Invacare P9000 User Manual
Service Manual
Excel and P9000
DEALER: KEEP THIS MANUAL. THE PROCEDURES
IN THIS MANUAL MUST BE PERFORMED BY A
QUALIFIED TECHNICIAN ONLY.
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WARNING/SPECIAL NOTES
THE PROCEDURES IN THIS MANUAL SHOULD ONLY BE PERFORMED
DO NOT SERVICE OR OPERATE THIS EQUIPMENT WITHOUT FIRST
READING AND UNDERSTANDING THIS MANUAL AND THE OWNERS
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MANUAL SUPPLIED WITH THE WHEELCHAIR. IF YOU ARE UNABLE TO
UNDERSTAND THE WARNINGS, CAUTIONS, AND INSTRUCTIONS,
CONTACT INVACARE TECHNICAL SUPPORT BEFORE ATTEMPTING TO
SERVICE OR OPERATE THIS EQUIPMENT - OTHERWISE INJURY OR
WARNING
BY A QUALIFIED TECHNICIAN.
DAMAGE MAY RESULT.
SPECIAL NOTES
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WARNING/CAUTION notices as used in this manual apply to hazards or unsafe practices
which could result in personal injury or property damage.
NOTICE
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THE INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE.
WHEELCHAIR USER
As a manufacturer of wheelchairs, Invacare endeavors to supply a wide variety of
wheelchairs 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.
WHEELCHAIR TIE-DOWN RESTRAINTS AND SEAT POSITIONING STRAPS
Invacare recommends that wheelchair users NOT be transported in vehicles of any
kind while in wheelchairs. As of this date, the Department of Transportation 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
seating 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 HEALTHCARE PROFESSIONALS TO DETERMINE IF A SEATING
POSITIONING STRAP IS REQUIRED TO ENSURE THE SAFE OPERATION OF THIS EQUIPMENT BY
THE USER. SERIOUS INJURY MAY OCCUR IN THE EVENT OF A FALL FROM A WHEELCHAIR.
SAVE THESE INSTRUCTIONS
2
TABLE OF CONTENTS
TABLE OF CONTENTS
The following procedures refer to POWER 9000 and EXCEL wheelchairs except where specified.
SPECIAL NOTES .........................................2
SPECIFICA TIONS ........................................4
PROCEDURE 1 - GENERAL GUIDELINES ....6
REPAIR OR SERVICE INFORMATION .................. 6
OPERATING INFORMATION ................................. 6
PROCEDURE 2 - TROUBLESHOOTING .......7
FIELD LOAD TEST .............................................. 7
USING HYDROMETER TO CHECK
BATTERY CELLS (LEAD ACID) ........................... 7
MOTOR TESTING ............................................... 8
MOTOR BRUSH INSPECTION ............................. 9
ELECTRO-MECHANICAL
PARKING BRAKE TEST .................................. 9
PROCEDURE 3 - UPHOLSTERY ................10
REPLACING BACK UPHOLSTERY .................... 10
PROCEDURE 4 - SEA T FRAME.................. 11
ADJUSTING SEAT DEPTH ................................. 11
ADJUSTING BACK HEIGHT/REPLACING
BACK CANES ............................................. 11
PROCEDURE 5 - ELECTRONICS............... 12
PREPARING MKIV JOYSTICK FOR USE ............ 12
REPOSITIONING MKIV JOYSTICK ...................... 12
PROCEDURE 6 - WHEELS ........................ 13
REPLACING PNEUMATIC TIRES/TUBES
- DRIVE WHEELS/CASTERS ....................... 13
REMOVING/INSTALLING DRIVE WHEELS .......... 13
REPLACING CASTERS ..................................... 14
REPLACING FORKS ......................................... 14
PROCEDURE 7 - BATTERIES .................... 15
INSTALLING REMOVING BATTERIES
INTO/FROM BATTERY BOXES .................... 15
CONNECTING BATTERY CABLES ..................... 16
PROCEDURE 8 - FWD WHEELCHAIRS ..... 20
ASSEMBLING EXCEL ........................................ 20
ADJUSTING FLIP-UP REMOVABLE
FOOTBOARD ............................................. 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
LIMIT SWITCH .............................................. 26
ADJUSTING LIMIT SWITCH ................................ 26
REMOVING/INSTALLING SHROUDS ................... 27
CHANGING SEAT WIDTH
- INTEGRATED SLING SEATS ......... ............. 29
REPLACING CROSSBRACES
- CAPTAIN'S SEAT ....................................... 30
WHEN TO CHARGE BATTERIES ....................... 32
CHARGING BATTERIES ..................................... 32
REPLACING BATTERIES ................................... 33
INSTALLING/REMOVING BATTERY BOXES ......... 33
BATTERY TRAY ................................................. 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
BATTERY TRAY ................................................. 43
CHANGING SEAT WIDTH ................................... 43
ADJUSTING SEAT-TO-FLOOR HEIGHT .............. 44
DISCONNECTING/CONNECTING
MKIV CONTROLLER, MOTOR
AND BATTERY LEADS ................................ 44
REMOVING/INSTALLING MKIV
CONTROLLER ........................................... 45
REPLACING WIRING HARNESS ........................ 45
REPLACING MOTOR/GEARBOX ....................... 46
LIMITED WARRANTY ................................. 47
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SPECIFICATIONS
NOTE: All specifications are
approximate.
