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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TABLE OF CONTENTS
TABLE OF CONTENTS
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The following procedures refer to POWER 9000 and EXCEL wheelchairs except where specified.
REPLACINGSEATPOSITIONINGSTRAP ............ 23
REPLACINGCAPTAIN'SSEAT ........................... 23
REPOSITIONINGMKIVJOYSTICK
-CAPTAIN’SSEAT ....................................... 23
REMOVING/INSTALLING
MKIVCONTROLLER ................................... 24
REPLACINGWIRINGHARNESS ........................ 25
DISCONNECTING/CONNECTING
LIMITSWITCH .............................................. 26
ADJUSTINGLIMITSWITCH ................................ 26
REMOVING/INSTALLINGSHROUDS ................... 27
CHANGINGSEATWIDTH
SPECIAL NOTES .........................................2
SPECIFICATIONS ........................................4
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PROCEDURE 1 - GENERAL GUIDELINES ....6
REPAIRORSERVICEINFORMATION .................. 6
OPERATINGINFORMATION ................................. 6
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PROCEDURE 2 - TROUBLESHOOTING .......7
FIELD LOAD TEST .............................................. 7
USING HYDROMETER TO CHECK
BATTERY CELLS (LEAD ACID) ........................... 7
MOTORTESTING ............................................... 8
MOTORBRUSHINSPECTION ............................. 9
ELECTRO-MECHANICAL
S
-INTEGRATEDSLINGSEATS ...................... 29
REPLACING CROSSBRACES
PARKINGBRAKETEST .................................. 9
-CAPTAIN'SSEAT ....................................... 30
WHEN TO CHARGE BATTERIES ....................... 32
CHARGINGBATTERIES ..................................... 32
REPLACINGBATTERIES ................................... 33
INSTALLING/REMOVINGBATTERYBOXES ......... 33
BATTERYTRAY ................................................. 34
REPOSITIONINGMOTORS ............................... 36
REPLACINGCLUTCHHANDLES ....................... 38
REPLACINGMOTOR/GEARBOX ....................... 38
PROCEDURE 3 - UPHOLSTERY ................ 10
REPLACINGBACKUPHOLSTERY .................... 10
PROCEDURE 4 - SEAT FRAME .................. 11
ADJUSTINGSEATDEPTH ................................. 11
ADJUSTINGBACKHEIGHT/REPLACING
BACK CANES ............................................. 11
PROCEDURE 5 - ELECTRONICS............... 12
PREPARINGMKIVJOYSTICKFORUSE ............ 12
REPOSITIONINGMKIVJOYSTICK ...................... 12
PROCEDURE 9 - RWD WHEELCHAIRS ..... 40
ASSEMBLING POWER 9000 .............................. 40
WHEN TO CHARGE BATTERIES ....................... 41
CHARGINGBATTERIES ..................................... 41
REPLACINGBATTERIES ................................... 42
INSTALLING/REMOVINGBATTERYBOXES ......... 42
BATTERYTRAY ................................................. 43
CHANGINGSEATWIDTH ................................... 43
ADJUSTINGSEAT-TO-FLOORHEIGHT .............. 44
DISCONNECTING/CONNECTING
PROCEDURE 6 - WHEELS ........................ 13
REPLACINGPNEUMATICTIRES/TUBES
- DRIVE WHEELS/CASTERS....................... 13
REMOVING/INSTALLINGDRIVEWHEELS .......... 13
REPLACING CASTERS ..................................... 14
REPLACING FORKS ......................................... 14
PROCEDURE 7 - BATTERIES .................... 15
INSTALLINGREMOVINGBATTERIES
INTO/FROM BATTERY BOXES.................... 15
CONNECTING BATTERY CABLES..................... 16
MKIV CONTROLLER, MOTOR
AND BATTERY LEADS ................................ 44
REMOVING/INSTALLINGMKIV
CONTROLLER ........................................... 45
REPLACINGWIRINGHARNESS ........................ 45
REPLACINGMOTOR/GEARBOX ....................... 46
PROCEDURE 8 - FWD WHEELCHAIRS ..... 20
ASSEMBLINGEXCEL ........................................ 20
ADJUSTINGFLIP-UPREMOVABLE
FOOTBOARD ............................................. 21
REPLACINGARMRESTPADS ........................... 22
REPLACINGARMRESTPLATE .......................... 22
LIMITEDWARRANTY ................................. 47
3
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SPECIFICATIONS
SPECIFICATIONS
NOTE: All specifications are
approximate.
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EXC EL
INTEGRATED SLING SEAT
CAPTAIN'S SEAT
BACKTYPE
LOW SOLID SEAT HIGH
LOW
(LOB)
19-in.
17-in.
(LOBSS)
(HIB)
19-in.
17-in.
Seat Width Range:
Seat Depth Range:
16, 18or20-in.
19-in.
16, 17 or 18-in. - In 1-in. increments
(17and18-in. byextension)
17-in.
Back Height Range
Std.:
Opt. Headrest:
Opt. BackrestExt.:
16, 17, 18, 19 or 20-in. - In 1-in. increments
16-in.
N/A
23-in.
18-in.
N/A
22-in.
28-in.
N/A
N/A
N/A
N/A
O
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Back Angle Range:
Seat-to-Floor:
N/A
ª55o - 114o
ª98o
19-1/2-in.
24-3/4-in.
35-in.
ª35o - 170o
18-1/2-in.
22-in.
22-in.
OverallWidth(NoJoystick): 24-5/8-in.
24-3/4-in.
35-in.
24-3/4-in.
39-in.
Overall Height:
34-3/8-in. -16-in. BackHeight
✪Weight
W/O Batteries:
W/Batteries (Gel Cell):
Shipping:
90 to 100 lbs.
170 to 180 lbs.
105 to 115 lbs.
122 to 127 lbs.
203 to207 lbs.
153 to 157 lbs.
Armrests:
Removable, FlipBack, FixedorAdjustable 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-in. deep wheelchair with MKIV RII electronics.
ªNOTE: Low and High Back Types have an infinite adjustment. Low Backs with Solid Seat have no adjustment.
INTEGRATED SLING SEAT AND CAPTAIN'S SEAT
vDRIVEWHEELPOSITION
Overall Length
REARPOSITION
MIDDLE POSITION
FORWARDPOSITION
With 8-in. Rear Casters and
93FrontRiggings:
With 8-in. Rear Casters
and no Front Riggings:
47-1/2-in.
32-1/2-in.
47-1/2-in.
33-1/2-in.
N/A
N/A
vNOTE:RefertoREPOSITIONING MOTORSinPROCEDURE7 ofthismanual.
Drive Wheels/Tires:
12-1/2x2-1/4-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.)
6 x 2-in. Semi Pneumatic (Opt.)
Footrest/Legrest:
Swingaway,RemovableAdjustableFlipUpRemovableFootboard
DualGroup22NFGelCell
Battery/Size (Not Supplied):
PERFORMANCE
Speed (M.P.H.):
Turning Radius:
* Range (variable):
0 to 3.8
> 26-in.
17-22 miles
** v Weight Limitation: 250 lbs.
*NOTE: Range will vary with battery conditions, surface, terrain and operators weight.
**NOTE: Includes seating systems and accessories.
v NOTE: Refer to REPOSITIONING MOTORS in PROCEDURE 8 of this manual.
4
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SPECIFICATIONS
SPECIFICATIONS
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PO WER 9000
NOTE: All specifications are approximate.
Seat Width Range:
14,16,18or20-in. - ADULTFRAME
16, 18 or 20-in. - LOW SEAT FRAME
Seat Depth Range:
16,17or18-in.(17and18-in.byextension)
16, 17, 18, 19 or20-in.
Back Height Range Standard:
F
I
Seat-to-Floor:
18-1/2-in.-LOWSEATFRAME
20-1/4-in.-ADULTFRAME
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Overall Width:
Overall Height:
21-3/4 to 27-3/4-in. (With MKIV Joystick)
33-1/4to37-1/4-in.-LOWSEATFRAME
35-1/4to39-1/4-in.-ADULTFRAME
Overall Length
RWD Wheelchairs:
FWD with 93FrontRiggings:
FWD with noFrontRiggings:
36-1/2to47-1/4-in.
N/A
N/A
✪Weight
W/O Batteries:
82 lbs.
W/ Batteries and PW93 Front Riggings
U1GelCell(14-inchChairs):
Dual Group 22NF Gel Cell
(16,18or20-inchChairs):
Shipping:
145 lbs.
157 lbs.
110 lbs.
Drive Wheels/Tires
(Flat Free or Pneumatic):
12-1/2x2-1/4-in.
8x1-3/4-in.SemiPneumatic(Standard)
Casters w/Precision Sealed Bearings: 8x2-in.Pneumatic(Optional)
Rotating,Removable(Standard)
Anti-Tippers:
Swingaway,Removable
Footrest/Legrest:
FixedHeight-DeskandFullLength
Armrests:
(Standard)AdjustableHeight-Deskand
FullLength(Optional)
Black Nylon
Upholstery:
Battery/Size (Not Supplied)
Two (2) Required:
U1 Gel Cell (14-in. chairs), Dual Group
22NFGelCell(16, 18or20-in. chairs)
✪ NOTE: 18-inch wide x 16-inch deep wheelchair with MKIV RII electronics.
PERFORMANCE
0 to 4
Speed (M.P.H.):
Turning Radius:
* Range (variable):
35-inches
12-14 miles with U1 batteries
18-22mileswith22NFbatteries
250 lbs.
** Weight Limitation:
*NOTE: Range will vary with battery conditions, surface, terrain and operators weight.
**NOTE: Includes seating systems and accessories.
5
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PROCEDURE 1
GENERAL GUIDELINES
This Procedure Includes the Following:
Repair or Service Information
Operating Information
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REPAIR OR SERVICE INFORMATION
Se t-up of the Ele c tronic Control Unit is to b e p e rform e d ONLY b y ind ivid ua ls c e rtifie d b y
Inva c a re . The fina l tuning a d justm e nts o f the c o ntro lle r m a y a ffe c t o the r a c tivitie s o f
the whe e lc ha ir. Da m a g e to the e q uip m e nt c o uld o c c ur und e r the se c irc um sta nc e s. If
no n-c e rtifie d ind ivid ua ls p e rfo rm a ny wo rk o n the se units, the wa rra nty is vo id .
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O PERATING INFO RMATIO N
GENERAL WARNINGS
Pe rfo rm a nc e a d justm e nts sho uld o nly b e m a d e b y p ro fe ssio na ls o f the he a lthc a re fie ld
o r p e rso ns fully c o nve rsa nt with this p ro c e ss a nd the d rive r's c a p a b ilitie s. Inc o rre c t
se tting s c o uld c a use injury to the d rive r, b ysta nd e rs, d a m a g e to the c ha ir a nd to
surro und ing p ro p e rty.
Afte r the whe e lc ha ir ha s b e e n se t-up , c he c k to m a ke sure tha t the whe e lc ha ir p e rform s
to the sp e c ific a tio ns e nte re d d uring the se t-up p ro c e d ure . If the whe e lc ha ir d o e s NOT
p e rfo rm to sp e c ific a tio ns, turn the whe e lc ha ir OFF im m e d ia te ly a nd re e nte r se t-up
sp e c ific a tio ns. Re p e a t this p ro c e d ure until the whe e lc ha ir p e rfo rm s to sp e c ific a tio ns.
DO NOT use p a rts, a c c e sso rie s, o r a d a p te rs o the r tha n tho se a utho rize d b y Inva c a re .
TIRE PRESSURE
DO NOT use your whe e lc ha ir unle ss it ha s the p rop e r tire p re ssure (P.S.I.). DO NOT ove rin-
fla te the tire s. Fa ilure to fo llo w the se sug g e stio ns m a y c a use the tire to e xp lo d e a nd
c a use b od ily ha rm . The re c om m e nd e d tire p re ssure is liste d on the sid e wa ll of the tire .
ELEC TRIC AL
Gro und ing Instruc tio ns:
DO NOT, und e r a ny c irc um sta nc e s, c ut o r re m o ve the ro und g ro und ing p ro ng fro m a ny
p lug use d with o r fo r Inva c a re p ro d uc ts. So m e d e vic e s a re e q uip p e d with thre e -p ro ng
(g ro und ing ) p lug s fo r p ro te c tio n a g a inst p o ssib le sho c k ha za rd s. Whe re a two -p ro ng
wa ll re c e p ta c le is e nc o unte re d , it is the p e rso na l re sp o nsib ility a nd o b lig a tio n o f the
c usto m e r to c o nta c t a q ua lifie d e le c tric ia n a nd ha ve the two -p ro ng re c e p ta c le
re p la c e d with a p ro p e rly g ro und e d thre e -p ro ng wa ll re c e p ta c le in a c c o rd a nc e with
the Na tio na l Ele c tric a l Co d e . If yo u m ust use a n e xte nsio n c o rd , use ONLY a thre e -wire
e xte nsio n c o rd ha ving the sa m e o r hig he r e le c tric a l ra ting a s the d e vic e b e ing
c o nne c te d . In a d d itio n, Inva c a re ha s p la c e d RED/ ORANGE WARNING TAGS o n so m e
e q uip m e nt. DO NOT re m o ve the se ta g s.
BATTERIES
The wa rra nty a nd p e rfo rm a nc e sp e c ific a tio ns c o nta ine d in this m a nua l a re b a se d o n
the use o f d e e p c yc le g e l c e ll o r se a le d le a d a c id b a tte rie s. Inva c a re stro ng ly re c o m -
m e nd s the ir use a s the p o we r so urc e fo r this unit.
6
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TROUBLESHOOTING
PROCEDURE 2
7. TurnthewheelchairONandpushthejoystickforward,
trying to drive the wheelchair through the stationary
object. Thisputsaheavyloadonthebatteriesasthey
try to push through the stationary object. Read the
meter while the motors are straining to determine the
voltageunderload.
This Procedure Includes the Following:
Field Load Test
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Using Hydrometer To Check Battery Cells (Lead
Acid)
Motor Testing
NOTE: If the voltage drops to less than 23.5 volts from a
pairoffullychargedbatterieswhileunderload, theyshould
be replaced regardless of the unloaded voltages.
Motor Brush Inspection
Electro-Mechanical Parking Brake Test
Battery Charger
(-)
FIELD LOAD TEST (FIGURE 1)
Connector
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.
(+)
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Oldbatterieslosetheirabilitytostoreandreleasepower,due
to increased internal resistance. This means that as you try
totakepowerfromthebattery,someofthatpowerisusedup
intheprocessofpassingthroughthebattery,resultinginless
voltage at the posts. The more power drawn, the lower the
voltageavailable.Whenthislostvoltagedropstheoutput1.0
volts under load (2.0 for a pair), replace the batteries.
