Service Manual Excel and P9000 DEALER: KEEP THIS MANUAL. THE PROCEDURES IN THIS MANUAL MUST BE PERFORMED BY A QUALIFIED TECHNICIAN ONLY.
WARNING/SPECIAL NOTES WARNING THE PROCEDURES IN THIS MANUAL SHOULD ONLY BE PERFORMED BY A QUALIFIED TECHNICIAN. W A R N I N G DO NOT SERVICE OR OPERATE THIS EQUIPMENT WITHOUT FIRST READING AND UNDERSTANDING THIS MANUAL AND THE OWNERS 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 DAMAGE MAY RESULT.
TABLE OF CONTENTS TABLE OF CONTENTS The following procedures refer to POWER 9000 and EXCEL wheelchairs except where specified. 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 .........................
SPECIFICATIONS SPECIFICATIONS S P E C I F I C A T I O N S NOTE: All specifications are approximate. EXCEL INTEGRATED SLING SEAT CAPTAIN'S SEAT BACK TYPE LOW SOLID SEAT HIGH (LOBSS) (HIB) LOW (LOB) Seat Width Range: 16, 18 or 20-in. 19-in. 19-in. 19-in. Seat Depth Range: 16, 17 or 18-in. - In 1-in. increments (17 and 18-in. by extension) 17-in. 17-in. 17-in. Back Height Range Std.: Opt. Headrest: Opt. Backrest Ext.: 16, 17, 18, 19 or 20-in. - In 1-in. increments N/A N/A 16-in. N/A 23-in.
SPECIFICATIONS SPECIFICATIONS NOTE: All specifications are approximate. POWER 9000 Seat Width Range: 14, 16, 18 or 20-in. - ADULT FRAME 16, 18 or 20-in. - LOW SEAT FRAME Seat Depth Range: 16, 17 or 18-in. (17 and 18-in. by extension) Back Height Range Standard: 16, 17, 18, 19 or 20-in. Seat-to-Floor: 18-1/2-in.- LOW SEAT FRAME 20-1/4-in.- ADULT FRAME Overall Width: 21-3/4 to 27-3/4-in. (With MKIV Joystick) Overall Height: 33-1/4 to 37-1/4-in.- LOW SEAT FRAME 35-1/4 to 39-1/4-in.
PROCEDURE 1 GENERAL GUIDELINES This Procedure Includes the Following: G E N E R A L G U I D E L I N E S 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.
TROUBLESHOOTING PROCEDURE 2 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.
PROCEDURE 2 TROUBLESHOOTING ONLY use distilled water when topping off the battery cells. 8. Flush the liquid back into the same cell after reading the float. Repeat this step until all cells have been properly read. A shorted or dead cell can be detected when it is the only cell that does not charge. Most batteries are not sold with instructions. However, warnings are frequently noted on the cell caps. Read them carefully. 9.
TROUBLESHOOTING PROCEDURE 2 MOTOR BRUSH INSPECTION (FIGURE 4) ELECTRO-MECHANICAL PARKING BRAKE TEST (FIGURE 5) 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. 1.
PROCEDURE 3 UPHOLSTERY This Procedure Includes the Following: Back Upholstery Washer Replacing Back Upholstery U P H O L S T E R Y 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. Phillips Screw REPLACING BACK UPHOLSTERY (FIGURE 1) Washer 1. Remove one (1) armrest from the wheelchair. 2.
SEAT FRAME PROCEDURE 4 ADJUSTING BACK HEIGHT/ REPLACING BACK CANES (FIGURE 2) This Procedure Includes the Following: Adjusting Seat Depth Adjusting Back Height /Replacing Back Canes 1. Remove the four (4) hex screws, washers and locknuts that secure the two (2) back canes to the wheelchair frame. 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. 2.
PROCEDURE 5 ELECTRONICS This Procedure Includes the Following: Preparing MKIV Joystick for Use E L E C T R O N I C S Repositioning MKIV Joystick 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. WARNING After ANY adjustments, repair or service and BEFORE use, make sure all attaching hardware is tightened securely - otherwise injury or damage may result.
WHEELS PROCEDURE 6 Installing This Procedure Includes the Following: Replacing Pneumatic Tires/Tubes Drive Wheels/Casters NOTE: The keystock in the wheel hub MUST lineup with the cutout in the gearbox drive shaft. Removing/Installing Drive Wheels Replacing Casters 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. Replacing Forks 2. Install washer onto motor drive shaft. 3.
PROCEDURE 6 W H E E L S WHEELS 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: Check bearing assemblies and replace if necessary. NOTE: Tighten hex screw only. DO NOT loosen hex screw to make one of the tabs on the locking washer parallel. 8. Install nylon washer and secure with locknut. 7.
BATTERIES PROCEDURE 7 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).