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Seat Width Range:
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Seat Depth Range:
Back Height Range
Std.:
Opt. Headrest:
Opt. Backrest Ext.:
Back Angle Range:
Seat-to-Floor:
Overall Width (No Joystick):
Overall Height:
✪✪
✪Weight
✪✪
W/O Batteries:
W/Batteries (Gel Cell):
Shipping:
Armrests:
Upholstery:
SPECIFICATIONS
INTEGRATED SLING SEAT
16, 18 or 20-in.
16, 17 or 18-in. - In 1-in. increments
(17 and 18-in. by extension)
16, 17, 18, 19 or 20-in. - In 1-in. increments
N/A
N/A
N/A
18-1/2-in.
24-5/8-in.
34-3/8-in. - 16-in. Back Height
90 to 100 lbs.
170 to 180 lbs.
105 to 115 lbs.
Removable, Flip Back, Fixed or Adjustable
Height - Desk and Full Length
Black Nylon
EXCEL
CAPTAIN'S SEAT
BACK TYPE
LOW LOW SOLID SEA T HI GH
(LOB) (LOBSS) (HIB)
19-in. 19-in. 19-in.
17-in. 17-in. 17-in.
16-in. 18-in. 22-in.
N/A N/A 28-in.
23-in. N/A N/A
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22-in. 19-1/2-in. 22-in.
24-3/4-in. 24-3/4-in. 24-3/4-in.
35-in. 35-in. 39-in.
122 to 127 lbs.
203 to 207 lbs.
153 to 157 lbs.
Flip Back - Adjustable Height - Full Length (Std.)
Vinyl or Cloth with Vinyl
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ª35o - 170
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NOTE: 18-in. wide x 16-in. deep wheelchair with MKIV RII electronics.
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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
LDRIVE WHEEL POSITION
Overall Length
With 8-in. Rear Casters and
93 Front Riggings:
With 8-in. Rear Casters
and no Front Riggings:
Drive Wheels/Tires:
Casters w/Precision Sealed Bearings:
Footrest/Legrest:
Battery/Size (Not Supplied):
REAR POSITION MIDDLE POSITION FOR WARD POSITION
47-1/2-in. 47-1/2-in. N/A
32-1/2-in. 33-1/2-in. N/A
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NOTE: Refer to REPOSITIONING MOTORS in PROCEDURE 7 of this manual.
12-1/2 x 2-1/4-in. (Flat Free or Pneumatic)
8 x 1-3/4-in. Semi Pneumatic (Std.), 8 x 2-in. Pneumatic (Opt.)
6 x 2-in. Semi Pneumatic (Opt.)
Swingaway, Removable Adjustable Flip Up Removable Footboard
Dual Group 22NF Gel Cell
PERFORMANCE
Speed (M.P.H.): 0 to 3.8
T urning Radius: > 26-in.
* Range (variable): 17-22 miles
** L Weight Limitation: 250 lbs.
*NOTE: Range will vary with battery conditions, surface, terrain and operators weight.