Digital Voltmeter
FIGURE 1 - FIELD LOAD TEST
USING HYDROMETER TO CHECK
BATTERY CELLS (LEAD ACID)
(FIGURE 2)
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.
NOTE: Perform this procedure when a digital voltmeter is
notavailable.
Use a digital voltmeter to check battery charge level at
the charger connector. It is located on the base of the
wheelchair frame.
WARNING
NOTE: READ the instructions CAREFULLY before us-
NEVER sm o ke o r strike a m a tc h ne a r the
b a tte rie s. If the c a p s o f the b a tte ry c e lls
a re re m o ve d , NEVER lo o k d ire c tly into
the m whe n c ha rg ing the b a tte ry.
ing the digital voltmeter.
NOTE: Invacare recommends that ONLY qualified ser-
vice personnel perform this test.
The use o f rub b e r g lo ve s a nd sa fe ty
g la sse s is re c om m e nd e d whe n te sting the
b a tte ry c e lls.
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.
Whe n re a ding a hydrome te r, DO NOT a llow
a ny liq uid to c o m e in c o nta c t with yo ur
e ye s o r skin. It is a fo rm o f a c id a nd c a n
c a use se rio us b urns, a nd in so m e c a se s,
b lind ne ss. If yo u d o g e t b a tte ry a c id o n
yo u, flush the e xp o se d a re a s with c o o l
wa te r IMMEDIATELY. If the a c id c om e s into
c onta c t with e ye s or c a use s se rious b urns,
g e t m e d ic a l he lp IMMEDIATELY.
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. Placethevoltmeterleadsintothechargerplugonthe
wheelchair. Mostdigitalvoltmetersarenotaffectedby
polarity, however, analog meters (meters with swinging
needles)canbeandshouldbeusedcarefully. Agood
meter reading should be 25.5 to 26 VDC.
The b a tte ry a c id c a n d a m a g e yo ur
whe e lc ha ir, c lo thing , a nd ho use ho ld
ite m s. The re fo re , ta ke re a d ing s c a utio usly
a nd o nly in d e sig na te d a re a s.
6. Have two (2) individuals (one [1] on each arm) apply
asmuchdownwardpressureaspossibleonthearms
of the wheelchair.
7
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PROCEDURE 2
TROUBLESHOOTING
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.
WARNING
ONLY use d istille d wa te r whe n top p ing off
the b a tte ry c e lls.
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Most ba tte rie s a re not sold with instruc tions.
Howe ve r, wa rning s a re fre q ue ntly note d
on the c e ll c a p s. Re a d the m c a re fully.
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.
1. Remove the battery box(es). Refer to one (1) of the
following:
11. Reinstallbatteryboxes. Refertoone(1)ofthefollowing:
A. FWDWHEELCHAIRS:INSTALLING/REMOVING
BATTERY BOXES in PROCEDURE 8 of this
manual.
A. FWDWHEELCHAIRS:INSTALLING/REMOVING
BATTERY BOXES in PROCEDURE 8 of this
manual.
B. RWDWHEELCHAIRS:INSTALLING/REMOVING
BATTERY BOXES in PROCEDURE 9 of this
manual.
B. RWDWHEELCHAIRS:INSTALLING/REMOVING
BATTERY BOXES in PROCEDURE 9 of this
manual.
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2. Remove the battery caps from the battery.
3. Squeeze the air from the hydrometer.
4. Place the hydrometer into a battery cell.
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.
2. Set the digital multimeter to measure ohms (Ω).
3. Measure the resistance between the two (2) motor
contacts.
7. Number of floating balls indicates charge.
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.
Num ber of Floating Balls
0
1
2
3
4
* 5
Discharged
25% Charged
50% Charged
75% Charged
100% Charged
Overcharged
* Check charging system.
Number of Floating
Balls Will Vary
According to Charge
Ohmmeter
Motor Connector
FIG URE 3 - MO TO R TESTING
FIG URE 2 - USING A HYDRO METER TO
C HEC K BATTERY C ELLS (LEAD AC ID)
8
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TROUBLESHOOTING
PROCEDURE 2
MOTOR BRUSH INSPECTION
(FIGURE 4)
ELECTRO-MECHANICAL PARKING
BRAKE TEST (FIGURE 5)
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There are two (2) contact brushes on the motors located 1. On the four-pin motor connector, locate the side by
under the brush caps on the motor housing. If these caps
are hard to remove they are either overtightened or the
side connectors in the black housings.
motor has become very hot. Let motors cool. If caps still 2. Set the digital multimeter to read ohms (Ω).
cannot be removed, it is recommended that the motor be
sent to Invacare Technical Services for inspection/repair. 3. Measure the resistance between the two (2)
brake contacts. A normal reading is 100 ohms (Ω).
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.
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.
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”.
Thisisaccomplishedbyrunningthemotorforonehour
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
replacedwillonlycarryasmallpercentageofitsrated
load capacity until the NEW brush is burned in.
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C AUTIO N
A sho rte d e le c tro -m e c ha nic a l b ra ke will
d a m a g e the b ra ke o utp ut se c tio n in the
c o ntro lle r. DO NOT c o nne c t a sho rte d
e le c tro -m e c ha nic a l b ra ke to
c o ntro lle r m o d ule . A sho rte d b ra ke MUST
b e re p la c e d .
a
g o o d
NOTE: A bad motor can damage the controller module
but a bad controller should NOT damage a motor.
Motor
Cap
Motor
Cap
4 Pin Motor Connector
Ohmmeter
4 Pin Motor Connector
FIGURE 4 - MOTOR BRUSH INSPECTION
FIG URE 5 - ELEC TRO -MEC HANIC AL
PARKING BRAKE TEST
9
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PROCEDURE 3
UPHOLSTERY
This Procedure Includes the Following:
Replacing Back Upholstery
Back Upholstery
Washer
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WARNING
Afte r ANY a djustme nts, re pa ir or se rvic e a nd
BEFORE use , m a ke sure tha t a ll a tta c hing
ha rd wa re is tig hte ne d se c ure ly - othe rwise
injury or da ma ge ma y re sult.
Phillips
Screw
REPLACING BACK UPHOLSTERY
(FIGURE 1)
Washer
1. Remove one (1) armrest from the wheelchair.
2. Cutthetie-wrapsthatsecurethebottomoftheexisting
back upholstery to the wheelchair frame.
Tie Wrap Mounting Hole
3. Remove the two (2) phillips screws and washers that
securetheexistingbackupholsterytothebackcanes.
Locknuts
Washer
4. Remove the two (2) hex screws, washers and locknuts
thatsecureone(1)backcanetothewheelchairframe.
NOTE: It is necessary to remove only one (1) back cane
to replace the back upholstery.
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.
FIGURE 1 - REPLACING BACK UPHOLSTERY
7. Installthenewbackupholsteryoverthemountedback
cane.
8. Slide the loose back cane through the new back up-
holstery.
WARNING
The ba c k c a ne s MUST be se c ure ly fa ste ne d
to the whe e lc ha ir fra m e BEFORE using the
whe e lc ha ir.
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.
10
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SEAT FRAME
PROCEDURE 4
ADJ USTING BACK HEIGHT/
REPLACING BACK CANES
(FIGURE 2)
This Procedure Includes the Following:
Adjusting Seat Depth
Adjusting Back Height /Replacing Back Canes
S
E
A
T
1. Remove the four (4) hex screws, washers and
locknuts that secure the two (2) back canes to the
wheelchair frame.
WARNING
Afte r ANY a d justm e nts, re p a ir o r se rvic e
a nd BEFORE use , m a ke sure tha t a ll
a tta c hing ha rd wa re is tig hte ne d se c ure ly
- othe rwise injury or d a m a g e m a y re sult.
2. Reposition the back canes to one (1) of five (5) pairs
of height adjustment holes:
F
R
A
M
E
ORIGINAL BACK HEIGHT (IN INCHES)
✪ HOLE PAIR #
1
2
3
4
5
ADJ USTING SEAT DEPTH
(FIGURE 1)
16-20-inches
16 17 18 19 20
✪✪Holes numbered from bottom to top for reference only.
(There are no numbers on the back canes.)
1. Removetheexistingseatupholsteryfromthewheelchair.
RefertoREPLACINGSEATUPHOLSTERYinPRO-
CEDURE5oftheOwnersManual,partnumber1080737.
3. Reinstall the four (4) hex screws, washers and locknuts
that secure the back canes to the wheelchair frame.
NOTE: If adjusting seat depth of the wheelchair, the seat
upholstery MUST be changed as well.
4. Securely tighten the hex screws and locknuts.
2. Remove the two (2) plug buttons from the ends of the
crossbraces that are towards front of wheelchair.
HOLE PAIR
Back Cane
#
NOTE:Thetwo(2)plugbuttonswillbeusedintheendsof
the seat extensions.
5
4
3
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.
Locknuts
2
1
4. Install the new seat upholstery onto the wheelchair.
Refer to REPLACING SEAT UPHOLSTERY in
PROCEDURE 5 of the Owners Manual, part
number 1080737.
Washers
Hex Screws
NOTE: Make sure to line up the mounting holes in the
seat extension tubes with the new seat upholstery.
Wheelchair Frame
5. Installplugbuttonsintotheendsoftheseatextension
tubes.
FIGURE 2 - ADJUSTING BACK HEIGHT/
REPLAC ING BAC K C ANES
Washer
Phillips
Screws
Plug Button
Crossbrace
Seat Extension Tube
FIG URE 1 - ADJUSTING SEAT DEPTH
11
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PROCEDURE 5
ELECTRONICS
REPOSITIONING MKIV J OYSTICK
(FIGURE 2)
This Procedure Includes the Following:
Preparing MKIV Joystick for Use
Repositioning MKIV Joystick
1. Turn the lever on the adjustment lock to release the
E
L
E
C
T
R
O
N
I
adjustment lock from joystick mounting tube (tube).
2. Remove the joystick from the wheelchair.
WARNING
3. Remove the three (3) hex screws that secure joystick
mounting bracket (bracket), the threaded hole half
clampandtheopenedholehalfclamptothearmtube.
Afte r ANY a d justm e nts, re p a ir o r se rvic e
a nd BEFORE use , m a ke sure a ll a tta c hing
ha rd wa re is tig hte ne d se c ure ly - othe rwise
injury or d a m a g e m a y re sult.
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
USE (FIGURE 1)
C
S
5. While holding the two (2) half clamps, install the front
hexscrewintothetwo(2)halfclamps.Securelytighten.
6. Lineupmountingholesofthejoystickmountingbracket
with the mounting holes in the two (2) half clamps.
NOTE:TorepositiontheMKIVjoystickonaCaptain’sSeat,
refertoREPOSITIONINGMKIVJOYSTICK-CAPTAIN’S
SEAT in PROCEDURE 8 of this manual.
7. Secure the joystick mounting bracket to the two (2)
half clamps with the remaining two (2) hex screws.
NOTE: The MKIV joystick is factory installed on the right
sideofthewheelchair. TorepositiontheMKIVjoystickonto
the left side of the wheelchair, refer to REPOSITIONING
MKIV JOYSTICK in this procedure of the manual.
8. Slidetubethroughthebrackettothedesiredposition.
9. Slidetheadjustmentlockovertheendofthetubeand
secure the adjustment lock to the tube by turning the
lever on the adjustment lock.
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.
Threaded Hole
Half Clamp
3. Turn the lever on the adjustment lock to secure the
adjustment lock to the joystick mounting tube.
Arm Tube
Joystick
MKIV Joystick
Joystick Mounting
Tube
Hex Screws
Joystick
Mounting Tube
Joystick Mounting Bracket
Adjustment Lock
Lever
Adjustment
Lock
Lever
Opened Hole Half Clamp
FIGURE 1 - PREPARING MKIV JOYSTICK
FO R USE
FIG URE 2 - REPO SITIO NING MKIV
J O YSTIC K
12
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WHEELS
PROCEDURE 6
Installing
This Procedure Includes the Following:
NOTE: The keystock in the wheel hub MUST lineup with
the cutout in the gearbox drive shaft.
Replacing Pneumatic Tires/Tubes -
Drive Wheels/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.
Removing/Installing Drive Wheels
Replacing Casters
W
H
E
E
L
Replacing Forks
2. Install washer onto motor drive shaft.
3. Install the NEW locking tab washer onto the motor
driveshaft. Makesurethelockingtabisinlinewiththe
keyway of the front wheel.
4. Apply Loctite® 242 to the hex screw.
WARNING
Afte r ANY a d justm e nts, re p a ir o r se rvic e
a nd BEFORE use , m a ke sure a ll a tta c hing
ha rd wa re is tig hte ne d se c ure ly - othe rwise
injury or d a m a g e m a y re sult.
S
5. Install the hex screw. Use a torque wrench only and
torque to 90-inch pounds.
C AUTIO N
6. Examinetheheadofthehexscrewandthelockingtab
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.
As with a ny ve hic le , the whe e ls a nd tire s
should b e c he c ke d p e riod ic a lly for c ra c ks
a nd we a r a nd sho uld b e re p la c e d .
Keystock
REPLACING PNEUMATIC TIRES/
TUBES - DRIVE WHEELS/ CASTERS
Chamfered
Side of Wheel
WARNING
Hub
Motor
Driveshaft
DO NOT use your whe e lc ha ir unle ss it ha s
the p ro p e r tire p re ssure (p .s.i.). DO NOT
ove rinfla te the tire s. Fa ilure to follow the se
sug g e stions m a y c a use the tire to e xp lod e
a nd c a use b od ily ha rm .
Keyway
Locking Tab
Washer
If tire s a re p ne um a tic , re p la c e m e nt o f
tire o r tub e MUST b e p e rfo rm e d b y a n
Inva c a re d e a le r o r q ua lifie d te c hnic ia n.
NOTE: If drive wheels or casters are pneumatic,
under-inflation causes excessive wear which results in
poor performance of the tires.
Washer
Hex Screw (Apply Loctite 242 and use a Torque
Wrench only to Torque to 90-inch pounds)
REMOVING/ INSTALLING DRIVE
WHEELS (FIGURE 1)
TIGHTEN Hex Screw if Locking Tab is not
Parallel with Flat on Head (STEP 7)
WARNING
Locking Tab Parallel
with Flat on Head of
Hex Screw (STEP 6)
Flat on Head
of Hex Screw
NEVER use a lo c king ta b wa she r m o re
tha n onc e . ALWAYS use a NEW loc king ta b
wa she r whe n insta lling the d rive whe e ls.
