2 REPLACING CASTERS REPLACING FORKS FIGURE 3 1 Remove the hex screw washers and locknut that secure the caster to the existing fork Remove the caster from the existing fork Remove the dust cover Remove the locknut and nylon washer Drop the existing fork out of the caster head tube oa Slide the new fork into the caster head tube WHEELS NOTE Check bearing assemblies and replace if necessary 7 Ensure that new fork slides completely into the caster head tube 8 Install nylon washer and secure with locknut Improper positioning of the washer will prohibit the free movement of the forks 9 Install Loctite 242 onto the hex screw 10 Position the caster into the new fork 11 Reinstall the hex screw washers and locknut that secure the caster to the new fork 12 Torque the locknut to 120 inch pounds 13 Loosen the locknut 1 8 of a turn 14 Move the caster side to side NOTE If the caster moves side to side tighten the locknut slightly Repeat STEP 14 until there is no side to side movement of the caster 15 Adjust the fork Refer to ADJUSTING FORKS in PROCEDURE 8 of the owner s manual part number 1080737 Dust Cover 72 Locknut Nylon Washer
73. sting crossbraces 8 Install the four 4 pivot tube plug pins into the bottom of the two 2 new crossbraces 9 Assemble the two 2 new crossbraces together Refer to FIGURE 8 for hardware orientation 10 Reinstall the hex screws washers and locknuts that secure the bottom of the two 2 new crossbraces to the wheelchair frame R W D W H E E L H R S PROCEDURE 9 RWD WHEELCHAIRS 11 Reinstall dust covers onto bottom of crossbraces 14 Reinstall the battery tray and battery boxes batteries 12 Reinstall the hex screws and locknuts that secure the onto the wheelchair Refer to BATTERY TRAY and pivot links to the wheelchair frame and crossbraces INSTALLING REMOVING BATTERY BOXES in this procedure of the manual 13 Install the new back and seat upholstery onto the wheelchair Refer to REPLACING BACK UPHOL STERY in PROCEDURE 3 of this manual and REPLACING SEAT UPHOLSTERY in PROCEDURE 5 of the owners manual part number 1080737 Crossbrace O Locknut Hex Screws R W D W H E E L H R S Dust Cover Pivot Tube plug Pin No Wheelchair Frame Locknut Note orientation of hex screw bushing washers coved washers and locknut for in stallation of new crossbraces FIGURE 8 CHANGING SEATWDIH ADJ USTING SEAT TO FLOOR Fastening Straps HEIGHT VOX Adjusting seat to floorheight MUSTbe performed by Inva
74. t Some battery manufacturers mold a canying stap and or hold down flanges directly into the battery case Batteries NOTE For CHARGING BATTERIES or REMOVING which interfere with the battery box INSTALLING THE BATTERY BOXES refer to cannot be used for these applications PROCEDURE 8 FWD wheelchairs or PROCEDURE Attempting to wedge a battery into a 9 RWD wheelchairs battery box may damage the box and or the battery INSTALLING REMOVING a aaa ST BATTERIES INTO FROM BATTERY bn piis e ng Str BOXES FIGURE 1 aney PAS EP Molded Carrying Strap Hold D FI NOTE To remove the battery ies from the battery E ARRIER box es reverse the following procedure NOTE Have the following tools available TOOL QTY COMMENTS Battery Lifting Strap 1 See Note 1 2 inch 6 pt Box Wrench 1 Not Supplied 7 16 inch 6pt Box Wrench 1 Not Supplied 3 8 inch 6pt Box Wrench 1 Not Supplied Diagonal Cutters 1 Not Supplied Dual 22 NF NOTE The Battery Lifting strap supplied is for Dual ONLY 22 NF Batteries ONLY Refer to the battery manufac Battery Terminal s Post s turer for the proper lifting strap and or battery tools for U1 battery removal installation U1 Battery Box ALWAYS use a battery lifting strap when lifting a battery It is the most convenient gt method and assures that the battery acid Dual22NF will not spill It also helps to prolong the Battery Box
75. that secure the two 2 existing crossbraces together NOTE Note coved spacer washer and locknut order for reinstallation 10 Remove the four 4 pivot tube plug pins from the bottom of the two 2 existing crossbraces 11 Install the four 4 pivot tube plug pins into the bottom of the two 2 new crossbraces 12 Assemble the two 2 new crossbraces together Refer to DETAIL A in FIGURE 15 for hardware orientation NOTE There are right and left crossbraces Refer to DETAIL B in FIGURE 15 13 Reinstall the hex bolts washers and locknuts that secure the bottom of the two 2 new crossbraces to the wheelchair frame and tighten securely 14 Reinstall the hex bolts and locknuts