**NOTE: Includes seating systems and accessories.
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NOTE: Refer to REPOSITIONING MOTORS in PROCEDURE 8 of this manual.
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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 n o Front Riggings:
✪✪
✪Weight
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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:
14, 16, 18 or 20-in. - ADULT FRAME
16, 18 or 20-in. - LOW SEAT FRAME
16, 17 or 18-in. (17 and 18-in. by extension)
16, 17, 18, 19 or 20-in.
18-1/2-in.- LOW SEAT FRAME
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.
N/A
N/A
POWER 9000
82 lbs.
145 lbs.
157 lbs.
110 lbs.
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Drive Wheels/Tires
(Flat Free or Pneumatic):
Casters w/Precision Sealed Bearings:
Anti-Tippers:
Footrest/Legrest:
Armrests:
Upholstery:
Battery/Size (Not Supplied)
T wo (2) Required:
✪✪
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NOTE: 18-inch wide x 16-inch deep wheelchair with MKIV RII electronics.
✪✪
12-1/2 x 2-1/4-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)
PERFORMANCE
Speed (M.P.H.):
T urning Radius:
* Range (variable):
** Weight Limitation:
0 to 4
35-inches
12-14 miles with U1 batteries
18-22 miles with 22NF batteries
250 lbs.
*NOTE: Range will vary with battery conditions, surface, terrain and operators weight.
**NOTE: Includes seating systems and accessories.
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This Procedure Includes the Following:
GENERAL GUIDELINESPROCEDURE 1
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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
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the wheelchair. Damage to the equipment could occur under these circumstances. If
non-certified individuals 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 driver's capabilities. Incorrect
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 NOT
perform to specifications, turn 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.I.). DO NOT overin-
flate the tires. Failure to follow these suggestions may cause the tire to explode and
cause bodily harm. 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
customer to contact a qualified electrician and have the two-prong receptacle
replaced with a properly 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 recommends their use as the power source for this unit.
6
TROUBLESHOOTING PROCEDURE 2
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 internal resistance. This means that as you try
to take power from the battery, some of that power is used up
in the 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 1.0
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,
it is 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 using the digital voltmeter.
NOTE: Invacare recommends that ONL Y qualified service personnel perform this test.
1. 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. Remove the footrests from the wheelchair and place
the stabilizer wheels or the front of the wheelchair
against the piece of wood.
5. Place the 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. Have two (2) individuals (one [1] on each arm) apply
as much downward pressure as possible on the arms
of the wheelchair.
7. Turn the wheelchair ON and push the joystick forward,
trying to drive the wheelchair through the stationary
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
pair of fully charged batteries while under load, they should
be replaced regardless of the unloaded voltages.
Battery Charger
(-)
Connector
(+)
Digital Voltmeter
FIGURE 1 - FIELD LOAD TEST
USING HYDROMETER TO CHECK
BATTERY CELLS (LEAD ACID)
(FIGURE 2)
NOTE: Perform this procedure when a digital voltmeter is
not available.
WARNING
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 burns, 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 burns,
get medical help IMMEDIATELY.
The battery acid can damage your
wheelchair, clothing, and household
items. Therefore, take readings cautiously
and only in designated areas.
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TROUBLESHOOTINGPROCEDURE 2
WARNING
8. Flush the liquid back into the same cell after reading
the float. Repeat this step until all cells have been
ONLY use distilled water when topping of f
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the battery cells.
Most batteries are not sold with instructions.
However, warnings are frequently noted
on the cell caps. Read them carefully.
1. Remove the battery box(es). Refer to one (1) of the
following:
A. FWD WHEELCHAIRS:
INSTALLING/REMOVING
BATTERY BOXES in PROCEDURE 8 of this
manual.
B. RWD WHEELCHAIRS:
INSTALLING/REMOVING
BATTERY BOXES in PROCEDURE 9 of this
manual.
2. Remove the battery caps from the battery.
3. Squeeze the air from the hydrometer.
4. Place the hydrometer into a battery cell.
properly read. A shorted or dead cell can be detected
when it is the only cell that does not charge.
9. Flush hydrometer in cold running water by allowing
the water to rise into hydrometer as far as possible.
Do this several times to guard against burn damage.