Othe rwise injury o r d a m a g e m a y re sult.
Locking
Tab
Rem oving
1. Removethehexscrew,lockingtabwasherandwasher
that secure the existing drive wheel to the wheel hub.
Bend Tab up tight against Flat on
Head of Hex Screw (STEP 8)
2. Useawheelpullertoremovetheexistingdrive wheel
from the motor drive shaft.
FIGURE 1 - REMOVING/ INSTALLING
DRIVE WHEELS
Loctite- Registered trademark of Loctite Corporation.
13
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PROCEDURE 6
WHEELS
7. If one (1) of the tabs on the locking tab washer is NOT NOTE: Check bearing assemblies and replace if
parallel with one (1) of the flats on the head of the hex necessary.
screw (FIGURE 1), TIGHTEN the hex screw until the
closest flat and locking tab are parallel.
7. Ensure that new fork slides completely into the
caster head tube.
NOTE:Tightenhexscrewonly.DONOTloosenhexscrew
8. Install nylon washer and secure with locknut.
to make one of the tabs on the locking washer parallel.
W
H
E
E
L
WARNING
Im p ro p e r p o sitio ning o f the wa she r will
p ro hib it the fre e m o ve m e nt o f the fo rks.
8. Bend the parallel tab of locking tab washer up tight
against flat of the hex screw (FIGURE 1).
9. Install Loctite 242 onto the hex screw.
10. Position the caster into the new fork.
REPLACING CASTERS (FIGURE 2)
1. Remove the hex screw, washers and locknut that
secure the caster to the fork.
S
11. Reinstall the hex screw, washers and locknut that
secure the caster to the new 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.
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.
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.
15. Adjust the fork. Refer to ADJUSTING FORKS in
PROCEDURE 8 of the owner's manual, part number
1080737.
Locknut
Fork
Dust Cover
Hex Screw
Locknut
Nylon Washer
Caster Head Tube
Locknut
Fork
Washer
Washer
Washer
Hex Screw
Caster
FIGURE 2 - REPLACING CASTERS
Washer
FIGURE 3 - REPLACING FORKS
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.
6. Slide the new fork into the caster head tube.
14
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BATTERIES
PROCEDURE 7
NOTE:Ifthereisbatteryacidinthebottomoronthesides
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).
This Procedure includes the following:
Installing/RemovingBatteriesinto/FromBatteryBoxes
Connecting Battery Cables
B
A
T
T
E
R
I
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.
WARNING
Ma ke sure p owe r to the whe e lc ha ir is OFF
b e fo re p e rfo rm ing this p ro c e d ure .
The use of rub b e r g love s a nd sa fe tyg la sse s
is re c o m m e nd e d whe n wo rking with
b a tte rie s.
1. If necessary, remove the battery boxes from the
wheelchair. Refer to INSTALLING/REMOVING
BATTERY BOXES in PROCEDURE 8 - FWD or
PROCEDURE 9 - RWD of this manual.
E
S
Inva c a re strongly re c om m e nds tha t ba tte ry
insta lla tio n a nd b a tte ry re p la c e m e nt
ALWAYS be done by a qua lifie d te c hnic ia n.
2. Secure the battery lifting strap to battery terminal(s)/
post(s) (FIGURE 1).
Afte r ANY a d justm e nts, re p a ir o r se rvic e
a nd BEFORE use , m a ke sure a ll a tta c hing
ha rd wa re is tig hte ne d se c ure ly - othe rwise
injury or d a m a g e m a y re sult.
C AUTIO N
So m e b a tte ry m a nufa c ture rs m o ld
a
c a rrying stra p a nd / o r ho ld d o wn fla ng e s
d ire c tly into the b a tte ry c a se . Ba tte rie s
whic h inte rfe re with the b a tte ry b o x
c a nno t b e use d fo r the se a p p lic a tio ns.
Atte m p ting to “we d g e ” a b a tte ry into a
b a tte ry b ox m a y d a m a g e the b ox a nd / or
the b a tte ry.
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)
3. Place batteries into battery box bottom.
Battery Lifting Strap
Molded Carrying Strap
Or Hold Down Flanges
NOTE: To remove the battery(ies) from the battery
box(es), reverse the following procedure.
NOTE: Have the following tools available:
TOOL
QTY
COMMENTS
Battery LiftingStrap
1
1
1
1
1
See Note
1/2-inch (6 pt) Box Wrench
7/16-inch (6pt) Box Wrench
3/8-inch (6pt) Box Wrench
DiagonalCutters
Not Supplied
Not Supplied
Not Supplied
Not Supplied
Battery
Dual 22 NF
ONLY
Battery Terminal(s)/Post(s)
*NOTE: The Battery Lifting strap supplied is for Dual
22 NF Batteries ONLY. Refer to the battery manufac-
turer for the proper lifting strap and/or battery tools for
U1 battery removal/installation.
U1 Battery Box
Bottom
WARNING
ALWAYS use a b a tte ry lifting stra p whe n
lifting a b a tte ry. It is the m o st c o nve nie nt
m e thod a nd a ssure s tha t the b a tte ry a c id
will no t sp ill. It a lso he lp s to p ro lo ng the
life o f the b a tte ry.
Dual 22 NF
Battery Box
Bottom
DO NOT tip the b a tte rie s. Ke e p the
b a tte rie s in a n up rig ht p o sitio n.
FIG URE 1 - INSTALLING / REMO VING
BATTERIES INTO / FRO M BATTERY BO XES
15
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PROCEDURE 7
BATTERIES
CONNECTING BATTERY CABLES
C AUTIO N
Whe n c onne c ting the ba tte ry c a ble s to the
b a tte ry(ie s), the b a tte ry c a b le (s) MUST b e
c onne c te d to the ba tte ry te rmina l(s)/ post(s)
a s shown in DETAIL “A” or DETAIL “B” of
FIGURE 3 (d e p e nd ing on b a tte ry typ e ),
othe rwise da ma ge to the ba tte ry c a ble ma y
re sult whe n insta lling ba tte ry te rm ina l c a ps.
WARNING
NEVER a llo w a ny o f yo ur to o ls a nd / o r
b a tte ry c a b le (s) to c o nta c t BOTH b a tte ry
te rm ina l(s)/ p o st(s) a t the sa m e tim e . An
e le c tric a l sho rt m a y o c c ur a nd se rio us
p e rsona l injury or d a m a g e m a y oc c ur.
B
A
T
T
E
R
I
The use o f rub b e r g lo ve s a nd sa fe ty
g la sse s is re c o m m e nd e d whe n wo rking
with b a tte rie s.
2. Connect battery cable(s) to battery(ies) terminal(s)/
post(s) as follows (DETAIL “A” or DETAIL “B”of
FIGURE3, dependingonbatterytype):
Dual U1 or Dual 22NF Battery Boxes
A. NEGATIVE(-)BLACKbatterycabletoNEGATIVE
(-) battery terminal/post.
E
S
Perform one (1) of the following methods for connecting
the battery cable(s):
B. POSITIVE (+) RED battery cable to POSITIVE
(+) battery terminal/post.
A. FOR DUAL U1 BATTERIES - Use direct mount
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 (-)
andREDtoPOSITIVE(+), withtheprovided1/4-20x
7/8-inch hex flange screw and hex flange locknut.
Securely tighten. (DETAIL “A” or DETAIL “B”of
FIGURE3, dependingonbatterytype).
B. FOR DUAL 22NF BATTERIES THAT HAVE
MOUNTING HOLES IN THE BATTERY
TERMINAL(S)/POST(S) - Use direct mount
method. Refer to FIGURES 2 AND 3.
C. FOR DUAL 22NF BATTERIES THAT DO NOT
HAVE MOUNTING HOLES IN THE BATTERY
TERMINAL(S)/POST(S) - Use battery clamp
method. Refer to FIGURES 4, 5 AND 6.
4. Verifyallbatterycable(s)/ringterminal(s)arecorrectly
installed and securely tightened.
5. Slide terminal cap(s) down battery cable(s) and onto
battery clamps (FIGURE 3).
DIRECT MOUNT METHOD (FIGURE 2 AND 3).
1. Install battery terminal cap(s) onto battery cable(s)as
follows (FIGURE 2):
6. Secure each terminal cap in place with a tie-wrap
(Use tie-wraps 11-1/2-inches long) (FIGURE 3).
NOTE: It will be necessary to trim excess tie-wrap in or-
der to install the battery box top(s).
DUAL U1 BATTERIES:
A. ORANGE battery terminal cap onto RED battery
cable.
7. Install the battery box top(s).
B. GRAYbatteryterminalcapontoBLACKbatterycable.
8. Installthebatterybox(es)intothewheelchair. Referto
INSTALLING/REMOVINGBATTERYBOX(ES)inthe
PROCEDURE8-FWDMODELSorPROCEDURE
9 - RWD MODELS of this manual.
DUAL 22NF BATTERIES:
A. REDbatteryterminalcaponto REDbatterycable.
B. BLACKbatteryterminalcapontoBLACKbattery
cable.
NOTE:NewBattery(ies)MUSTbefullychargedBEFORE
using, otherwise the life of the battery(ies) will be reduced.
9. If necessary, charge the battery(ies). Refer
to CHARGING BATTERIES in the PROCEDURE
8 - FWD MODELS or PROCEDURE 9 - RWD
MODELS of this manual.
INSTALLING BATTERY TERMINAL C APS
Battery Cable
Battery Terminal Cap
NOTE:Onlyone(1)batterycableandterminalcapshown
for clarity. Both caps install in the same manner.
FIG URE 2 - C O NNEC TING BATTERY
C ABLES - DIREC T MO UNT METHO D
16
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BATTERIES
PROCEDURE 7
DETAIL “A”
DUAL U1 BATTERIES
DETAIL “B”
DUAL 22NF BATTERIES
POSITIVE (+) Battery Terminal/Post
1/4-20 x 7/8-Inch
Hex Flange Screw
Negative (-)
Battery Terminal/
Post
1/4-20 x 7/8-Inch
Hex Flange Screw
POSITIVE (+) Red
Battery Cable
B
A
T
T
E
R
I
1/4-20 Hex
Flange
Locknut
U1 Battery
E
S
1/4-20 Hex
Flange Locknut
Positive (+) Battery
Terminal/Post
NEGATIVE (-)
Black Battery
Cable
22NF Battery
NEGATIVE (-) Battery
Terminal/Post
CONNECT BATTERY
CABLE TO BATTERY
CONNECT
BATTERY
TERMINAL AS SHOWN.
CABLE(S) RING
TERMINAL(S) TO
THIS SIDE OF
BATTERY
TERMINAL(S)/
POST(S)
DUAL U1 BATTERIES
DUAL 22NF BATTERIES
Gray Battery
Terminal Cap
POSITIVE
(+) Battery
Terminal/
Post
RED
Battery
Terminal
Cap
NEGATIVE (-)
Battery Terminal/
Post
NEGATIVE
(-) Battery
Terminal/
Post
POSITIVE (+) Battery
Terminal Post
Tie-
Wrap
Tie-
Wrap
Tie-
Wrap
U-1
Battery
Tie-Wrap
Orange Battery
Terminal Cap
BLACK BatteryTerminal
Cap
22NF Battery
FIG URE 3 - C O NNEC TING BATTERY C ABLES - DIREC T MO UNT METHO D
17
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PROCEDURE 7
BATTERIES
2. Install battery clamp covers onto battery cables as
follows (FIGURE 5):
Battery Clam p Method (FIGURES 4, 5 and 6).
WARNING
A. REDbatteryclampcoverontoREDbatterycable.
The b a tte ry c la m p o f the POSITIVE (+)
b a tte ry te rm ina l/ p ost MUST b e m ounte d in
the p o sitio n sho wn in FIGURE 5, o the rwise
the b a tte ry b o x to p c a nno t b e insta lle d
p ro p e rly.
B. BLACKbatteryclampcoverontoBLACKbattery
cable.
B
A
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I
NOTE:Onlyone(1)batterycableandbatteryclampcover
are shown for clarity. Both battery clamp covers install in
the same manner.
1. Perform one (1) of the following:
INSTALLING BATTERY CLAMP COVERS
A. If the battery clamp of the POSITIVE (+) battery
terminal/post is NOT mounted in the orientation
shown in FIGURE 5, perform the following:
Battery Clamp
Battery Cable
Cover
E
S
✪ Loosenthehexnutthatsecuresthebatteryclamp
tothePOSITIVE(+)batteryterminal/post.
C AUTIO N
FIGURE 5 - CONNECTING BATTERY
CABLES - BATTERY CLAMP METHOD
Whe n tig hte ning
a lwa ys use a b ox wre nc h. Plie rs will
“ro und o ff” the nuts. NEVER wig g le
the
c la m p s,
C AUTIO N
the
b a tte ry
te rm ina l(s)/ p o st(s)
whe n tig hte ning . The b a tte ry m a y
b e c o m e d a m a g e d .
Whe n c o nne c ting the b a tte ry c a b le / ring
te rm ina l(s) to the b a tte ry(ie s) c la m p (s), the
b a tte ry c a b le (s) MUSt b e c onne c te d in the
p o sitio n sho wn in DETAIL “A”, o the rwise
d a m a g e m a y o c c ur to the b a tte ry c a b le
a nd / o r b a tte ry c la m p c o ve rs.
✪ RemovethebatteryclampfromthePOSITIVE
(+) battery terminal/post.
✪ Reposition the battery clamp on the POSITIVE
(+)batteryterminal/postasshowninFIGURE4.
3. Connect battery cable(s) to battery(ies) terminal(s)/
post(s) as follows (DETAIL “A”):
✪ Securely tighten the hex nut that secures
the battery clamp to the positive (+) battery
terminal/post.
A. NEGATIVE(-)BLACKbatterycable/ringterminal
betweenthemountingplateandbatteryclampof
NEGATIVE(-)batteryterminal/post.
B. If the battery clamp on the POSITIVE (+) battery
terminal/postispositionedasshowninFIGURE4,
proceed to STEP 2.
B. POSITIVE(+)REDbatterycable/ringterminalbe-
tween the mounting plate and battery clamp bat-
tery clamp of POSITIVE (+) battery terminal/post.
CORRECT ORIENTATION OF THE POSITIVE (+)
BATTERY TERMINAL/ POST BATTERY CLAMP
4. Securethebatterycable(s)/ringterminal(s)tothebat-
tery clamp(s), BLACK to NEGATIVE (-) and RED to
POSITIVE (+), with exisitng hex screws. Securely
Tighten. (DETAIL“A”)
POSITIVE (+) Battery Terminal/Post
(Note position of battery clamp)
NEGATIVE (-) Battery
Terminal/Post and Battery Clamp
5. Verify battery cable ring terminal(s) are correctly in-
stalled and securely tightened.
