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Invacare P9000 manual

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Table of contents for the manual

  • Page 1

    Ser vice Manual Excel and P9000 DEALER: KEEP THIS MANU AL. THE PR OCEDURES IN THIS MANUAL MUST BE PERFORMED BY A QU ALIFIED TECHNICIAN ONL Y .[...]

  • Page 2

    2 W ARNING/SPECIAL NOTES W A R N I N G SA VE THESE INSTRUCTIONS W ARNING THE PROCEDURES IN THIS MANUAL SHOULD ONL Y BE PERFORMED BY A QUALIFIED TECHNICIAN. DO NOT SER VICE OR OPERA TE THIS EQUIPMENT WITHOUT FIRST READING AND UNDERST ANDING THIS MANUAL AND THE OWNERS MANUAL SUPPLIED WITH THE WHEELCHAIR. IF YOU ARE UNABLE TO UNDERST AND THE W ARNINGS[...]

  • Page 3

    3 T ABLE OF CONTENTS T A B L E O F C O N T E N T S TABLE OF CONTENTS SPECIAL NOTES ......................................... 2 SPECIFICA TIONS ........................................ 4 PROCEDURE 1 - GENERAL GUIDELINES .... 6 REP AIR OR SERVICE INFORMA TION .................. 6 OPERA TING INFORMA TION ................................. 6 PROCEDURE 2[...]

  • Page 4

    4 S P E C I F I C A T I O N S SPECIFICA TIONS SPECIFICATIONS NOTE: All specifications are approximate. EXCEL Seat Width Range: Seat Depth Range: Back Height Range Std.: Opt. Headrest: Opt. Backrest Ext.: Back Angle Range: Seat-to-Floor: Overall Width (No Joystick): Overall Height: ✪ ✪ ✪ ✪ ✪ Weight W/O Batteries: W/Batteries (Gel Cell): Sh[...]

  • Page 5

    5 SPECIFICA TIONS S P E C I F I C A T I O N S *NOTE: Range will vary with battery conditions, surface, terrain and operators weight. **NOTE: Includes seating systems and accessories. SPECIFICATIONS Speed (M.P .H.): T urning Radius: * Range (variable): ** Weight Limitation: 0 to 4 35-inches 12-14 miles with U1 batteries 18-22 miles with 22NF batteri[...]

  • Page 6

    6 GENERAL GUIDELINES PROCEDURE 1 G E N E R A L G U I D E L I N E S REP AIR OR SER VICE INFORMA TION Set-up of the Electronic Contr ol Unit is to be perfor med ONL Y by individuals certified by Invacare. The final tuning adjustments of the controller may affect other activities of the wheelchair. Damage to the equipment could occur under these circu[...]

  • Page 7

    7 TROUBLESHOOTING PROCEDURE 2 T R O U B L E S H O O T I N G (+) (-) FIGURE 1 - FIELD LOAD TEST Battery Charger Connector Digital V oltmeter FIELD LOAD TEST (FIGURE 1) NOTE: The following test can also be performed through the controller of the wheelchair along with a remote programmer . Refer to the individual CONTROLLER MANUAL supplied with each w[...]

  • Page 8

    8 T R O U B L E S H O O T I N G TROUBLESHOOTING PROCEDURE 2 W ARNING ONL Y use distilled water when topping of f the battery cells. Most batteries are not sold with instructions. However, warnings are frequently noted on the cell caps. Read them carefully. 1 . Remove the battery box(es). Refer to one (1) of the following: A. FWD WHEELCHAIRS: INST A[...]

  • Page 9

    9 ELECTRO-MECHANICAL PARKING BRAKE TEST (FIGURE 5) 1 . On the four-pin motor connector , locate the side by side connectors in the black housings. 2 . Set the digital multimeter to read ohms ( Ω ). 3 . Measure the resistance between the two (2) brake contacts. A normal reading is 100 ohms ( Ω ). A reading of 0 ohms (W) or a very high reading; i[...]

  • Page 10

    10 This Procedure Includes the Following: Replacing Back Upholstery W ARNING After ANY adjustments, repair or service and BEFORE use, make sure that all attaching hardware is tightened securely - otherwise injury or damage may result. FIGURE 1 - REPLACING BACK UPHOLSTERY Hex Screws Locknuts Back Upholstery Washer Phillips Screw Washer Tie Wrap Moun[...]