that secure the new existing pivot links to the wheelchair frame and crossbraces and tighten NOTE Seat widths are stamped on the pivot links 15 Secure wiring hamess to the new crossbraces with new tie wraps 16 Reinstall the dust covers onto the bottom of the crossbraces 17 Installthe newbackand seatupholstery ontothe wheel chair Referto REPLACING BACK UPHOLSTERY in PROCEDURE 3 of this manual and REPLACING SEAT UPHOLSTERY in PROCEDURE 5 of the owner s manual part number 1080737 18 Change the width of the battery tray Refer to CHANGING WIDTH OF BATTERY TRAY in this procedure of the manual 19 Unfoldthe battery tray Referto FOLDING BATTERY TRAY FOR USE in this procedure of the manual 20 Reinstall the battery boxes onto
76. the wheelchair bolt and locknut 6 Line up the mounting holes in the new battery tray 5 Tighten the two 2 hex bolts and locknuts hanger bracket with the mounting holes in the NOTE Tighten the Two 2 hex bolts and locknuts uni Wheelchair frame the tray stays up by itself Over tightening the hex bolts 7 Perform one 1 of the following and locknuts will make the battery tray difficult to flip up A WHEELCHAIR EQUIPPED WITH FLIP UP 6 Reinstall the battery boxes Refer to INSTALLING REMOVABLE FOOTBOARD Reinstall the hex REMOVING BATTERY BOXES in this procedure of screw and spacer that secures the new right the manual battery tray hanger bracket and footboard mounting bracket to the wheelchair frame Use Loctite 242 and torque to 156 in lbs 35 W D W H E E L H R S PROCEDURE 8 B WHEELCHAIR NOT EQUIPPED WITH FLIP UP REMOVABLE FOOTBOAPD Reinstall the front hex screw that secures the new right battery tray hanger bracket to the wheelchair frame Use Loctite 242 and torque to 156 in lbs Reinstall the rear hex screw Use Loctite 242 and torque to 156 in lbs Reinstall the battery tray Refer to INSTALLING BATTERY TRAY in this procedure of the manual Wheelchair Frame Rear Hex Screw ES Hex Screw Spacer P d Footboard Mounting Bracket Battery Tra Hanger Bracket FIGURE 24 BATIERY TRAY REPLACING RIGHT BATIERY TRAY HANGER BRACKET Replacing Left Batter
77. the wheelchair Refer to INSTALLING REMOVING BATTERY BOXES in this procedure of the manual 21 If necessary reinstall the shrouds Referto REMOV ING INSTALLING SHROUDS in this procedure of the manual 30 FWD WHEELCHAIRS REPLACING CROSSBRACES CAPTAIN S SEAT FIGURE 16 1 Remove the captain s seat from the wheelchair Referto REMOVING INSTALLING CAPTAIN S SEAT in PROCEDURE 9 of the owner s manual part number 1080737 2 Remove the shrouds Refer to REMOVING INSTALLING SHROUDS in this procedure of the manual 3 Remove the battery boxes from the wheelchair Refer to INSTALLING REMOVING BATTERY BOXES this procedure of the manual 4 Fold the battery tray Refer to FOLDING BATTERY TRAY FOR TRANSPORT in this procedure of the manual 5 Remove the hex bolts and locknuts that secure the two 2 pivot links to the existing crossbraces 6 Removethe hex bolts spacers washers and locknuts that secure the two 2 push brackets to the existing crossbraces 7 Remove the dust covers from the bottom of the existing crossbraces NOTE Note position of the tie wraps that secure the wiring hamess to the existing crossbraces 8 Cut the tie wraps that secure the wiring hamess to the existing crossbrace 9 Remove the hex bolts washers and locknuts that secure the bottom of the two 2 existing crossbraces to the wheelchair frame 10 Remove the hex bolt coved spacers washers an
78. tion If left unattended the charger should automatically shut off when full charge is obtained There are some basic concepts which will help you understand this automatic process The amount of electrical current drawn within a given time to charge a battery is called charge rate If due to usage the charge stored in the battery is low the charge rate is high as indicated by the green light on the char ger Initially the green light will stay illuminated for a short period of time followed by a longer period of off time As a charge builds up the charge rate is reduced and the green light will stay illuminated for a longer period of time followed by a shorter off time NOTE Ifperforming the charging procedures independently READ and CAREFULLY follow the individual instructions for each charger supplied or purchased NOTE If charging instructions are not supplied consult a qualified service technician for proper procedures Required Items TOOL QUANTITY COMMENTS Battery Charger 1 Supplied Extension Cord 1 Not Supplied 3 prong plug 15 ampere current rating industrial type Attach the battery charger connector to the charger cable battery harness 2 Plugthe charger s AC power cord or extension into the grounded 120 VAC wall outlet 3 Wait until charging is complete NOTE Allow eight 8 hours for normal charging Larger batteries greater than 55 ampere hours or severely d