Hex Nut
6. Slide battery clamp covers down battery cables and
onto battery terminals. (DETAIL “B”)
7. Secure each terminal cap in place with a tie-wrap
(Use tie-wraps 11-1/2-inches long). (DETAIL “B”)
NOTE: It will be necessary to trim excess tie-wrap in
order to install the battery box top(s).
22NF Battery
8. Install the battery box top(s).
FIG URE 4 - C O NNEC TING BATTERY
C ABLES - BATTERY C LAMP METHO D
18
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BATTERIES
PROCEDURE 7
9. Installthebatterybox(es)intothewheelchair. Referto 10. If necessary, charge the battery(ies). Refer to
INSTALLING/REMOVINGBATTERYBOX(ES)inthe
PROCEDURE8-FWDMODELSorPROCEDURE
9 - RWD MODELS of this manual.
CHARGING BATTERIES in the PROCEDURE
8 - FWD MODELS or PROCEDURE 9 - RWD
MODELS of this manual.
NOTE:NewBattery(ies)MUSTbefullychargedBEFORE
using, otherwise the life of the battery(ies) will be reduced.
B
A
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CONNECTING BATTERY CABLE(S) TO BATTERY(IES) TERMINAL(S)/ POST(S)
POSITIVE (+) Battery Terminal/
Post and Battery Clamp
NEGATIVE (-) Battery Terminal/
Post and Battery Clamp
Fuse Box placement
when box top
is installed
Negative (-) BLACK
Battery Cable
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Positive (+)
RED Battery
Cable
TOP VIEW
Group 22NF Battery
Fuse Box
DETAIL "A"
Positive (+) RED
Battery Cable
Hex Screw
Mounting Plate
Battery Clamp
Negative (-) BLACK
Battery Cable
EXPLO DED
VIEW
POSITIVE (+) Battery
Terminal/Post
22NF Battery
NEGATIVE (-) Battery Terminal/Post
NOTE: Battery clamps exploded away for clarification purposes only.
DETAIL “B”
POSITIVE (+) Battery
RED Battery Clamp Cover
Terminal/Post
NEGATIVE (-) Battery
Terminal/Post
Tie-Wrap
Tie-Wrap
22NF Battery
BLACK Battery Clamp Cover
FIG URE 6 - C O NNEC TING BATTERY C ABLES - BATTERY C LAMP METHO D
19
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PROCEDURE 8
FWD WHEELCHAIRS
WARNING
Afte r ANY a djustme nts, re pa ir or se rvic e a nd BE-
FORE use , ma ke sure a ll a tta c hing ha rdwa re is
tighte ne d se c ure ly - othe rwise injury or da ma ge
ma y re sult.
This Procedure Includes the Following:
Assembling Excel
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Adjusting Flip-Up Removable Footboard
Replacing Armrest Pads
Replacing Armrest Plate
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Replacing Seat Positioning Strap
Replacing Captain's Seat
ASSEMBLING EXCEL
WARNING
Repositioning MKIV Joystick - Captain's Seat
Removing/Installing MKIV Controller
Replacing Wiring Harness
The weight of the wheelcha ir without the user a nd
ba tteries is still between 90 a nd 127 lbs. Use proper
lifting te c hnique s (lift with your le gs) to a void in-
jury. Extre me c a ution is a dvise d whe n it is ne c e s-
sa ry to move a n UNOCCUPIED powe r whe e l-
c ha ir. Inva c a re re c omme nds using two (2) a ssis-
ta nts a nd ma king thorough pre pa ra tions. Ma ke
sure to use ONLY se c ure , non-de ta c ha ble pa rts
for ha nd-hold supports.
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
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Ke e p ha nds a nd finge rs c le a r of moving pa rts to
a void injury.
Charging Batteries
The overa ll performa nce of the wheelcha ir WILL
be a ffected by the front wheel mounting posi-
tion. Re fe r to REPOSITIONING MOTORS - FWD
WHEELCHAIRS in this proc e dure of the ma nua l
BEFORE opera ting the wheelcha ir.
Replacing Batteries
Installing/Removing Battery Boxes
Battery Tray
Repositioning Motors
Unfolding/ Folding - Integrated Sling Seat
(FIGURE 1)
Replacing Clutch Handles
Replacing Motor/Gearbox
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
Refer to INSTALLING/REMOVING
Rails
FOOTRESTS or INSTALLING/REMOV-
INGELEVATINGLEGRESTSinPROCE-
DURE 3 of the owners manual, part num-
ber 1080737.
Refer to PREPARING MKIV
JOYSTICK FOR USE in
PROCEDURE 5 of this manual.
Referto INSTALLING/REMOV-
ING BATTERY BOXES in this
procedure of the manual.
Refer to REPOSITIONING
MOTORS in this procedure of
the manual.
Refer to BATTERY TRAY in this proce-
dure of the manual.
Seat Guides
FIGURE 1 - ASSEMBLING EXCEL - UNFOLDING/FOLDING - INTEGRATED SLING SEAT
20
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FWD WHEELCHAIRS
PROCEDURE 8
2. Remove the Captain's Seat. Refer to REMOVING/
INSTALLING CAPTAIN'S SEAT in PROCEDURE 9
of the owner's manual, part number 1080737.
FOLDING.
1. Remove the batteries and footrests/legrests from
the wheelchair. Refer to FIGURE 1.
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3. Removetheshrouds.RefertoREMOVING/INSTALL-
ING SHROUDS in this procedure of the manual.
2. Lift the battery tray UP and out of the way. Refer
to FIGURE 1.
4. Remove the batteries and footrests/legrests from the
wheelchair. Refer to FIGURE 2.
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3. Lift up on the seat rails of the wheelchair.
Unfolding/ Folding - Captain's Seat (FIGURE 2)
5. Lift the battery tray UP and out of the way. Refer to
FIGURE 2.
UNFOLDING.
1. Push down on the push brackets until they are flush
6. Lift up on push brackets located on the crossbraces.
with the pivot links on the crossbraces.
ADJ USTING FLIP-UP REMOVABLE
FOOTBOARD
2. Assemble the wheelchair. Refer to FIGURE 2.
3. Install the shrouds. Refer to REMOVING/INSTALLING
SHROUDS in this procedure of the manual.
Angle (FIGURE 3)
4. Install the Captain's Seat. Refer to REMOVING/
INSTALLING CAPTAIN'S SEAT in PROCEDURE 9
of the owner's manual, part number 1080737.
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NOTE: Angle availability is limited when the motors are
in the forward-most position.
1. Remove the caplug caps.
5. HIGH BACK CAPTAIN'S SEATS ONLY - Connect
the limit switch. Refer to DISCONNECTING/ 2. Remove the front hex screw and caplug washer that
CONNECTING LIMIT SWITCH in this procedure of
the manual.
secure the footboard mounting bracket and bushing
to the wheelchair.
3. Repeat STEP 2 for the opposite front hex screw and
caplug washer.
FOLDING.
1. HIGHBACKCAPTAIN'SSEATSONLY-Disconnect
the limit switch. Refer to DISCONNECTING/
CONNECTING LIMIT SWITCH in this procedure of
the manual.
4. 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 PREPARING MKIV
JOYSTICK FOR USE in PRO-
CEDURE 5 of this manual.
Refer to INSTALLING/REMOVING
FOOTRESTS or INSTALLING
ELEVATING LEGRESTS in
PROCEDURE 3 of the owner's
manual, part number 1080737.
Refer to REPOSITIONING
MOTORS in this procedure of
the manual.
Push Brackets
Pivot Link
Refer to BATTERY TRAY in this
procedure of the manual.
Crossbraces
Refer to INSTALLING/REMOVING
BATTERY BOXES in this procedure
of the manual.
FIGURE 2 - ASSEMBLING EXCEL - UNFOLDING/ FOLDING - CAPTAIN'S SEAT
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PROCEDURE 8
FWD WHEELCHAIRS
6. Torque the two (2) hex screws to 156-in/lbs.
7. Reinstall the two (2) caplug caps.
REPLACING ARMREST PADS
(FIGURE 5)
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Wheelchair Frame
Bushing
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
ofarmrestpadandarmrestinserttothearmrestplate.
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Footboard
Mounting
Bracket
Caplug
Washer
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.
Hex
5. Reinstall the rear mounting screw through the
armrest insert, armrest plate and armrest pad and
tighten securely.
Screw
Caplug
Cap
FIGURE 3 - ADJUSTING FLIP-UP
REMOVABLE FOOTBOARD - ANGLE
6. Reinstall the front mounting screw into the armrest
plate and new armrest pad and tighten securely.
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Height (FIGURE 4)
REAR
FRONT
1. If necessary, remove the four (4) caplug caps.
Armrest
Insert
Armrest
Pad
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.
Mount-
ing
Screw
4. Move the footboard pivots to one (1) of five (5)
positions.
Armrest Plate
Mounting
Screw
5. Resecure the two (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.
FIGURE 5 - REPLACING ARMREST PADS
REPLACING ARMREST PLATE
(FIGURE 6)
6. Torque the two (2) hex screws to 156in/lbs. and back
off the hex screws 1/8-1/4 of a revolution.
7. If necessary, reinstall the four (4) caplug caps.
1. If necessary, remove the three (3) hex bolts, spacers
andlocknutsthatsecurethejoystickmountingbracket
to the armrest plate.
Footboard Mounting
Bracket
2. Remove armrest pad. Refer to REPLACING
ARMREST PADS in this procedure of the manual.
Washer
Flip Up Footboard
3. Remove the lug bolt, washers and locknut that secure
the existing armrest plate to the seat frame assembly.
Hex
Screw
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.
Five (5)
Mounting
Positions
5. Reinstall armrest pad. Refer to REPLACING
ARMREST PADS in this procedure of the manual.
Locknut
Caplug
6. If necessary, reinstall the three (3) hex bolts, spacers
andlocknutsthatsecurethejoystickmountingbracket
to the armrest plate.
Footboard Pivot
Cap
FIGURE 4 - ADJUSTING FLIP-UP
REMOVABLE FOOTBOARD - HEIGHT
7. Repeat STEPS 1-6 for the opposite armrest plate,
if necessary.
22
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FWD WHEELCHAIRS
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.
Armrest Plate
Armrest Insert
Armrest Pad
Lug Bolt
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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
Locknuts
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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.
Washers
REPLACING CAPTAIN'S SEAT
(FIGURE 8)
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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.
Phillips
Screw
Washers
Hex Bolts
Spacers
2. Remove the four (4) hex screws and washers that se-
cure existing captain's seat to the seat frame assembly.
Seat Frame
Assembly
Joystick Mounting
Bracket
3. Line up mounting holes in the new captain's seat
with mounting holes in the seat frame assembly.
FIGURE 6 - REPLACING ARMREST PLATE
4. Apply Loctite 242 to the hex screws.
REPLACING SEAT POSITIONING
STRAP (FIGURE 7)
5. Install the four (4) hex screws and washers through
the seat frame assembly and into the new captain's
seat. Tighten securely.
NOTE:ThefollowingprocedureisforCaptain'sSeatsonly.
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.
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.
Captain's Seat
2. Remove the two (2) hex bolts, washers and locknuts
that secure the seat positioning strap to the seat frame
assembly.
3. Remove the two (2) halves of the seat positioning strap
from the seat frame assembly.
Seat Frame
Seat Frame
Assembly
Assembly
4. Position the two (2) new seat positioning strap halves
on the inside of the seat frame assembly as shown in
FIGURE 7.
Seat Positioning
Strap
Hex Screws
(Apply Loctite
Washers
242)
Washer
Seat Frame
FIGURE 8 - REPLACING CAPTAIN'S SEAT
Assembly
REPOSITIONING MKIV J OYSTICK -
CAPTAIN’S SEAT (FIGURE 9)
Locknut
1. Turn the lever on the adjustment lock to release the
adjustment lock from joystick mounting tube.
Hex Bolt
FIGURE 7 - REPLACING SEAT POSITIONING STRAP
2. Remove the joystick from the wheelchair.
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PROCEDURE 8
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
thatsecurejoystickmountingbrackettoarmrestplate.
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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. Remove the phillips screw that secures the rear of the
armrest pad and armrest insert to the armrest plate.
19. Secure adjustment lock to joystick mounting tube
by turning lever on adjustment lock.
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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.
REMOVING/ INSTALLING MKIV
CONTROLLER (FIGURE 10)
8. Repeat STEPS 4-7 for opposite side of wheelchair.
WARNING
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.
Re pla c e me nt c ontrolle r MUST be sa me pa rt
number a s fa ctory insta lled controller - Otherwise
injury or da ma ge ma y re sult.
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.
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Rem oving
11. Position the armrest pad on the armrest plate.
1. If necessary, remove the rear shroud and rear
compartment (if equipped). Refer to REMOVING/
INSTALLING SHROUDS in this procedure of the
manual.
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.
2. Disconnecttheleft/rightmotorleadsandbatteryleads.
14. Reinstall the front phillips screw into the armrest plate
and armrest pad and tighten securely.
3. Remove the two (2) locknuts that secure the exist-
ing MKIV controller and washer(s) to the wheelchair.
15. Repeat STEPS 11-14 for opposite side of wheelchair.
16. Install Loctite 242 onto the three (3) hex bolts.
4. RemoveexistingMKIVcontrollerfromthewheelchair.
Installing
Armrest Plate
Armrest Insert
1. Install washer(s) onto rear mounting stud.
Armrest Pad
Lug Bolt
(STEPS 7, 9)
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.
Phillips Screw
(STEPS 5, 13)
Locknuts
Locknuts
(STEPS 3, 17)
4. If necessary, install the rear shroud and rear compart-
ment (if equipped). Refer to REMOVING/INSTALLING
SHROUDS in this procedure of the manual.
(STEPS 7, 9)
Washers
(STEPS 7, 9)
Hex Bolts
Mounting Studs on
Wheelchair Frame
(STEPS 3, 16)
Washer
Locknut
MKIV Controller
Phillips Screw
(STEPS 4, 14)
Adjustment Lock Lever
Washers (STEPS 7, 9)
Spacers
(STEPS 3, 17)
Seat Frame Assembly
FIGURE 9 - REPOSITIONING MKIV JOYSTICK -
FIGURE 10 - REMOVING/INSTALLING MKIV
CONTROLLER
CAPTAIN’S SEAT
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PROCEDURE 8
FWD WHEELCHAIRS
6. Remove the two (2) phillips bolts and locknuts that
securethefrontbatteryconnectortowheelchairframe.