PROCEDURE 7 BATTERIES CONNECTING BATTERY CABLES CAUTION When connecting the battery cables to the battery(ies), the battery cable(s) MUST be connected to the battery terminal(s)/post(s) as shown in DETAIL “A” or DETAIL “B” of FIGURE 3 (depending on battery type), otherwise damage to the battery cable may result when installing battery terminal caps. WARNING B A T T E R I E S NEVER allow any of your tools and/or battery cable(s) to contact BOTH battery terminal(s)/post(s) at the same time.
BATTERIES PROCEDURE 7 DETAIL “A” DUAL U1 BATTERIES 1/4-20 x 7/8-Inch Hex Flange Screw DETAIL “B” DUAL 22NF BATTERIES POSITIVE (+) Battery Terminal/Post Negative (-) Battery Terminal/ Post POSITIVE (+) Red Battery Cable 1/4-20 x 7/8-Inch Hex Flange Screw 1/4-20 Hex Flange Locknut U1 Battery Positive (+) Battery Terminal/Post 1/4-20 Hex Flange Locknut 22NF Battery NEGATIVE (-) Battery Terminal/Post CONNECT BATTERY CABLE TO BATTERY TERMINAL AS SHOWN.
PROCEDURE 7 BATTERIES Battery Clamp Method (FIGURES 4, 5 and 6). 2. Install battery clamp covers onto battery cables as follows (FIGURE 5): WARNING B A T T E R I E S The battery clamp of the POSITIVE (+) battery terminal/post MUST be mounted in the position shown in FIGURE 5, otherwise the battery box top cannot be installed properly. A. RED battery clamp cover onto RED battery cable. B. BLACK battery clamp cover onto BLACK battery cable.
BATTERIES PROCEDURE 7 9. Install the battery box(es) into the wheelchair. Refer to INSTALLING/REMOVING BATTERY BOX(ES) in the PROCEDURE 8 - FWD MODELS or PROCEDURE 9 - RWD MODELS of this manual. 10. If necessary, charge the battery(ies). Refer to CHARGING BATTERIES in the PROCEDURE 8 - FWD MODELS or PROCEDURE 9 - RWD MODELS of this manual. NOTE: New Battery(ies) MUST be fully charged BEFORE using, otherwise the life of the battery(ies) will be reduced.
PROCEDURE 8 F W D W H E E L C H A I R S FWD WHEELCHAIRS WARNING 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 Replac
FWD WHEELCHAIRS PROCEDURE 8 FOLDING. 1. Remove the batteries and footrests/legrests from the wheelchair. Refer to FIGURE 1. 2. Remove the Captain's Seat. Refer to REMOVING/ INSTALLING CAPTAIN'S SEAT in PROCEDURE 9 of the owner's manual, part number 1080737. 2. Lift the battery tray UP and out of the way. Refer to FIGURE 1. 3. Remove the shrouds. Refer to REMOVING/INSTALLING SHROUDS in this procedure of the manual. 3. Lift up on the seat rails of the wheelchair. 4.
PROCEDURE 8 FWD WHEELCHAIRS 6. Torque the two (2) hex screws to 156-in/lbs. F W D W H E E L C H A I R S REPLACING ARMREST PADS (FIGURE 5) 7. Reinstall the two (2) caplug caps. Wheelchair Frame 1. Remove the mounting screws that secures the front of the armrest pad to the armrest plate. Bushing Footboard Mounting Bracket Caplug Washer Caplug Cap 2. Remove the mounting screw that secures the rear of armrest pad and armrest insert to the armrest plate. 3.
FWD WHEELCHAIRS PROCEDURE 8 Armrest Plate 5. Position the mounting holes in the two (2) new seat positioning strap halves with the mounting holes in the seat frame assembly. Armrest Pad Armrest Insert Lug Bolt 6. Reinstall the two (2) hex bolts, washers and locknuts that secure the seat positioning strap to the seat frame assembly and tighten securely. Locknuts Phillips Screw 7. Install the captain's seat onto the wheelchair.
PROCEDURE 8 F W D W H E E L C H A I R S FWD WHEELCHAIRS 3. Remove the three (3) hex bolts, spacers and locknuts that secure joystick mounting bracket to armrest plate. 17. Install the 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. 18. Slide the joystick mounting tube through the joystick mounting bracket to the desired position. 5.
PROCEDURE 8 FWD WHEELCHAIRS 6. Remove the two (2) phillips bolts and locknuts that secure the front battery connector to wheelchair frame. REPLACING WIRING HARNESS (FIGURE 11) 7. Remove the two (2) phillips screws that secure the wiring harness to the charger cable mounting bracket. 1. If necessary, remove the front and rear shrouds. Refer to REMOVING/INSTALLING SHROUDS in this procedure of the manual. 8.