10. Replace the battery caps.
11. Reinstall battery boxes. Refer to one (1) of the following:
A. FWD WHEELCHAIRS:
INSTALLING/REMOVING
BATTERY BOXES in PROCEDURE 8 of this
manual.
B. RWD WHEELCHAIRS:
INSTALLING/REMOVING
BATTERY BOXES in PROCEDURE 9 of this
manual.
MOTOR TESTING (FIGURE 3)
1. On the 4-pin motor connector, locate the two (2)
contacts in the red and black housings.
NOTE: DO NOT fill hydrometer more than 3/4 full.
5. Draw up sufficient acid to cover float balls.
6. Tap lightly to remove air bubbles.
7. Number of floating balls indicates charge.
Number of Floating Balls
0 Discharged
1 25% Charged
2. Set the digital multimeter to measure ohms (Ω).
3. Measure the resistance between the two (2) motor
contacts.
NOTE: A normal reading is between 1 and 5 ohms (Ω).
A reading of 0 ohms (Ω) or in excess of 15 ohms (Ω)
indicates a problem. High readings are generally caused
by bad connections and/or damaged brushes. Contact
authorized dealer or Invacare.
2 50% Charged
3 75% Charged
4 100% Charged
* 5 Overcharged
* Check charging system.
Number of Floating
Balls Will Vary
According to Charge
FIGURE 2 - USING A HYDROMETER TO
CHECK BATTERY CELLS (LEAD ACID)
Ohmmeter
Motor Connector
FIGURE 3 - MOTOR TESTING
8
TROUBLESHOOTING PROCEDURE 2
MOTOR BRUSH INSPECTION
(FIGURE 4)
There are two (2) contact brushes on the motors located
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
cannot be removed, it is recommended that the motor be
sent to Invacare Technical Services 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
not be damaged or discolored. If one or both of the
brushes are damaged, only the damaged or worn
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.
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
replaced will only carry a small percentage of its rated
load capacity until the NEW brush is burned in.
ELECTRO-MECHANICAL PARKING
BRAKE TEST (FIGURE 5)
1. On the four-pin motor connector, locate the side by
side connectors in the black housings.
2. Set the digital multimeter to read ohms (Ω).
3. Measure the resistance between the two (2)
brake contacts. A normal reading is 100 ohms (Ω).
A reading of 0 ohms (W) or a very high reading; 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.
CAUTION
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.
NOTE: A bad motor can damage the controller module
but a bad controller should NOT damage a motor.
Cap
Motor
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Cap
Motor
4 Pin Motor Connector
FIGURE 4 - MOTOR BRUSH INSPECTION
4 Pin Motor Connector
Ohmmeter
FIGURE 5 - ELECTRO-MECHANICAL
PARKING BRAKE TEST
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PROCEDURE 3 UPHOLSTERY
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This Procedure Includes the Following:
Replacing Back Upholstery
WARNING
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. Cut the tie-wraps that secure the bottom of the existing
back upholstery to the wheelchair frame.
3. Remove the two (2) phillips screws and washers that
secure the existing back upholstery to the back canes.
4. Remove the 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.
Back Upholstery
Washer
Phillips
Screw
Washer
Tie Wrap Mounting Hole
Locknuts
Washer
Hex Screws
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. Install the new back upholstery over the mounted back
cane.
8. Slide the loose back cane through the new back upholstery.
WARNING
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 back 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.
FIGURE 1 - REPLACING BACK UPHOLSTERY
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SEAT FRAME PROCEDURE 4
This Procedure Includes the Following:
Adjusting Seat Depth
Adjusting Back Height /Replacing Back Canes
WARNING
After ANY adjustments, repair or service
and BEFORE use, make sure that all
attaching hardware is tightened securely
- otherwise injury or damage may result.
ADJUSTING SEAT DEPTH
(FIGURE 1)
1. Remove the existing seat upholstery from the wheelchair.
Refer to
CEDURE 5 of the 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 from 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
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 of the seat extension
tubes.
REPLACING SEAT UPHOLSTERY in PRO-
REPLACING SEAT UPHOLSTERY in
ADJUSTING 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)
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✪ HOLE PAIR # 1 2 3 4 5
✪✪
16-20-inches 16 17 18 19 20
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✪ Holes numbered from bottom to top for reference only.