REPLACING WIRING HARNESS
(FIGURE 11)
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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. Note the position of the tie wraps that secure the exist-
ingwiringharnessandmotorcablestothecrossbraces.
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2. HIGH BACK CAPTAIN'S SEAT MODEL WHEEL-
CHAIRSONLY(DETAIL"A")-Performthefollowing:
9. Cut the tie wraps that secure the existing wiring
harness and motor cables to the crossbraces.
A. Disconnectthelimitswitch.RefertoDISCONNECT-
ING/CONNECTING LIMIT SWITCH in this proce-
dure of the manual.
10. Remove the existing wiring harness from wheelchair.
11. Position the rear battery connector on the wheelchair
frame as shown in FIGURE 11 and secure with the
two (2) phillips screws and spacers.
B. Remove the phono jack nut that secures the
phono jack to the side shroud.
12. Position the front battery connector on the wheelchair
frame as shown in FIGURE 11 and secure with the
two (2) phillips bolts and locknuts.
3. Remove the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure of
the manual.
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13. Secure the wiring harness to existing charger cable
mounting bracket on the seat frame with the two (2)
phillips screws.
4. Disconnect the wiring harness (BLUE) from the
controller connector (BLUE).
5. Remove the two (2) phillips screws and spacers that
secure the rear battery connector to the wheelchair
frame.
14. Connect the wiring harness (BLUE) to the controller
connector (BLUE).
15. Resecure the wiring harness and motor cables to the
crossbraces with new tie wraps at the positions noted
in STEP 8.
DETAIL "A"
(STEPS 2, 16)
Phono Jack
16. HIGH BACK CAPTAIN'S SEAT MODEL WHEEL-
CHAIRS ONLY - Perform the following:
Nut
A. Position the new phono jack on the side shroud.
Side
Shroud
B. Reinstall the phono jack nut onto the new phono
jack and tighten securely.
Phono Jack
Phillips Screws
(STEPS 5, 11)
Spacers
(STEPS 5, 11)
Wiring
Harness
Tie Wraps
(STEPS 8, 15)
Phillips Bolts
(STEPS 6, 12)
To Controller
(STEPS 4, 14)
Charger Cable Mounting Bracket
Locknuts (STEPS 6, 12)
Phillips Screws (STEPS 7, 13)
FIGURE 11 - REPLACING WIRING HARNESS
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PROCEDURE 8
FWD WHEELCHAIRS
C. Connectthelimitswitch. RefertoDISCONNECT-
ING/CONNECTING LIMIT SWITCH in this
procedure of the manual.
ADJ USTING LIMIT SWITCH
(FIGURE 13)
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NOTE:ThefollowingprocedureisforHighBackCaptain's
seat model wheelchairs only.
17. Reinstall the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure of
the manual.
WARNING
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NEVER ope ra te the whe e lc ha ir while in a ny re -
c line position ove r 114o RELATIVE TO THE SEAT
FRAME. If the limit switc h doe s not stop the whe e l-
c ha ir from ope ra ting in a re c line position gre a te r
tha n 114o RELATIVE TO THE SEAT FRAME, DO NOT
ope ra te the whe e lc ha ir. Adjust the limit switc h or
ha ve the whe e lc ha ir se rvic e d by a de a le r or
qua lifie d te c hnic ia n, othe rwise injury or da ma ge
ma y oc c ur.
18. If necessary, install the front and rear shrouds. Refer
to REMOVING/INSTALLING SHROUDS in this pro-
cedure of the manual.
DISCONNECTING/ CONNECTING
LIMIT SWITCH (FIGURE 12)
NOTE:ThefollowingprocedureisforHighBackCaptain's
seat model wheelchairs only.
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1. Place the wheelchair on a level surface.
CAUTION
2. Recline the captain's seat back to a 24o to achieve the
114o angle relative to the seat frame. Refer to AD-
JUSTING CAPTAIN'S SEAT in PROCEDURE 9 of
the owner's manual, part number 1080737.
Disc onne c t limit switc h BEFORE re moving se a t or
da ma ge to switc h ma y oc c ur.
1. Perform one (1) of the following:
NOTE: The captain's seat frame is at a 5o angle relative to
the ground. When the back angle is adjusted to 114o rela-
tive to the seat, it will measure 61o relative to the ground.
DISCONNECTING - While holding the body of
the limit switch phono plug,
lift up gently.
NOTE: To determine 114o 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 61o.
NOTE:Whenthelimitswitchisunpluggedthewheel-
chair will NOT operate.
CONNECTING -
Pluglimitswitchplugintothe
limit switch phono jack.
3. Turn the wheelchair power switch on the joystick to
the ON position.
Limit
Switch
Phono
Plug
NOTE: The wheelchair should not operate.
4. IFwheelchairoperates, proceedtothefollowingsteps
toadjusttheactuatorontheupperlimitswitchbracket:
Body
A. Fully recline the back. Refer to ADJUSTING
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. SlideactuatorUP(towardstopofthewheelchair).
Limit Switch
Phono Jack
CAUTION
DO NOT ove r tighte n the phillips sc re ws tha t
se c ure the a c tua tor to the uppe r limit switc h
bra c ke t. Da ma ge to the a c tua tor ma y oc c ur.
FIGURE 12 - DISCONNECTING/CONNECTING LIMIT
SWITCH
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
operatewhencaptain'sseatbackisata24o angle.
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FWD WHEELCHAIRS
PROCEDURE 8
114o
24o Back
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Recline Angle
5-3/4 inches
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Upper Limit
Switch
Bracket
61o
Phillips
Screws,
Washers
and Lock-
nuts
Magnetic Protractor -
(Will read 61o when back
recline angle is at 114o
relative to the seat
frame)
5o Seat Angle
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Actuator
FIGURE 13 - ADJUSTING LIMIT SWITCH
Rem oving Side Shrouds and Fillers
REMOVING/ INSTALLING SHROUDS
(FIGURE 14)
1. Remove the front shroud from the wheelchair. Refer
to REMOVING/INSTALLING FRONT SHROUD in
this procedure of the manual.
Rem oving Front Shroud
1. Unclip the retaining strap securing the front shroud
and battery box to the wheelchair.
2. Remove the rear shroud from the wheelchair. Refer
toREMOVING/INSTALLINGREARSHROUDinthis
procedure of the manual.
2. Feed the retaining strap through the front shroud.
3. Remove the front shroud from the wheelchair.
3. Perform one (1) of the following:
A. INTEGRATED SLING SEAT MODELS - Fold
thewheelchair.RefertoTRANSPORTINGEXCEL
in this procedure of the manual.
Installing Front Shroud
1. Feed the retaining strap through the front shroud as
shown in FIGURE 14.
B. CAPTAIN'S SEAT MODELS - Remove the
Captain's Seat from the wheelchair. Refer to
REMOVING/INSTALLING CAPTAIN'S SEATin
PROCEDURE 9 of the owner's manual, part
number 1080737.
2. Position the bottom of the front shroud between the
battery box and the battery tray.
3. Clip the retaining strap together.
Rem oving Rear Shroud
4. HIGH BACK CAPTAIN'S SEAT MODEL WHEEL-
CHAIRS ONLY (DETAIL "A") - Remove the phono
jacknutthatsecuresthephonojacktothesideshroud.
1. Unclip the retaining strap securing the rear shroud
and battery box to the wheelchair.
5. Remove the phillips screws, bolts, washers and lock-
nuts that secure side shroud and filler to the wheel-
chair frame. Refer to FIGURE 14 for phillips screw
and washer locations.
2. Feed the retaining strap through the rear shroud.
3. Remove the rear shroud from the wheelchair.
Installing Rear Shroud
6. Remove side shroud and filler from the wheelchair.
1. Feed the retaining strap through the front shroud as
shown in FIGURE 14.
7. RepeatSTEPS5-6 fortheoppositesideofthewheel-
chair, if necessary.
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.
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PROCEDURE 8
FWD WHEELCHAIRS
Installing Side Shrouds and Fillers
B. Reinstall the phono jack nut onto the phono jack
and tighten securely.
1. Positionsideshroudandfilleronthewheelchairframe.
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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
thewheelchair.RefertoTRANSPORTINGEXCEL
in this procedure of the manual.
CAUTION
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DO NOT ove rtighte n the phillips sc re ws a nd phil-
lips bolt tha t se c ure the side shroud to the whe e l-
c ha ir fra me - othe rwise da ma ge to the side
shroud c a n oc c ur.
B. CAPTAIN'S SEAT MODELS - Reinstall the
Captain's Seat onto the wheelchair. Refer to
REMOVING/INSTALLING CAPTAIN'S SEATin
PROCEDURE 9 of the owner's manual, part
number 1080737.
3. Install the phillips screws, bolts, washers and locknuts
that secure the side shroud and filler to the wheelchair
frameandtightensecurely.DONOTOVERTIGHTEN.
Refer to FIGURE 14 for phillips screw, bolt, washer
and locknut locations.
7. Reinstall the rear shroud onto the wheelchair. Refer
toREMOVING/INSTALLINGREARSHROUDinthis
procedure of the manual.
8. Reinstall the front shroud onto the wheelchair. Refer
to REMOVING/INSTALLING FRONT SHROUD in
this procedure of the manual.
4. Repeat STEPS 1-3 for the opposite side of the
wheelchair, if necessary.
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5. HIGH BACK CAPTAIN'S SEAT MODEL WHEEL-
CHAIRS ONLY - If necessary, perform the following:
Phillips Screws
A. Position the phono jack on the side shroud.
Phillips Screws
Side Shroud
Locknut
Retaining
Strap
Rear Shroud
Washers
Wheelchair
Frame
Battery Charger
Cover
Phillips Bolts
Front Shroud
Phono Jack
Nut
Retaining Strap
Filler
Side
Shroud
Battery Tray
Battery Box
Phono Jack
FIGURE 14 - REMOVING/INSTALLING SHROUDS - FWD WHEELCHAIRS
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FWD WHEELCHAIRS
PROCEDURE 8
4. Remove the existing back and seat upholstery from
thewheelchair. RefertoREPLACINGBACKUPHOL-
STERY in PROCEDURE 5 of this manual and
REPLACINGSEATUPHOLSTERYinPROCEDURE
5 of the owner's manual, part number 1080737.
CHANGING SEAT WIDTH -
INTEGRATED SLING SEATS
(FIGURE 15)
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1. If necessary remove the shrouds. Refer to REMOV-
ING/INSTALLING SHROUDS in this procedure of
the manual.
NOTE: If adjusting the seat width of the wheelchair, the
back and seat upholstery MUST be changed as well.
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2. Remove the battery boxes from the wheelchair.
Refer to INSTALLING/REMOVING BATTERY
BOXES in this procedure of the manual.
5. Remove the hex bolts and locknuts that secure the two
(2) pivot links to the wheelchair frame and crossbraces.
Refer to the following chart to determine if new pivot
links will be needed:
3. Fold the battery tray. Refer to FOLDING BATTERY
TRAY FOR TRANSPORT in this procedure of the
manual.
PIVOT LINK SEAT WIDTH RANGE (in inches)
16-18 or 20
Locknut
(STEPS
8, 13)
Crossbrace
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Hex Bolt
(STEPS
5, 14)
Wheelchair Frame
Locknut
(STEPS 5, 14)
Washer (STEPS 8, 13)
Hex Bolts (STEPS 8, 13)
Dust Cover (STEPS 6, 16)
Pivot Link
Pivot Tube Plug Pin (STEPS 9, 10)
Hex Bolts (STEPS 5, 14)
Locknut (STEPS 5, 14)
Tie Wraps (STEPS 7, 15)
DETAIL "B"
DETAIL "A" - (STEPS 9, 12)
RIGHT
LEFT
Front of Wheelchair
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 SEAT WIDTH - INTEGRATED SLING SEAT S
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PROCEDURE 8
FWD WHEELCHAIRS
6. Remove the dust covers from the bottom of the
crossbraces.
REPLACING CROSSBRACES -
CAPTAIN'S SEAT (FIGURE 16)
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NOTE: Note position of the tie wraps that secure the
wiring harness to the crossbraces.
1. Remove the captain's seat from the wheelchair.
RefertoREMOVING/INSTALLINGCAPTAIN'SSEAT
in PROCEDURE 9 of the owner's manual, part
number 1080737.
7. Cut the tie wraps that secure the wiring harness to
the crossbrace.
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8. Remove the hex bolts, washers and locknuts that
secure the bottom of the two (2) crossbraces to the
wheelchair frame.
2. Remove the shrouds. Refer to REMOVING/
INSTALLING SHROUDS in this procedure of the
manual.
9. Remove the hex bolt, coved spacers, washers and
locknut that secure the two (2) existing crossbraces
together.
3. Remove the battery boxes from the wheelchair.
Refer to INSTALLING/REMOVING BATTERY
BOXES in this procedure of the manual.
NOTE: Note coved spacer, washer and locknut order for
reinstallation.
4. Fold the battery tray. Refer to FOLDING BATTERY
TRAY FOR TRANSPORT in this procedure of the
manual.
10. Remove the four (4) pivot tube plug pins from the
bottom of the two (2) existing crossbraces.
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5. Remove the hex bolts and locknuts that secure the
two (2) pivot links to the existing crossbraces.
11. Install the four (4) pivot tube plug pins into the bottom
of the two (2) new crossbraces.
6. Remove the hex bolts, spacers, washers and locknuts
that secure the two (2) push brackets to the existing
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.
7. Remove the dust covers from the bottom of the
existing crossbraces.
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.
NOTE: Note position of the tie wraps that secure the wiring
harness to the existing crossbraces.
8. Cut the tie wraps that secure the wiring harness to the
existing crossbrace.
14. Reinstall the hex bolts and locknuts that secure the
new/existing pivot links to the wheelchair frame and
crossbraces and tighten.
9. Remove the hex bolts, washers and locknuts that
secure the bottom of the two (2) existing crossbraces
to the wheelchair frame.
NOTE: Seat widths are stamped on the pivot links.
15. Secure wiring harness to the new crossbraces with
new tie wraps.
10. Remove the hex bolt, coved spacers, washers and
locknut that secure the two (2) existing crossbraces
together.
16. Reinstall the dust covers onto the bottom of the
crossbraces.
17. Installthenewbackandseatupholsteryontothe wheel-
chair. Refer to REPLACING BACK UPHOLSTERY in
PROCEDURE 3 of this manual and REPLACING
SEAT UPHOLSTERY in PROCEDURE 5 of the
owner's manual, part number 1080737.