  • Page 11

    11 FIGURE 1 - ADJUSTING SEA T DEPTH Phillips Screws Washer Plug Button Crossbrace Seat Extension T ube ADJUSTING SEAT DEPTH (FIGURE 1) 1. Remove the existing seat upholstery from the wheelchair . Refer to REPLACING SEA T UPHOLSTER Y in PRO- CEDURE 5 of the Owners Manual, part number 1080737. NOTE: If adjusting seat depth of the wheelchair , the sea[...]

  • Page 12

    12 PROCEDURE 5 ELECTRONICS This Procedure Includes the Following: Preparing MKIV Joystick for Use Repositioning MKIV Joystick PREPARING MKIV JOYSTICK FOR USE (FIGURE 1) NOTE: T o reposition the MKIV joystick on a Captain’s Seat, refer to REPOSITIONING MKIV JOYSTICK - CAPT AIN’S SEA T in PROCEDURE 8 of this manual. NOTE: The MKIV joystick is fac[...]

  • Page 13

    13 W H E E L S PROCEDURE 6 WHEELS REPLACING PNEUMATIC TIRES/ TUBES - DRIVE WHEELS/CASTERS W ARNING DO NOT use your wheelchair unless it has the proper tire pressure (p.s.i.). DO NOT overinflate the tires. Failure to follow these suggestions may cause the tire to explode and cause bodily harm. If tires are pneumatic, replacement of tire or tube MUST[...]

  • Page 14

    14 7 . If one (1) of the tabs on the locking tab washer is NOT parallel with one (1) of the flats on the head of the hex screw (FIGURE 1), TIGHTEN the hex screw until the closest flat and locking tab are parallel. NOTE: Tighten hex screw only . DO NOT loosen hex screw to make one of the tabs on the locking washer parallel. 8 . Bend the parallel tab[...]

  • Page 15

    15 PROCEDURE 7 BA TTERIES B A T T E R I E S This Procedure includes the following: Installing/Removing Batteries into/From Battery Boxes Connecting Battery Cables W ARNING Make sure power to the wheelchair is OFF before perfor ming this procedure. The use of rubber gloves and safetyglasses is recommended when working with batteries. Invacare strong[...]

  • Page 16

    16 PROCEDURE 7 BA TTERIES B A T T E R I E S CONNECTING BATTERY CABLES W ARNING NEVER allow any of your tools and/or battery cable(s) to contact BOTH battery terminal(s)/post(s) at the same time. An electrical short may occur and serious personal injury or damage may occur. The use of rubber gloves and safety glasses is recommended when working with[...]

  • Page 17

    17 PROCEDURE 7 BA TTERIES B A T T E R I E S FIGURE 3 - CONNECTING BA TTERY CABLES - DIRECT MOUNT METHOD Orange Battery T erminal Cap POSITIVE (+) Battery T erminal Post U-1 Battery Gray Battery T erminal Cap Tie-Wrap NEGA TIVE (-) Battery T erminal/ Post Tie- Wrap 1/4-20 Hex Flange Locknut Negative (-) Battery T erminal/ Post 1/4-20 x 7/8-Inch Hex [...]

  • Page 18

    18 Battery Cable Battery Clamp Cover 2 . Install battery clamp covers onto battery cables as follows (FIGURE 5): A . RED battery clamp cover onto RED battery cable. B. BLACK battery clamp cover onto BLACK battery cable. NOTE: Only one (1) battery cable and battery clamp cover are shown for clarity . Both battery clamp covers install in the same man[...]

  • Page 19

    19 9 . Install the battery box(es) into the wheelchair . Refer to INST ALLING/REMOVING BA TTER Y BOX(ES) in the PROCEDURE 8 - FWD MODELS or PROCEDURE 9 - RWD MODELS of this manual. NOTE: New Battery(ies) MUST be fully charged BEFORE using, otherwise the life of the battery(ies) will be reduced. 1 0 . If necessary , charge the battery(ies). Refer to[...]

  • Page 20

    20 This Procedure Includes the Following: Assembling Excel Adjusting Flip-Up Removable Footboard Replacing Armrest Pads Replacing Armrest Plate Replacing Seat Positioning Strap Replacing Captain's Seat Repositioning MKIV Joystick - Captain's Seat Removing/Installing MKIV Controller Replacing Wiring Harness Disconnecting/Connecting Limit S[...]

  • Page 21

    21 FIGURE 2 - ASSEMBLING EXCEL - UNFOLDING/FOLDING - CAPT AIN'S SEA T 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 . Unfolding/Folding - Captain's Seat (FIGURE 2) UNFOLDING.[...]