✪ ✪
(There are no numbers on the back canes.)
3. Reinstall the four (4) hex screws, washers and locknuts
that secure the back canes to the wheelchair frame.
4. Securely tighten the hex screws and locknuts.
HOLE P AIR
#
5
4
3
2
1
Washers
Hex Screws
Wheelchair Frame
Back Cane
Locknuts
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Phillips
Washer
Screws
Plug Button
Crossbrace
Seat Extension Tube
FIGURE 1 - ADJUSTING SEAT DEPTH
FIGURE 2 - ADJUSTING BACK HEIGHT/
REPLACING BACK CANES
11
PROCEDURE 5 ELECTRONICS
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This Procedure Includes the Following:
Preparing MKIV Joystick for Use
Repositioning MKIV Joystick
L
WARNING
After ANY adjustments, repair or service
and BEFORE use, make sure all attaching
hardware is tightened securely - otherwise
injury or damage may result.
I
PREPARING MKIV JOYSTICK FOR
USE (FIGURE 1)
NOTE: To reposition the MKIV joystick on a Captain’s Seat,
refer to
SEAT in PROCEDURE 8 of this manual.
NOTE: The MKIV joystick is factory installed on the right
side of the wheelchair. To reposition the MKIV joystick onto
the left side of the wheelchair, refer to
MKIV JOYSTICK in this procedure of the manual.
1. Turn the lever on the adjustment lock to release the
2. Slide joystick mounting tube to the desired position.
3. Turn the lever on the adjustment lock to secure the
REPOSITIONING MKIV JOYSTICK - CAPTAIN’S
REPOSITIONING
adjustment lock from joystick mounting tube.
adjustment lock to the joystick mounting tube.
REPOSITIONING MKIV JOYSTICK
(FIGURE 2)
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.
3. Remove the three (3) hex screws that secure joystick
mounting bracket (bracket), the threaded hole half
clamp and the opened hole half clamp to the arm tube.
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.
5. While holding the two (2) half clamps, install the front
hex screw into the two (2) half clamps. Securely tighten.
6. Line up mounting holes of the joystick mounting bracket
with the mounting holes in the two (2) half clamps.
7. Secure the joystick mounting bracket to the two (2)
half clamps with the remaining two (2) hex screws.
8. Slide tube through the bracket to the desired position.
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.
Threaded Hole
Half Clamp
Arm Tube
MKIV Joystick
Joystick
Mounting Tube
Adjustment
Lock
Lever
FIGURE 1 - PREPARING MKIV JOYSTICK
FOR USE
Joystick
Joystick Mounting
Tube
Hex Screws
Joystick Mounting Bracket
Adjustment Lock
Lever
Opened Hole Half Clamp
FIGURE 2 - REPOSITIONING MKIV
JOYSTICK
12
PROCEDURE 6WHEELS
This Procedure Includes the Following:
Replacing Pneumatic Tires/Tubes -
Drive Wheels/Casters
Removing/Installing Drive Wheels
Replacing Casters
Replacing Forks
WARNING
After ANY adjustments, repair or service
and BEFORE use, make sure all attaching
hardware is tightened securely - otherwise
injury or damage may result.
CAUTION
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
WARNING
DO NOT use your wheelchair unless it has
the proper tire pressure (p.s.i.). DO NOT
overinflate the tires. Failure to follow these
suggestions may cause the tire to explode
and cause bodily harm.
If tires are pneumatic, replacement of
tire or tube MUST be performed by an
Invacare dealer or qualified technician.
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.
2. Install washer onto motor drive shaft.
3. Install the NEW locking tab washer onto the motor
drive shaft. Make sure the locking tab is in line with the
keyway of the front wheel.
®
4. Apply Loctite
5. Install the hex screw. Use a torque wrench only and
torque to 90-inch pounds.
6. 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.
Keystock
Chamfered
Side of Wheel
Hub
Locking Tab
Washer
242 to the hex screw.
Motor
Driveshaft
Keyway
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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)
WARNING
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. Use a wheel puller to remove the existing drive wheel
from the motor drive shaft.
Loctite - Registered trademark of Loctite Corporation.