79. trical current drawn within a given time to charge a battery is called charge rate If due to usage the charge stored in the battery is low the charge rate is high as indicated by the green light on the charger Initially the green light will stay illuminated for a short period of time followed by a longer period of off time As a charge builds up the charge rate is reduced and the green light will stay illuminated for a longer period of time followed by a shorter off time NOTE If performing the charging procedures indepen dently READ and CAREFULLY follow the individual instructions for each charger supplied or purchased NOTE If charging instructions are not supplied consult a qualified service technician for proper procedures Required Items TOOL QUANTITY COMMENTS Battery Charger 1 Supplied Q Extension Cord 1 Not Supplied 3 prong plug 15 ampere current rating industrial type 1 If necessary remove the rear shroud Refer to REMOVING INSTALLING SHROUDS in this procedure of the manual 2 Attach the battery charger connector to the charger cable battery harness 3 Plug the charger s AC power cord or extension into the grounded 120 VAC wall outlet 4 Wait until charging is complete NOTE Allow eight 8 hours for normal charging Larger batteries greater than 55 ampere hours or severely discharged batteries may require up to sixteen 16 hours to be properly charged and equaliz
80. ts that secure side shroud and filler to the wheel chair frame Refer to FIGURE 14 for phillips screw and washer locations Remove side shroud and filler from the wheelchair Repeat STEPS 5 6 for the opposite side of the wheel chair if necessary W D W H E E L ie H R S PROCEDURE 8 FWD WHEELCHAIRS Installing Side Shrouds and Fillers B Reinstall the phono jack nut onto the phono jack 1 Position side shroud and filler on the wheelchair frame NEE SSCS 6 Perform one 1 of the following 2 Line up the mounting holes in the side shroud and filler with the mounting holes in the wheelchair frame A INTEGRATED SLING SEAT MODELS Unfold the wheelchair Referto TRANSPORTING EXCEL in this procedure of the manual DO NOTovertighten the phillips sc rews and phil lipsboltthatsec ure the side shroud to the wheel B CAPTAIN S SEAT MODELS Reinstall the Captain s Seat onto the wheelchair Refer to chair frame otherwise damage to the side dioud can REMOVING INSTALLING CAPTAIN S SEAT in PROCEDURE 9 of the owner s manual part 3 Install the phillips screws bolts washers and locknuts number 1080737 that secure the side shroud and filler to the wheelchair 7 Reinstall the rear shroud onto the wheelchair Refer frame and tighten securely DO NOT OVERTIGHTEN to REMOVING INSTALLING REAR SHROUD inthis Refer to FIGURE 14 for phillips screw bolt washer procedure of the m
81. wn towards the ground floor Motor Mount Wheelchair Support Tube Motor Gearbox HGURE 12 REPLACING MOTOR GEARBOX The longer soc ket sc rews must be positioned in the mounting holes on the OUTSIDE of the wheelchairframe and the shortsocketsc rews must be in the mounting holes on the INSIDE of the wheelchair frame Otherwise damage to the gearbox casting can result 7 Use Loctite 242 and securely tighten the support tube and motor gearbox to the wheelchair frame with the six 6 socket screws Torque to 60 inch pounds 8 Reinstall the drive wheels onto the wheelchair Refer to REPLACING DRIVE WHEELS in PROCEDURE 6 of this manual 9 Reconnect the right and or left motor connector to the controller 46 LIMITED WARRANTY PLEASE NOTE THE WARRANTY BELOW HAS BEEN DRAFTED TO COMPLY WITH FEDERAL LAW APPLICABLE TO PRODUCTS MANUFACTURED AFTER J 4 1975 This wananty is extended only to the original haser user of our products This wananty gives you specific legal rights and you may also have otherlegal rights which vary fiom date ip slate Invacare wananits the side frames and ciossbracestp be fiee from defects in materials and workmanship fora period of five 5 years from date of purchase electronics fora period of one 1 year from the date of purchase motors and gearboxes for a period of twelve 12 months from the date of purchase all remaining components including gas cylinders for rec liner