PROCEDURE 8 F W D W H E E L C H A I R S FWD WHEELCHAIRS C. Connect the limit switch. Refer to DISCONNECTING/CONNECTING LIMIT SWITCH in this procedure of the manual. ADJUSTING LIMIT SWITCH (FIGURE 13) 17. Reinstall the battery boxes. Refer to INSTALLING/ REMOVING BATTERY BOXES in this procedure of the manual. NOTE: The following procedure is for High Back Captain's seat model wheelchairs only. 18. If necessary, install the front and rear shrouds.
FWD WHEELCHAIRS PROCEDURE 8 24o Back Recline Angle 114o F W D 5-3/4 inches Upper Limit Switch Bracket 61o Phillips Screws, Washers and Locknuts Actuator Magnetic Protractor (Will read 61o when back recline angle is at 114o relative to the seat frame) 5o Seat Angle FIGURE 13 - ADJUSTING LIMIT SWITCH REMOVING/INSTALLING SHROUDS (FIGURE 14) Removing Side Shrouds and Fillers 1. Remove the front shroud from the wheelchair. Refer to REMOVING/INSTALLING FRONT SHROUD in this procedure of the manual.
PROCEDURE 8 FWD WHEELCHAIRS Installing Side Shrouds and Fillers F W D W H E E L C H A I R S 1. Position side shroud and filler on the wheelchair frame. 2. Line up the mounting holes in the side shroud and filler with the mounting holes in the wheelchair frame. B. Reinstall the phono jack nut onto the phono jack and tighten securely. 6. Perform one (1) of the following: A. INTEGRATED SLING SEAT MODELS - Unfold the wheelchair. Refer to TRANSPORTING EXCEL in this procedure of the manual.
FWD WHEELCHAIRS PROCEDURE 8 CHANGING SEAT WIDTH INTEGRATED SLING SEATS (FIGURE 15) 4. Remove the existing back and seat upholstery from the wheelchair. Refer to REPLACING BACK UPHOLSTERY in PROCEDURE 5 of this manual and REPLACING SEAT UPHOLSTERY in PROCEDURE 5 of the owner's manual, part number 1080737. 1. If necessary remove the shrouds. Refer to REMOVING/INSTALLING SHROUDS in this procedure of the manual.
PROCEDURE 8 FWD WHEELCHAIRS 6. Remove the dust covers from the bottom of the crossbraces. F W D W H E E L C H A I R S 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.
FWD WHEELCHAIRS PROCEDURE 8 17. Reinstall the hex bolts, spacers, washers and locknuts that secure the (2) push brackets to the new crossbraces and tighten securely. 20. Reinstall the battery boxes onto the wheelchair. Refer to INSTALLING/REMOVING BATTERY BOXES in this procedure of the manual. 18. Reinstall the hex bolts, washers and locknuts that secure the pivot links to the crossbraces and tighten securely. 21. Reinstall shrouds. Refer to REMOVING/INSTALLING SHROUDS in this procedure of the manual.
FWD WHEELCHAIRS PROCEDURE 8 F W D W H E E L C H A I R S WHEN TO CHARGE BATTERIES (FIGURE 17) Description and Use of Battery Chargers 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.
PROCEDURE 8 FWD WHEELCHAIRS Cleaning Battery Terminals Battery Charger Connector (on side of Wheelchair) WARNING DO NOT allow the liquid in the battery to come in contact with skin, clothes or other possessions. It is a form of acid and harmful or damaging burns may result. Should the liquid touch your skin, wash the area immediately and thoroughly with cool water. In serious cases or if eye contact is made, seek medical attention IMMEDIATELY.
PROCEDURE 8 FWD WHEELCHAIRS 2. Lift up on the pin side of the battery tray and rotate UP towards the battery tray pivot. WARNING F W D W H E E L C H A I R S The Battery Box Retaining Strap MUST be fastened securely and adjusted properly to hold battery boxes in place before using the wheelchair. 3. Fold the wheelchair. Refer to ASSEMBLING EXCEL in this procedure of the manual. 6.
FWD WHEELCHAIRS PROCEDURE 8 Battery Tray Pin Battery Tray Hanger Bracket Battery Tray Washers F W D Hex Bolts Locknuts Battery Tray Pivot Hex Bolts 16-inch Wheelchair 18-inch Wheelchair 20-inch Wheelchair Locknuts Battery Tray FIGURE 23 - BATTERY TRAY - REMOVING/ INSTALLING BATTERY TRAY Replacing Right Battery Tray Hanger Bracket (FIGURE 24) FIGURE 22 - BATTERY TRAY - CHANGING WIDTH OF BATTERY TRAY NOTE: Right and left is determined by sitting in the wheelchair. 1.