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
of Hex Screw
Bend Tab up tight against Flat on
Head of Hex Screw (STEP 8)
Locking Tab Parallel
with Flat on Head of
Hex Screw (STEP 6)
Locking
Ta b
FIGURE 1 - REMOVING/INSTALLING
DRIVE WHEELS
13
PROCEDURE 6 WHEELS
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7. If one (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.
2. Remove the caster from the fork.
3. Install Loctite 242 onto the hex screw.
4. Replace caster and reverse STEPS 1-3.
5. Torque the locknut to 120-inch pounds.
6. Loosen the locknut 1/8 of a turn.
7. Move the caster 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
Hex Screw
Locknut
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.
WARNING
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
Locknut
Washer
Washer
FIGURE 2 - REPLACING CASTERS
Caster
REPLACING FORKS (FIGURE 3)
1. Remove the hex screw, washers and locknut that
secure the caster to the existing fork.
2. Remove the caster from the existing fork.
3. Remove the dust cover.
4. Remove the locknut and nylon washer.
5. Drop the existing fork out of the caster head tube.
Nylon Washer
Caster Head Tube
Fork
Hex Screw
Washer
FIGURE 3 - REPLACING FORKS
Locknut
Washer
Caster
6. Slide the new fork into the caster head tube.
14
PROCEDURE 7BATTERIES
This Procedure includes the following:
Installing/Removing Batteries into/From Battery Boxes
Connecting Battery Cables
WARNING
Make sure power to the wheelchair is OFF
before performing this procedure.
The use of rubber gloves and safetyglasses
is recommended when working with
batteries.
Invacare strongly recommends that battery
installation and battery replacement
ALWAYS be done by a qualified technician.
After ANY adjustments, repair or service
and BEFORE use, make sure all attaching
hardware is tightened securely - otherwise
injury or damage may result.
NOTE: For CHARGING BATTERIES or REMOVING/
INSTALLING THE BATTERY BOXES, refer to
PROCEDURE 8 - FWD wheelchairs or PROCEDURE
9 - RWD wheelchairs.
INSTALLING/REMOVING
BATTERIES INTO/FROM BATTERY
BOXES (FIGURE 1)
NOTE: To remove the battery(ies) from the battery
box(es), reverse the following procedure.
NOTE: If there is battery acid in the bottom or on the sides
of the battery box(es) or battery(ies), apply baking soda
to these areas to neutralize the battery acid. Before
reinstalling the NEW or existing battery(ies), clean the
baking soda from the battery box(es) or battery(ies).
NOTE: When securing battery lifting strap to battery,
observe polarity markings located on the ends of the battery
lifting strap, (+) side to POSITIVE (+) battery terminal/post
and (-) side to NEGATIVE (-) battery terminal/post.
1. If necessary, remove the battery boxes from the
wheelchair. Refer to
BATTERY BOXES in PROCEDURE 8 - FWD or
PROCEDURE 9 - RWD of this manual.
2. Secure the battery lifting strap to battery terminal(s)/
post(s) (FIGURE 1).
INSTALLING/REMOVING
CAUTION
Some battery manufacturers mold a
carrying strap and/or hold down flanges
directly into the battery case. Batteries
which interfere with the battery box
cannot be used for these applications.
Attempting to “wedge” a battery into a
battery box may damage the box and/or
the battery.
3. Place batteries into battery box bottom.
Battery Lifting Strap
Molded Carrying Strap
Or Hold Down Flanges
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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
*NOTE: The Battery Lifting strap supplied is for Dual
22 NF Batteries ONLY. Refer to the battery manufacturer for the proper lifting strap and/or battery tools for
U1 battery removal/installation.
WARNING
ALWAYS use a battery lifting strap when
lifting a battery. It is the most convenient
method and assures that the battery acid
will not spill. It also helps to prolong the
life of the battery.
DO NOT tip the batteries. Keep the
batteries in an upright position.
Battery
Dual 22 NF
ONLY
Battery Terminal(s)/Post(s)
U1 Battery Box
Bottom
Dual 22 NF
Battery Box
Bottom
FIGURE 1 - INSTALLING/REMOVING
BATTERIES INTO/FROM BATTERY BOXES
15
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