82. wo 2 footboard pivots to the footboard mounting brackets with the hex screws spacers washers and locknuts Refer to FIGURE 4 for the correct hardware orientation 6 Torque the two 2 hex screws to 156 65 and back off the hex screws 1 8 1 4 of a revolution 7 If necessary reinstall the four 4 caplug caps Footboard Mounting Bracket Washer Five 5 Mounting Positions o SQ A oi E Caplug Cap Footboard Pivot FIG URE 4 ADJ USTING FLIP UP REMOVABLE FOOTBOARD 22 FWD WHEELCHAIRS REPLACING ARMREST PADS FIGURE 5 1 Remove the mounting screws that secures the front of the armrest pad to the armrest plate 2 Remove the mounting screw that secures the rear of armrest pad and armrest insertto the armrest plate 3 Remove the existing armrest pad and position the new armrest pad on the armrest plate 4 Line up the mounting holes in the armrest insert armrest plate and new armrest pad 5 Reinstall the rear mounting screw through the armrest insert armrest plate and armrest pad and tighten securely 6 Reinstall the front mounting screw into the armrest plate and new armrest pad and tighten securely REAR FRONT Armrest G Amrest Insert Pad P Mount ing Mounting Screw Screw FIGURE 5 REPLACING ARMREST PADS REPLACING ARMREST PLATE FIGURE 6 1 If necessary remove the three 3 hex bolts spacers and locknuts that secure the joystick mounting brack
83. y Tray Hanger Bracket FIGURE 25 NOTE Right and left is determined by sitting in the wheelchair 1 Remove the battery boxes from the wheelchair Refer to INSTALLING REMOVING BATTERY BOXES in this procedure of the manual 2 Loosen but do not remove the rear locknut that secures MKIV controller to the wheelchair 3 Perform one 1 of the following A WHEELCHAIR EQUIPPED WITH FLIP UP REMOVABLE FOOTBOARD Remove the hex screw and spacer that secures the existing left battery tray hanger bracket and footboard mounting bracket to the wheelchair frame B WHEELCHAIR NOT EQUIPPED WITH FLIP UP REMOVABLE FOOTBOARD Remove the front hex screw that secures the existing left battery tray bracket to the wheelchair frame 4 Remove the locknut that secures the existing left battery tray hanger bracket and MKIV controller from the wheelchair 5 Remove the existing left battery tray hanger bracket from the wheelchair 6 Line up the mounting holes in the new battery tray hanger bracket with the front mounting hole and rear stud on the wheelchair frame 36 MKIV Controller FWD WHEELCHAIRS Perform one 1 of the following A WHEELCHAIR EQUIPPED WITH FLIP UP REMOVABLE FOOTBOARD Reinstall the hex screw and spacer that secures the new left battery tray hanger bracket and footboard mounting bracket to the wheelchair frame Use Loctite 242 and torque to 156 65 B WHEELCHAIR NOT EQUIPPED WITH FLIP UP REMOVABLE FOOTBO
84. ystick onto the left side of the wheelchair refer to REPOSITIONING MKIV JOYSTICK in this procedure of the manual 1 Turn the lever on the adjustment lock to release the adjustment lock from joystick mounting tube 2 Slide joystick mounting tube to the desired position 3 Tum the lever on the adjustment lock to secure the Threaded Hole adjustment lock to the joystick mounting tube Clamp 9 Slide the adjustment lock over the end of the tube and secure the adjustment lock to the tube by turning the lever on the adjustment lock Arm Tube Joystick Joystick Mounting ue Hex Screws Joystick 6 Mounting Tube a Joystick Mounting Bracket Adjustment ES Adjustment Lock Lock Lever Lever Opened Hole Half Clamp FIGURE 1 PREPARING MKIV JOYSTICK FIGURE 2 REPOSITIONING MKIV R pone JOYSTICK 12 WHEELS This Procedure Includes the Following Replacing Pneumatic Tires Tubes Drive Wheels Casters Removing Installing Drive Wheels Replacing Casters Replacing Forks After ANY adjustments repair or service and BEFORE use make sure all attaching hardware is tightened securely otherwise injury or damage may result As with any vehicle the wheels and tires should be checked periodically for cracks and wear and should be replaced REPLACING PNEUMATIC TIRES TUBES DRIVE WHEELS CASTERS DO NOT use your wheelchair unless it

Invacare Power 9000 & Excel Service Manual

Contents

Download Pdf Manuals

Related Search

Related Contents

Invacare Power 9000 &amp; Excel Service Manual

Contents

Download Pdf Manuals

Related Search

Related Contents

Invacare Power 9000 & Excel Service Manual