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.
18. Change the width of the battery tray. Refer to
CHANGING WIDTH OF BATTERY TRAY in this
procedure of the manual.
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.
19. Unfoldthebatterytray. RefertoFOLDINGBATTERY
TRAY FOR USE in this procedure of the manual.
14. Reinstall the hex bolts, washers and locknuts that
secure the bottom of the two (2) new crossbraces to
the wheelchair frame and tighten.
20. Reinstall the battery boxes onto the wheelchair.
Refer to INSTALLING/REMOVING BATTERY
BOXES in this procedure of the manual.
15. Secure the wiring harness to the new crossbraces with
new tie wraps.
21. If necessary, reinstall the shrouds. Refer to REMOV-
ING/INSTALLING SHROUDS in this procedure of
the manual.
16. Reinstall the dust covers onto the bottom of the new
crossbraces.
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FWD WHEELCHAIRS
PROCEDURE 8
20. Reinstall the battery boxes onto the wheelchair.
Refer to INSTALLING/REMOVING BATTERY
BOXES in this procedure of the manual.
17. Reinstall the hex bolts, spacers, washers and
locknuts that secure the (2) push brackets to the new
crossbraces and tighten securely.
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21. Reinstallshrouds. RefertoREMOVING/INSTALLING
SHROUDS 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.
22. Reinstall the Captain's seat. Refer to REMOVING/
INSTALLING CAPTAIN'S SEAT in PROCEDURE 9
of the owner's manual, part number 1080737.
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19. Unfoldthebatterytray. RefertoFOLDINGBATTERY
TRAY FOR USE in this procedure of the manual.
Hex Bolt
Wheelchair Frame
(STEPS 5, 18)
Washer
(STEPS 6, 17)
Pivot Link
Dust Cover (STEPS 7, 16)
Locknut (STEPS 8, 14)
Hex Bolts
(STEPS 6, 17)
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Hex Bolts
(STEPS 6, 17)
Spacer
(STEPS 9, 13)
Push Bracket
Crossbrace
Hex Bolts
(STEPS 9, 14)
Pivot Tube Plug Pin (STEPS 11, 12)
DETAIL "C" - (STEPS 10, 13)
Spacer
(STEPS 6, 17)
Locknut
(STEPS 6, 17)
Locknut
Front of
(STEPS 5, 18)
Wheelchair
Note orientation of hex bolt, washers, coved wash-
ers and locknut for installation of new crossbraces.
Tie Wraps (STEPS 8, 15)
FIGURE 16 - REPLACING CROSSBRACES - CAPTAIN'S SEAT
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FWD WHEELCHAIRS
PROCEDURE 8
Description and Use of Battery Chargers
WHEN TO CHARGE BATTERIES
(FIGURE 17)
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.
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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.
There are some basic concepts which will help you
understand this automatic process:
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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 turn AMBER
(YELLOW), then RED and finally FLASHING RED. If
the BDI is FLASHING RED, the user should charge the
batteries as soon as possible.
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 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: Accurate readings are displayed when in neutral.
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Battery Discharge
Indicator
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 Item s:
TOOL
QUANTITY
COMMENTS
FIGURE 17 - WHEN TO CHARGE BATTERIES
Battery Charger
✪ Extension Cord
1
1
Supplied
Not Supplied
CHARGING BATTERIES (FIGURE 18)
✪ 3-prong plug, 15 ampere current rating; industrial type
WARNING
Ne ve r a tte m pt to re c ha rge the ba tte rie s by
a tta c hing c a ble s dire c tly to the ba tte ry te rmi-
na ls or c la mps. Alwa ys use the re c ha rging plug
loc a te d on the side of the whe e lc ha ir fra me .
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.
DO NOT a tte mpt to re c ha rge the ba tte rie s a nd
ope ra te the powe r whe e lc ha ir a t the sa me time .
3. Plug the charger’s AC power cord, or extension, into
During use a nd c ha rging, unse a le d ba tte rie s will
ve nt hydroge n ga s whic h is e xplosive in the right
c onc e ntra tion with a ir.
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 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.
CAUTION
Alwa ys c ha rge ne w ba tte rie s fully BEFORE initia l
use or ba tte ry life will be re duc e d.
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.
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.
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.
5. If necessary, install the rear shroud. Refer to
REMOVING/INSTALLINGSHROUDS inthisproce-
dure of the manual.
32
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PROCEDURE 8
FWD WHEELCHAIRS
Cleaning Battery Term inals
Battery Charger
Connector (on side
of Wheelchair)
WARNING
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DO NOT a llow the liquid in the ba tte ry to c ome
in c onta c t with skin, c lothe s or othe r posse ssions.
It is a form of a c id a nd ha rmful or da ma ging
burns ma y re sult. Should the liquid touc h your
skin, wa sh the a re a imme dia te ly a nd thoroughly
with c ool wa te r. In se rious c a se s or if e ye c onta c t
is ma de , se e k me dic a l a tte ntion IMMEDIATELY.
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From Battery Charger
NEVER smoke or strike a ma tc h ne a r ba tte rie s. If
the c a ps of the ba tte ry c e lls a re re move d, NEVER
look dire c tly into the m while c ha rging ba tte rie s.
NOTE: Position of Battery Charger Connector may
vary depending on wheelchair options.
FIGURE 18 - CHARGING BATTERIES
1. Examine battery clamps and terminals for corrosion.
2. Verify that the plastic caps are in place over the
battery cell holes.
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REPLACING BATTERIES
3. Clean the terminals and inside the battery clamps
by using a battery cleaning tool, wire brush, or
medium grade sand paper.
WARNING
Most ba tte rie s a re not sold with instruc tions.
Howe ve r, wa rnings a re fre que ntly note d on the
c e ll c a ps. Re a d the m c a re fully, othe rwise injury
or da ma ge c a n oc c ur.
NOTE: When done, these areas should be shiny, not dull.
4. Carefully dust off all metal particles.
NOTE: Invacare recommends that both batteries be
replaced if one (1) battery is defective.
INSTALLING/ REMOVING BATTERY
BOXES (FIGURE 19)
Recom m ended Battery Types
WARNING
WARNING
The wa rra nty a nd pe rforma nc e spe c ific a tions
c onta ine d in this ma nua l a re ba se d on the use
of de e p c yc le ge l c e ll or se a le d le a d a c id
ba tte rie s. Inva c a re strongly re c omme nds the ir
use a s the powe r sourc e for this unit.
NEVER unplug the ba tte ry c a ble s by pulling
on the wire s. Unp lug the b a tte ry c a b le s b y
p ulling on the c onne c tor ONLY. Othe rwise
injury or da ma ge ma y re sult.
CAUTION
NOTE: To remove the battery boxes from the
wheelchair, reverse the following procedure.
Fa ilure to use the c orre c t ba tte ry size a nd/ or
volta ge ma y c a use da ma ge to your whe e lc ha ir
a nd give you unsa tisfa c tory pe rforma nc e .
1. Verify that the ON/OFF switch on the joystick is in
the OFF position.
2. If necessary, remove the Captain's Seat. Refer to
REMOVING/INSTALLING CAPTAIN'S SEAT in
PROCEDURE 9 of the owner's manual, part number
1080737.
CHAIR SEAT
WIDTH
QTY VOLTS BATTERY REMARKS
SIZE
16,18, 20-inches
2
12
22NF
Deep Cycle
1. Remove the battery boxes from the wheelchair.
Refer to REMOVING/INSTALLING BATTERY
BOXES in this procedure of the manual.
3. If necessary, remove the front and rear shrouds.
Refer to REMOVING/INSTALLING SHROUDS in
this procedure of the manual.
2. Removetheexistingbatteriesfromthebatteryboxes.
RefertoINSTALLING/REMOVINGBATTERIESTO
FROMBATTERYBOXESinPROCEDURE7ofthis
manual.
4. Position the battery boxes onto the battery tray.
NOTE:Makesurethebatterycablesonthebatteryboxes
are on the same side as the battery connectors on the
wheelchair frame.
3. Clean the new battery terminals.
4. Install the new batteries into the battery boxes. Refer
toINSTALLING/REMOVINGBATTERIESTO/FROM
BATTERYBOXESinPROCEDURE7ofthismanual.
5. Connect the battery cables from the battery boxes
to the battery connectors on the wheelchair frame.
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PROCEDURE 8
FWD WHEELCHAIRS
2. Lift up on the pin side of the battery tray and rotate UP
towards the battery tray pivot.
WARNING
The Ba ttery Box Reta ining Stra p MUST be fa stened
securely a nd a djusted properly to hold ba ttery
boxes in pla ce before using the wheelcha ir.
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3. Fold the wheelchair. Refer to ASSEMBLING EXCEL
in this procedure of the manual.
6. Position retaining straps around each battery box as
showninFIGURE19, clipretainingstraptogetherand
adjust if necessary.
Unfolding Battery Tray for Use (FIGURE 21)
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1. Unfoldthewheelchair.RefertoASSEMBLINGEXCEL
in this procedure of the manual.
NOTE: If wheelchair is equipped with shrouds, refer to
REMOVING/INSTALLING SHROUDS in this procedure 2. Rotate the pin side of the battery tray DOWN towards
of the manual before connecting retaining strap together.
the mounting slots on the hanger bracket.
7. If necessary, install the Captain's Seat. Refer to
REMOVING/INSTALLING CAPTAIN'S SEAT in
PROCEDURE 9 of the owner's manual, part number
1080737.
WARNING
Ma ke sure pins of ba ttery tra y a re secure in the
mounting slots of the ha nger bra cket, otherwise in-
jury or da ma ge ma y result.
Retaining
Retaining
Strap Clip
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3. Install the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure
of the manual.
Strap
Rear
Battery
Box
Front Battery
Box
Hanger
Bracket
Front of the
Wheelchair
Battery Cable
Wires (NEVER
pull to unplug.)
Battery Tray
Connector
Battery Connections on
Side of Wheelchair Frame
Pins
Mounting
Slots
NOTE: Wheelchair Frame not
shown for clarity.
FIGURE 21 - BATTERY TRAY - UNFOLDING BATTERY
TRAY FOR USE
FIGURE 19 - INSTALLING/REMOVING BATTERY BOXES
BATTERY TRAY
Changing Width of Battery Tray (FIGURE 22)
Folding Battery Tray for Transport (FIGURE 20)
NOTE: This procedure is only necessary when changing
the width of the wheelchair.
1. Remove the battery boxes from the wheelchair. Refer
toINSTALLING/REMOVINGBATTERYBOXESinthis
procedure of the manual.
1. Fold the battery tray. Refer to FOLDING BATTERY
TRAY FOR USE in this procedure of the manual.
Pins
Battery
Tray
2. Remove the hex bolt and locknut that secure one (1) of
the battery tray pins to the battery tray.
3. Refer to 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.
Pivot
FIGURE 20 - BATTERY TRAY - FOLDING BATTERY TRAY
FOR TRANSPORT
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FWD WHEELCHAIRS
PROCEDURE 8
Battery Tray Pin
Battery Tray Hanger Bracket
Washers
Battery Tray
Hex Bolts
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Locknuts
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Battery Tray
Pivot
Hex Bolts
Locknuts
16-inch Wheelchair
18-inch Wheelchair
20-inch Wheelchair
Battery Tray
FIGURE 23 - BATTERY TRAY - REMOVING/
INSTALLING BATTERY TRAY
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Replacing Right Battery Tray Hanger Bracket
(FIGURE 24)
FIGURE 22 - BATTERY TRAY - CHANGING WIDTH OF
BATTERY TRAY
NOTE:Rightandleftisdeterminedbysittinginthewheel-
chair.
Rem oving Battery Tray (FIGURE 23)
1. Remove the battery boxes from the wheelchair. Refer
toINSTALLING/REMOVINGBATTERYBOXESinthis
procedure of the manual.
1. Remove the battery boxes from the wheelchair. Refer
toINSTALLING/REMOVINGBATTERYBOXESinthis
procedure of the manual.
2. Remove the battery tray. Refer to REMOVING
BATTERY TRAY in this procedure of the manual.
2. Remove the two (2) hex bolts and locknuts that secure
the existing battery tray and washers to the battery tray
hanger bracket.
3. Perform one (1) of the following:
A. WHEELCHAIR EQUIPPED WITH FLIP-UP
REMOVABLEFOOTBOARD-Removethehex
screw and spacer that secures the existing right
battery tray hanger bracket and footboard
mounting bracket to the wheelchair frame.
3. Remove the existing battery tray from the wheelchair.
Installing Battery Tray (FIGURE 23)
1. Line up the mounting holes in the new/existing
battery tray with the mounting holes in the battery
tray hanger bracket.
B. WHEELCHAIR NOT EQUIPPED WITH FLIP-UP
REMOVABLE FOOTBOARD -Remove the front
hex screw that secures the existing right battery
tray hanger bracket to the wheelchair frame.
2. Position one (1) of the washers between the battery
hanger bracket and the new/existing battery tray.
4. Removethe rearhexboltthatsecures theexistingright
battery tray hanger bracket to the wheelchair.
3. Reinstallone(1)ofthehexboltsandwashersthrough
the new/existing battery tray, washer and battery tray
hanger bracket and loosely tighten with one (1) of
the locknuts.
NOTE: NOTE hex screw size for reinstallation.
5. Remove the existing right battery tray hanger bracket
from the wheelchair.
4. Repeat STEPS 2-3 for the remaining washers, hex
bolt, and locknut.
6. Line up the mounting holes in the new battery tray
hanger bracket with the mounting holes in the
wheelchair frame.
5. Tighten the two (2) hex bolts and locknuts.
NOTE: Tighten the Two (2) hex bolts and locknuts until
the tray stays up by itself. Over tightening the hex bolts
and locknuts will make the battery tray difficult to flip up.
7. Perform one (1) of the following:
A. WHEELCHAIR EQUIPPED WITH FLIP-UP
REMOVABLEFOOTBOARD-Reinstallthehex
screw and spacer that secures the new right
battery tray hanger bracket and footboard
mounting bracket to the wheelchair frame. Use
Loctite 242 and torque to 156-in/lbs.
6. Reinstall the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure of
the manual.
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PROCEDURE 8
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.
7. Perform one (1) of the following:
A. WHEELCHAIR EQUIPPED WITH FLIP-UP
REMOVABLEFOOTBOARD-Reinstallthehex
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-in/lbs.
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8. Reinstall the rear hex screw. Use Loctite 242 and
torque to 156-in/lbs.
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9. Reinstall the battery tray. Refer to INSTALLING
BATTERY TRAY in this procedure of the manual.