PROCEDURE 8 F W D W H E E L C H A I R S FWD WHEELCHAIRS B. WHEELCHAIR NOT EQUIPPED WITH FLIP-UP REMOVABLE FOOTBOARD - 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. 8. Reinstall the rear hex screw. Use Loctite 242 and torque to 156-in/lbs. 9. Reinstall the battery tray. Refer to INSTALLING BATTERY TRAY in this procedure of the manual. Wheelchair Frame Spacer Rear Hex Screw Hex Screw 7.
FWD WHEELCHAIRS PROCEDURE 8 NOTE: If motors are repositioned, the front riggings may need to be repositioned. Refer to ADJUSTING/REPLACING TELESCOPING FRONT RIGGING SUPPORT in PROCEDURE 9 of the owner's manual, 1080737.
PROCEDURE 8 FWD WHEELCHAIRS 9. Connect the clutch handle to the motor/gearbox and line up the mounting holes in the clutch handle and motor/gearbox. CAUTION F W D W H E E L C H A I R S The longer socket screws must be positioned in the mounting holes on the OUTSIDE of the wheelchair frame and the short socket screws must be in the mounting holes on the INSIDE of the wheelchair frame. Otherwise damage to the gearbox may result. 10.
FWD WHEELCHAIRS PROCEDURE 8 5. Rotate battery tray hanger bracket up. 10. Remove the six (6) socket screws that secure the existing motor/gearbox to the wheelchair frame. 6. Left side of wheelchair only - Remove the front dust cover from the end of the crossbrace. 11. Position the new motor/gearbox on the wheelchair frame at the position noted in STEP 7 as shown in FIGURE 28. NOTE: Left is determined by sitting in the wheelchair. 7.
PROCEDURE 9 RWD WHEELCHAIRS ASSEMBLING POWER 9000 (FIGURE 1) This Procedure Includes the Following: R W D W H E E L C H A I R S Assembling Power 9000 WARNING When to Charge Batteries The weight of the wheelchair without the user and batteries is approximately 82 lbs. Use proper lifting techniques (lift with your legs) to avoid injury. Extreme caution is advised when it is necessary to move an UNOCCUPIED power wheelchair. Invacare recommends using two (2) assistants and making thorough preparations.
RWD WHEELCHAIRS PROCEDURE 9 WHEN TO CHARGE BATTERIES (FIGURE 4) 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. NOTE: As a general rule, batteries should be recharged daily to assure the longest possible life and minimize the required charging time.
PROCEDURE 9 RWD WHEELCHAIRS REPLACING BATTERIES R W D W H E E L C H A I R S 3. Clean the terminals and inside the battery clamps by using a battery cleaning tool, wire brush, or medium grade sand paper. WARNING Most batteries are not sold with instructions. However, warnings are frequently noted on the cell caps. Read them carefully, otherwise injury or damage may occur. NOTE: When done, these areas should be shiny, not dull. 4. Carefully dust off all metal particles.
RWD WHEELCHAIRS PROCEDURE 9 BATTERY TRAY (FIGURE 7) 2. Secure the hanger brackets to the battery tray in the mounting holes that the hex screws are mounted. 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.
PROCEDURE 9 RWD WHEELCHAIRS 11. Reinstall dust covers onto bottom of crossbraces. R W D W H E E L C H A I R S 12. Reinstall the hex screws and locknuts that secure the pivot links to the wheelchair frame and crossbraces. 13. Install the new back and seat upholstery onto 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. 14.
RWD WHEELCHAIRS PROCEDURE 9 REMOVING/INSTALLING MKIV CONTROLLER (FIGURE 10) REPLACING WIRING HARNESS (FIGURE 11) 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. Disassembly 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.
RWD WHEELCHAIRS R W D W H E E L C H A I R S PROCEDURE 9 3. Connect the wring harness (BLUE) to the controller connector (BLUE). 10. Repeat procedure for opposite side of the wheelchair, if necessary. 4. Re-secure the wiring harness and motor cables to the crossbraces with new tie wrap. 11. Reinstall the battery boxes. Refer to INSTALLING/ REMOVING BATTERY BOXES in this procedure of the manual. 5. Reinstall the battery boxes. Refer to INSTALLING/ REMOVING BATTERY BOXES in this procedure of the manual.
LIMITED WARRANTY PLEASE NOTE: THE WARRANTY BELOW HAS BEEN DRAFTED TO COMPLY WITH FEDERAL LAW APPLICABLE TO PRODUCTS MANUFACTURED AFTER JULY 4, 1975. This warranty is extended only to the original purchaser/user of our products. This warranty gives you specific legal rights and you may also have other legal rights which vary from state to state.
Invacare Corporation www.invacare.com USA Canada One Invacare Way Elyria, Ohio USA 44036-2125 800-333-6900 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.