B. WHEELCHAIR NOT EQUIPPED WITH FLIP-UP
REMOVABLE FOOTBOARD -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/lbs.
Wheelchair Frame
Rear Hex Screw
Hex Screw
Spacer
8. Reinstall the locknut. Use Loctite 242 and torque to
156-in/lbs.
Footboard
Mounting
Bracket
9. Torque the rear locknut that secures MKIV controller to
the wheelchair to 156-in/lbs.
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Battery Tray Hanger Bracket
Wheelchair
Frame
Battery Tray
Hanger Bracket
MKIV Controller
FIGURE 24 - BATTERY TRAY - REPLACING RIGHT
BATTERY TRAY HANGER BRACKET
Replacing Left Battery Tray Hanger Bracket
(FIGURE 25)
Spacer
NOTE: Right and left is determined by sitting in the
wheelchair.
Hex Screw
Footboard
Locknut
1. Remove the battery boxes from the wheelchair. Refer
toINSTALLING/REMOVINGBATTERYBOXESinthis
procedure of the manual.
Rear Locknut - Loosen, but
Do Not Remove
Mounting
Bracket
FIGURE 25 - BATTERY TRAY - REPLACING LEFT
BATTERY TRAY HANGER BRACKET
2. Loosen, but do not remove the rear locknut that
secures MKIV controller to the wheelchair.
3. Perform one (1) of the following:
REPOSITIONING MOTORS
(FIGURE 26)
A. WHEELCHAIR EQUIPPED WITH FLIP-UP
REMOVABLEFOOTBOARD-Removethehex
screw and spacer that secures the existing left
battery tray hanger bracket and footboard
mounting bracket to the wheelchair frame.
WARNING
The ove ra ll pe rforma nc e of the whe e lc ha ir WILL
b e a ffe c te d b y the fro nt whe e l m o unting
position. The following c ha rts show the mounting
position of the motors for e a c h se a t width a nd
de pth de pe nding on the fa c tory se tting or use r's
we ight. If the mounting position tha t c orre sponds
to the use r's we ight is diffe re nt tha n the fa c tory
se tting , the m otors MUST BE re p ositione d to
ma inta in prope r sta bility BEFORE using the whe e l-
c ha ir. Othe rwise injury or da ma ge ma y oc c ur.
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.
Periodica lly review the following cha rts to ma ke
sure the motor mounting position still corresponds
to the user's weight to ma inta in the proper sta bility.
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
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FWD WHEELCHAIRS
PROCEDURE 8
NOTE: If motors are repositioned, the front riggings may
needtoberepositioned. RefertoADJUSTING/REPLAC-
ING TELESCOPING FRONT RIGGING SUPPORT in
PROCEDURE 9 of the owner's manual, 1080737.
STEPS 2, 4, 10, 11, 12
Spacers
Dust Cover (Not Shown)
Battery Tray
Hanger
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FACTORY SETTINGS
MOTOR MOUNTING POSITIONS
Bracket
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Hex Screws
SEAT
WIDTH
16
SEAT DEPTH
17
16
18
Footboard
Mounting
Bracket
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
18
20
USERS' WEIGHT 200 LBS AND UNDER -
MOTOR MOUNTING POSITIONS
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LONG Socket Screws (Apply Loctite 242 and
torque to 60-inch pounds) (STEPS 6, 8)
SEAT
WIDTH
16
SEAT DEPTH
17
16
18
REAR
REAR
REAR
REAR
REAR
REAR
REAR
18
20
REAR
REAR
USERS' WEIGHT 201 TO 250 LBS -
MOTOR MOUNTING POSITIONS
SEAT DEPTH
Wheelchair
SEAT
Frame
WIDTH
16
17
18
SHORT
Socket Screws
(Apply Loctite
242 and
torque to 60-
inch pounds)
(STEPS 6, 8)
16
18
20
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
NOTE: The front motor mounting position is reserved
for future applications.
Motor/
Gearbox
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
REMOVABLEFOOTBOARD-Removethehex
screws and spacers that secure the battery tray
hanger bracket and footboard mounting bracket
to the wheelchair frame.
NOTE: It is not necessary to
disconnect the clutch handle
from the motor/gearbox.
B. WHEELCHAIRNOTEQUIPPEDWITHFLIP-UP
REMOVABLE FOOTBOARD - Remove the
front hex screw that secures the battery tray
hanger bracket to the wheelchair frame.
FRONT MOTOR
MOUNTING POSITION
3. Rotate battery tray hanger bracket up.
MIDDLE MOTOR
MOUNTING POSITION
4. Left side 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.
REAR MOTOR
MOUNTING POSITION
6. Remove the six (6) socket screws that secure the
motor to the wheelchair frame.
7. Position the motor on the wheelchair frame at the
position noted in STEP 5 as shown in FIGURE 26.
FIGURE 26 - REPOSITIONING MOTORS
37
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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
The longe r soc ke t sc re ws must be positione d in
the m ounting hole s on the OUTSIDE of the
whe e lc ha ir fra me a nd the short soc ke t sc re ws
must be in the mounting hole s on the INSIDE of
the whe e lc ha ir fra me . Othe rwise da ma ge to the
ge a rbox ma y re sult.
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10. Insert the pin through the clutch handle and motor/
gearbox as shown in DETAIL "A" in FIGURE 27.
NOTE: Make sure the detent ball on the pin is fully visible.
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11. Repeat STEPS 2-10 for the opposite side of the
wheelchair, if necessary.
8. Use Loctite 242 and tighten the motor to the
wheelchair frame securely with the six (6) socket
screws. Torque to 60-inch pounds.
12. Reinstall the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure
of the manual.
9. Repeat STEPS 2-8 for the opposite side of the
wheelchair, if necessary.
Tip (STEPS 2, 6, 8)
Clutch Handle
10. Line up the mounting hole in the battery tray hanger
bracketwiththemountingholeinthewheelchairframe.
(STEPS 4, 5, 7)
Outside of
Wheelchair
11. Left side of wheelchair only - Reinstall the front
R
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dust cover onto the end of the crossbrace.
12. Perform one (1) of the following:
A. WHEELCHAIREQUIPPEDWITHFLIP-UPRE-
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-in/lbs.
Motor/
Gearbox
B. WHEELCHAIR NOT EQUIPPED WITH FLIP-
UPREMOVABLEFOOTBOARD-Reinstallthe
front hex screw that secures the battery tray
hanger bracket to the wheelchair frame. Use
Loctite 242 and torque to 156-in/lbs.
Pin (STEPS 3, 10)
DETAIL "A"
Motor/Gearbox
Detent Ball
Clutch Handle (STEPS 9, 10)
FIGURE 27 - REPLACING CLUTCH HANDLES
13. Reinstall the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure of
the manual.
REPLACING MOTOR/ GEARBOX
(FIGURE 28)
REPLACING CLUTCH HANDLES
(FIGURE 27)
1. Remove the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure of
the manual.
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.
2. Remove the tip from the existing clutch handle.
3. Remove the drive wheels from the wheelchair.
RefertoREMOVING/INSTALLINGDRIVEWHEELS
in PROCEDURE 6 of this manual.
3. Removethepinthatsecurestheexistingclutchhandle
to the motor/gearbox.
4. Perform one (1) of the following:
4. Disconnect existing clutch handle from motor/gearbox.
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.
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.
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.
8. Install the rubber tip onto the new clutch handle.
38
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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
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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. Remove the pin that secures the clutch handle to the
existing motor/gearbox.
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CAUTION
8. Disconnect clutch handle from existing motor/gearbox.
The longe r soc ke t sc re ws must be positione d in
the m ounting hole s on the OUTSIDE of the
whe e lc ha ir fra me a nd the short soc ke t sc re ws
must be in the mounting hole s on the INSIDE of
the whe e lc ha ir fra me . Othe rwise da ma ge to the
ge a rbox ma y re sult.
9. Notemountingpositionofmotor/gearboxonthewheel-
chair frame for installation of the new motor/gearbox.
Dust Cover (Not Shown)
Spacers
STEPS 4, 6,
17, 18, 19
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12. Use Loctite 242 and tighten the motor/gearbox to the
wheelchair frame securely with the six (6) socket
screws. Torque to 60-inch pounds.
Battery Tray
Hanger
Bracket
13. Connect the clutch handle to the new motor/gearbox
and line up the mounting holes.
Hex Screws
14. Insert the pin through clutch handle and new motor/
gearbox as shown in DETAIL "B" in FIGURE 28.
Footboard
Mounting
Bracket
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.
LONG Socket Screws (Apply Loctite
242 and torque to 60-inch pounds)
16. Reinstall the drive wheels onto the wheelchair. Refer
to REMOVING/INSTALLING DRIVE WHEELS in
PROCEDURE 6 of this manual.
(STEPS 10, 12)
Wheelchair
Frame
17. Line up the mounting hole in the battery tray hanger
bracketwiththemountingholeinthewheelchairframe.
Clutch
Handle
18. Left side of wheelchair only - Reinstall the front
(STEP 8)
dust cover onto the end of the crossbrace.
Dust Cover
19. Perform one (1) of the following:
(STEPS
4B, 19B)
A. WHEELCHAIR EQUIPPED WITH FLIP-UP
REMOVABLEFOOTBOARD-Reinstallthehex
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/lbs.
SHORT Socket
Screws (Apply
Loctite 242 and
torque to 60-
inch pounds)
(STEPS 10,
12)
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/lbs.
Pin
(STEP 7)
Motor/
Gearbox
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 procedure of
the manual.
DETAIL "B"
Pin (STEP 14)
Motor/Gearbox
(STEP 14)
Clutch Handle
(STEP 13)
Detent Ball
FIGURE 28 - REPLACING MOTOR/ GEARBOX
39
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PROCEDURE 9
RWD WHEELCHAIRS
ASSEMBLING POWER 9000
(FIGURE 1)
This Procedure Includes the Following:
Assembling Power 9000
When to Charge Batteries
Charging Batteries
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WARNING
The we ight of the whe e lc ha ir without the use r
a nd b a tte rie s is a p p roxim a te ly 82 lb s. Use
prope r lifting te c hnique s (lift with your le gs) to
a void injury. Extre me c a ution is a dvise d whe n
it is ne c e ssa ry to move a n UNOCCUPIED powe r
whe e lc ha ir. Inva c a re re c omme nds using two (2)
a ssista nts a nd ma king thorough pre pa ra tions.
Ma ke sure to use ONLY se c ure , non-de ta c ha ble
pa rts for ha nd-hold supports.
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Replacing Batteries
Installing/Removing Battery Boxes
Battery Tray
Changing Seat Width
Adjusting Seat-to-Floor Height
Disconnecting/Connecting MKIV Controller, Motor
and Battery Leads
Unfolding/ Folding the Wheelchair
WARNING
Keep ha nds a nd fingers clea r of moving pa rts to
a void injury.
Removing/Installing MKIV Controller
Replacing Wiring Harness
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Replacing Motor/Gearbox
UNFOLDING.
1. Push down on the seat rails until the seat rails are
positioned in the seat guides.
WARNING
2. Assemble the wheelchair. Refer to FIGURE 1.
Afte r ANY a djustme nts, re pa ir or se rvic e a nd
BEFORE use , ma ke sure a ll a tta c hing ha rdwa re
is tighte ne d se c ure ly - othe rwise injury or
da ma ge ma y re sult.
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/
REMOVING BATTERY
BOXES and BATTERY
TRAY in this procedure
of the manual.
Seat
Rails
Seat
Guides
Refer to INSTALLING/REMOV-
ING FOOTRESTS or INSTALL-
ING/REMOVING ELEVATING
LEGRESTS in PROCEDURE 3
of the owners manual, part num-
ber 1080737.
Refer to INSTALLING ANTI-TIPPERS in
PROCEDURE 10 of the owners manual,
part number 1080737.
FIGURE 1 - ASSEMBLING POWER 9000
40
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RWD WHEELCHAIRS
PROCEDURE 9
Description and Use of Battery Chargers
WHEN TO CHARGE BATTERIES
(FIGURE 4)
Thechargerautomaticallyreducesthechargefromaninitially
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.
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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.
There are some basic concepts which will help you
understand this automatic process:
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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.
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 turn AMBER (YELLOW), then RED
and finally FLASHING RED. If the BDI is FLASHING RED,
the user should charge the batteries as soon as possible.
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NOTE:Ifperformingthechargingproceduresindependently,
READandCAREFULLYfollowtheindividualinstructions
for each charger (supplied or purchased).
Battery Discharge Indicator
NOTE: Accurate read-
ings are displayed
when in neutral.
NOTE: If charging instructions are not supplied, consult
a qualified service technician for proper procedures.
Required Item s:
FIGURE 4 - WHEN TO CHARGE BATTERIES
TOOL
QUANTITY
COMMENTS
Supplied
Not Supplied
Battery Charger
✪ Extension Cord
1
1
CHARGING BATTERIES (FIGURE 5)
✪ 3-prong plug, 15 ampere current rating; industrial type
NOTE: New batteries MUST be fully charged prior to initial
use of the wheelchair.
1. Attach the battery charger connector to the charger
cable/battery harness.
WARNING
2. Plug the charger’s AC power cord, or extension, into
Never a ttempt to recha rge the ba tteries by a tta ch-
ing c a ble s dire c tly to the ba tte ry te rmina ls or
cla mps. Alwa ys use the recha rging plug loca ted
on the side of the wheelcha ir fra me.
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
discharged 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.
DO NOT a ttempt to recha rge the ba tteries a nd
opera te the power wheelcha ir a t the sa me time.
During use a nd cha rging, unsea led ba tteries will
vent hydrogen ga s which is explosive in the right
concentra tion with a ir.
CAUTION
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.
Alwa ys cha rge new ba tteries before initia l use or
ba ttery 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.
Battery Charger Connector (on Side of Wheelchair)
Rangeperbatterychargeusingrecommendedbatteriesshould
be approximately 5 to 9 hours of typical operation. Extensive
use on inclines may substantially reduce per charge mileage.
From Battery
Charger
FIGURE 5- CHARGING BATTERIES
41
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PROCEDURE 9
RWD WHEELCHAIRS
3. Clean the terminals and inside the battery clamps by
using a battery cleaning tool, wire brush, or medium
grade sand paper.
REPLACING BATTERIES
WARNING
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Most ba tte rie s a re not sold with instruc tions.
Howe ve r, wa rnings a re frequently noted on the
cell ca ps. Rea d them ca refully, otherwise injury or
da ma ge ma y occur.
NOTE: When done, these areas should be shiny, not dull.
4. Carefully dust off all metal particles.
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INSTALLING/ REMOVING BATTERY
BOXES (FIGURE 6)
NOTE: Invacare recommends that both batteries be
replaced if one (1) battery is defective.
NOTE: To remove the battery boxes from the
wheelchair, reverse the following procedure.
Recom m ended Battery Types
1. Verify that the ON/OFF switch on the joystick is in
the OFF position.
WARNING
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.
The wa rra nty a nd pe rforma nc e spe c ific a tions
c onta ine d in this ma nua l a re ba se d on the use
of de e p c yc le ge l c e ll or se a le d le a d a c id
ba tte rie s. Inva c a re strongly re c omme nds the ir
use a s the powe r sourc e for this unit.
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3. Connect the battery cables from the battery boxes
to the battery connectors on the wheelchair frame.
4. Connect the battery box retaining strap clip together.
CAUTION
Retaining
Fa ilure to use the c orre c t ba tte ry size a nd/ or
volta ge ma y ca use da ma ge to your wheelcha ir
a nd give you unsa tisfa ctory performa nce.
Strap
Battery Boxes
CHAIR SEAT QTY VOLTS BCI STOCK REMARKS
WIDTH
14-inches
NO.
U1
2
12
Deep Cycle
16,18, 20-
inches
2
12
22NF
Deep Cycle
NOTE: Charge batteries daily. It is critical not to let them
run low at any time.
Battery Connections on
Side of Wheelchair Frame
Retaining Strap Clip
Cleaning Battery Term inals
FIGURE 6 - INSTALLING/REMOVING BATTERY BOXES
WARNING
DO NOT a llow the liquid in the ba tte ry to c ome
in c onta c t with skin, c lothe s or othe r posse ssions.
It is a form of a c id a nd ha rmful or da ma ging
burns ma y re sult. Should the liquid touc h your
skin, wa sh the a re a imme dia te ly a nd thoroughly
with c ool wa te r. In se rious c a se s or if e ye c onta c t
is ma de , se e k me dic a l a tte ntion IMMEDIATELY.
WARNING
The Ba tte ry Box Re ta ining Stra p MUST be fa ste ne d
se c ure ly a nd a djuste d prope rly to hold ba tte ry
boxe s in pla c e be fore using the whe e lc ha ir.
5. Connect the battery box retaining strap clip together
and adjust if necessary.
The use of sa fe ty gla sse s is re c omme nde d whe n
c le a ning the ba tte ry te rmina ls.
NEVER smoke or strike a ma tc h ne a r ba tte rie s. If
the c a ps of the ba tte ry c e lls a re re move d, NEVER
look dire c tly into the m while c ha rging ba tte rie s.
1. Examine battery clamps and terminals for corrosion.
2. Verify that the plastic caps are in place over the
battery cell holes.
42
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RWD WHEELCHAIRS
PROCEDURE 9
2. Secure the hanger brackets to the battery tray in the
mounting holes that the hex screws are mounted.
BATTERY TRAY (FIGURE 7)
NOTE: To remove the battery tray from the wheelchair,
reverse the following procedure.
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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.
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.
NOTE: If wheelchair is 14-inch wide and equipped with
MKIV RII electronics, it may be necessary to turn battery
tray slightly away from controller to install the battery tray.
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4. Attach the hanger brackets to the support tubes on
the wheelchair frame.
Hex Screws (Shown in 14 and 16-inch
Wheelchair Width positions)
18-inch
CHANGING SEAT WIDTH
(FIGURE 8)
Wheelchair
Width
Position
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.
Locknut
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20-inch Wheelchair
Locknut
2. Remove the existing back and seat upholstery from
the wheelchair. Refer to REPLACING BACK
UPHOLSTERYin PROCEDURE 3 of this manual and
REPLACINGSEATUPHOLSTERYinPROCEDURE
5 of the owners manual, part number 1080737.
Width Position
14-inch Adult
Key Slot
Bracket
16, 18, 20-inch Low
16, 18, 20-inch Adult
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:
Key Slot
Bracket
Crossbrace
Bolt Bushing
PIVOT LINK SEAT WIDTH RANGE (IN INCHES)
Battery Tray
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) existing crossbraces.
Hanger
Bracket
Battery Tray
8. Install the four (4) pivot tube plug pins into the
bottom of the two (2) new crossbraces.
Support Tube
FIGURE 7 - BATTERY TRAY
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.
43
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PROCEDURE 9
RWD WHEELCHAIRS
11. Reinstall dust covers onto bottom of crossbraces.
14. Reinstall the battery tray and battery boxes/batteries
onto the wheelchair. Refer to BATTERY TRAY and
INSTALLING/REMOVING BATTERY BOXES in this
procedure of the manual.
12. Reinstall the hex screws and locknuts that secure the
pivot links to the wheelchair frame and crossbraces.
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13. Install the new back and seat upholstery onto the
wheelchair. Refer to REPLACING BACK UPHOL-
STERY in PROCEDURE 3 of this manual and
REPLACINGSEATUPHOLSTERYinPROCEDURE
5 of the owners manual, part number 1080737.
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Crossbrace
Locknut
Hex
Screw
Hex
Screws
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Dust Cover
Pivot Tube
Plug Pin
Hex
Screws
Washer
Pivot Link
Wheelchair
Frame
Locknut
Note orientation of hex screw, bushing,
washers, coved washers and locknut for in-
stallation of new crossbraces.
FIGURE 8 - CHANGING SEAT WIDTH
Fastening Straps
ADJ USTING SEAT-TO-FLOOR
HEIGHT
Nylon Boot
WARNING
Adjusting sea t-to-floor height MUST be performed
by Inva ca re Technica l Support, 1-800-832-4707.
DISCONNECTING/ CONNECTING
MKIV CONTROLLER, MOTOR AND
BATTERY LEADS (FIGURE 9)
Battery Lead
Leads From
Controller
NOTE:ToconnectMKIVcontrollermotorandbatteryleads,
reverse the following procedure.
Left/Right Motor
Leads
1. Disconnect the fastening straps that secure the nylon
boot around the connected motor and battery leads.
2. Disconnect controller left/right motor and battery leads FIGURE 9 - DISCONNECTING/CONNECTING MKIV
from the leads secured to the wheelchair with tie wrap.
CONTROLLER, MOTOR AND BATTERY LEADS
44
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RWD WHEELCHAIRS
PROCEDURE 9
REMOVING/ INSTALLING MKIV
CONTROLLER (FIGURE 10)
REPLACING WIRING HARNESS
(FIGURE 11)
R
W
D
1. Disconnect the left/right motor leads and battery Disassem bly
leads. Refer to DISCONNECTING/CONNECTING
MKIV CONTROLLER, MOTOR AND BATTERY
LEADS in this procedure of the manual.
1. Remove the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure of
the manual.
W
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2. Removethetwo(2)hexscrewsthatsecuretheMKIV
controller onto the wheelchair.
2. Disconnect the wiring harness (BLUE) from the
controller connector (BLUE).
NOTE: When installing the MKIV controller onto the
wheelchair, use Loctite 242 on hex screws.
3. Remove the four (4) phillips screws that secure the
battery connectors and battery connector spacers to
the wheelchair frame.
3. Install the new/existing MKIV controller onto the
wheelchair by reversing STEPS 1 and 2.
4. Remove the two (2) phillips screws, washers and
locknuts that secure the charger cable to the charger
cable mounting bracket.
Wheelchair
Frame
R
S
5. Cut the tie wrap that secures the wiring harness and
motor cables to the crossbraces.
6. Remove the wiring harness from the wheelchair.
Reassem bly
1. Secure the two (2) battery connectors of the new
battery harness and the battery connector spacers to
the wheelchair frame with the four (4) phillips screws.
Hex Screws
MKIV Controller
FIGURE 10 - REMOVING/INSTALLING MKIV
CONTROLLER
2. Secure charger cable to existing mounting bracket
on seat frame with two (2) phillips screws, washers
and locknuts.
Battery Connector Spacer
Wiring Harness
Phillips
Screws
Charger
Cable
Mounting
Bracket
To Controller
Phillips Screws
and Locknuts
From Motors
FIGURE 11 - REPLACING WIRING HARNESS
45
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RWD WHEELCHAIRS
PROCEDURE 9
3. Connect the wring harness (BLUE) to the controller 10. Repeat procedure for opposite side of the
connector (BLUE). wheelchair, if necessary.
R
W
D
4. Re-secure the wiring harness and motor cables to the 11. Reinstall the battery boxes. Refer to INSTALLING/
crossbraces with new tie wrap.
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.
DETAIL "A"
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Underside of Motor
Mount Plate
REPLACING MOTOR/ GEARBOX
(FIGURE 12)
Alignment Pin
Long Socket
1. Remove the battery boxes. Refer to INSTALLING/
REMOVING BATTERY BOXES in this procedure of
the manual.
Short Socket Screws (Apply
Screws (Apply
Loctite 242 and torque to 60-
Loctite 242
2. Disconnect the right and/or left motor connector from
the controller.
inch pounds)
and torque to
R
S
3. Remove the drive wheels from the wheelchair. Re-
fer to REPLACING DRIVE WHEELS in PROCE-
DURE 6 of this manual.
60-inch
pounds)
4. Remove the six (6) socket screws that secure the mo-
tor/gearbox and support tube to the wheelchair frame.
Motor Mount
Plate
5. Repositionnewmotor/gearboxonthewheelchairframe.
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
the alignment pin on the motor mount plate.
Alignment
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.
Wheelchair
Frame
NOTE: When the alignment hole in the support tube is
positionedwiththealignmentpinonthewheelchairframe,
the anti-tipper wheels should be pointing down towards
the ground/floor.
Support Tube
Motor/Gearbox
CAUTION
FIGURE 12 - REPLACING MOTOR/ GEARBOX
The longe r soc ke t sc re ws must be positione d
in the mounting hole s on the OUTSIDE of the
whe e lc ha ir fra me a nd the short soc ke t sc re ws
must be in the mounting hole s on the INSIDE
of the whe e lc ha ir fra me . Othe rwise da ma ge
to the ge a rbox c a sting c a n re sult.
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
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LIMITED WARRANTY
PLEASE NOTE: THE WARRANTY BELOW HAS BEEN DRAFTED TO COMPLY WITH FEDERAL LAW APPLICABLE
TO PRODUCTS MANUFACTURED AFTER JULY 4, 1975.
L
I
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This wa rra nty is e xte nde d only to the origina l purc ha se r/use r of our produc ts.
T
E
D
This wa rra nty give s you spe c ific le ga l rights a nd you ma y a lso ha ve othe r le ga l rights whic h va ry from
sta te to sta te .
Inva ca re wa rra nts the side fra mes a nd crossbra ces to be free from defects in ma teria ls a nd workma nship
for a pe riod of five (5) ye a rs from da te of purc ha se ; e le c tronic s for a pe riod of one (1) ye a r from the
da te of purc ha se ; motors a nd ge a rboxe s for a pe riod of twe lve (12) months from the da te of
purc ha se ; a ll re ma ining c ompone nts (inc luding ga s c ylinde rs for re c line rs) for one (1) ye a r from the
da te of purc ha se e xc e pt upholste re d ma te ria ls, pa dde d ma te ria ls a nd tire s/whe e ls. If within suc h
wa rra nty pe riod a ny produc t sha ll be prove n to be de fe c tive , suc h produc t sha ll be re pa ire d or
re pla c e d, a t Inva c a re 's option. This wa rra nty doe s not inc lude a ny la bor or shipping c ha rge s inc urre d
in re pla c e me nt pa rt insta lla tion or re pa ir of a ny suc h produc t. Inva c a re 's sole obliga tion a nd your
e xc lusive re me dy unde r this wa rra nty sha ll be limite d to suc h re pa ir a nd/or re pla c e me nt.
W
A
R
R
A
N
T
Y
For wa rra nty se rvic e , ple a se c onta c t the de a le r from whom you purc ha se d your Inva c a re produc t. In
the e ve nt you do not re c e ive sa tisfa c tory wa rra nty se rvic e , ple a se write dire c tly to Inva c a re a t the
bottom of the ba c k c ove r. Provide de a le r's na me a ddre ss, da te of purc ha se , indic a te na ture of the
de fe c t a nd, if the produc t is se ria lize d, indic a te the se ria l numbe r. Do not re turn produc ts to our fa c tory
without our prior c onse nt.
LIMITATIONS AND EXCLUSIONS: THE FOREGOING WARRANTY SHALL NOT APPLY TO SERIAL NUMBERED
PRODUCTS IF THE SERIAL NUMBER HAS BEEN REMOVED OR DEFACED, PRODUCTS SUBJECT TO
NEGLIGENCE, ACCIDENT, IMPROPER OPERATION, MAINTENANCE OR STORAGE, COMMERCIAL OR
INSTITUTIONAL USE, PRODUCTS MODIFIED WITHOUT INVACARE'S EXPRESS WRITTEN CONSENT INCLUDING,
BUT NOT LIMITED TO, MODIFICATION THROUGH THE USE OF UNAUTHORIZED PARTS OR ATTACHMENTS;
PRODUCTS DAMAGED BY REASON OF REPAIRS MADE TO ANY COMPONENT WITHOUT THE SPECIFIC
CONSENT OF INVACARE, OR TO A PRODUCT DAMAGED BY CIRCUMSTANCES BEYOND INVACARE'S
CONTROL, AND SUCH EVALUATION WILL BE SOLELY DETERMINED BY INVACARE. THE WARRANTY SHALL NOT
APPLY TO PROBLEMS ARISING FROM NORMAL WEAR OR FAILURE TO ADHERE TO THESE INSTRUCTIONS.
A CHANGE IN OPERATING NOISE, PARTICULARLY RELATIVE TO MOTORS AND GEARBOXES DOES NOT
CONSTITUTE A FAILURE. ALL SUCH DEVICES WILL EXHIBIT A CHANGE IN OPERATING NOISE DUE TO 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 FITNESS FOR A
PARTICULAR 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 SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES WHATSOEVER.
THIS WARRANTY SHALL BE EXTENDED TO COMPLY WITH STATE/PROVINCIAL LAWS AND REQUIREMENTS.
47
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Invacare Corporation
USA
Canada
One Invacare Way
Elyria, Ohio USA
44036-2125
5970 Chedworth Way
Mississauga, Ontario
L5R 3T9, Canada
905-890-8838
Invacare and "Yes, you can" are trademarks of Invacare
Corporation.
© 2000 Invacare Corporation
800-333-6900
Form No. 98-271 Part No. 1085397 Rev B (1) 7/00
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