  • Page 22

    22 Flip Up Footboard Caplug Cap Washer Hex Screw Locknut Footboard Mounting Bracket Height (FIGURE 4) 1. If necessary , remove the four (4) caplug caps. 2. Remove the hex screw , two (2) spacers, washers and locknut that secure one (1) of the footboard pivots to the footboard mounting bracket. 3. Repeat STEP 2 for opposite side of the wheelchair . [...]

  • Page 23

    23 FIGURE 6 - REPLACING ARMREST PLA TE Joystick Mounting Bracket Hex Bolts Spacers Locknuts Phillips Screw Armrest Insert Phillips Screw Armrest Pad Armrest Plate Lug Bolt W ashers Locknuts W ashers Seat Frame Assembly REPLACING SEAT POSITIONING STRAP (FIGURE 7 ) NOTE: The following procedure is for Captain's Seats only . 1. Remove the Captain[...]

  • Page 24

    24 FIGURE 10 - REMOVING/INST ALLING MKIV CONTROLLER FIGURE 9 - REPOSITIONING MKIV JOYSTICK - CAPT AIN ’ S SEA T Adjustment Lock Lever Hex Bolts (STEPS 3, 16) Spacers (STEPS 3, 17) Locknuts (STEPS 3, 17) Phillips Screw (STEPS 4, 14) Armrest Insert Phillips Screw (STEPS 5, 13) Armrest Pad Armrest Plate Lug Bolt (STEPS 7, 9) W ashers (STEPS 7, 9) Lo[...]

  • Page 25

    25 6. Remove the two (2) phillips bolts and locknuts that secure the front battery connector to wheelchair frame. 7. Remove the two (2) phillips screws that secure the wiring harness to the charger cable mounting bracket. 8 . Note the position of the tie wraps that secure the exist- ing wiring harness and motor cables to the crossbraces. 9. Cut the[...]

  • Page 26

    26 C. Connect the limit switch. Refer to DISCONNECT- ING/CONNECTING LIMIT SWITCH in this procedure of the manual. 17 . Reinstall the battery boxes. Refer to INST ALLING/ REMOVING BA TTER Y BOXES in this procedure of the manual. 18 . If necessary , install the front and rear shrouds. Refer to REMOVING/INST ALLING SHROUDS in this pro- cedure of the m[...]

  • Page 27

    27 FIGURE 13 - ADJUSTING LIMIT SWITCH 5 o Seat Angle 24 o Back Recline Angle 61 o Magnetic Protractor - (Will read 61 o when back recline angle is at 1 14 o relative to the seat frame) Upper Limit Switch Bracket Phillips Screws, Washers and Lock- nuts Actuator 11 4 o 5-3/4 inches REMOVING/INSTALLING SHROUDS (FIGURE 14) Removing Front Shroud 1. Uncl[...]

  • Page 28

    28 FIGURE 14 - REMOVING/INST ALLING SHROUDS - FWD WHEELCHAIRS Front Shroud Phillips Screws Washers Rear Shroud Side Shroud Phillips Bolts Locknut Wheelchair Frame Filler Retaining Strap Retaining Strap Battery Box Battery T ray Phillips Screws Battery Charger Cover Installing Side Shrouds and Fillers 1 . Position side shroud and filler on the wheel[...]

  • Page 29

    29 CHANGING SEAT WIDTH - INTEGRATED SLING SEATS (FIGURE 15) 1. If necessary remove the shrouds. Refer to REMOV- ING/INST ALLING SHROUDS in this procedure of the manual. 2. Remove the battery boxes from the wheelchair . Refer to INST ALLING/REMOVING BA TTER Y BOXES in this procedure of the manual. 3. Fold the battery tray . Refer to FOLDING BA TTER [...]

  • Page 30

    30 6. Remove the dust covers from the bottom of the crossbraces. NOTE: Note position of the tie wraps that secure the wiring harness to the crossbraces. 7. Cut the tie wraps that secure the wiring harness to the crossbrace. 8. Remove the hex bolts, washers and locknuts that secure the bottom of the two (2) crossbraces to the wheelchair frame. 9. Re[...]

  • Page 31

    31 FIGURE 16 - REPLACING CROSSBRACES - CAPT AIN'S SEA T Note orientation of hex bolt, washers, coved wash- ers and locknut for installation of new crossbraces. Front of Wheelchair DET AIL "C" - (STEPS 10, 13) Wheelchair Frame Locknut (STEPS 5, 18) Hex Bolt (STEPS 5, 18) Hex Bolts (STEPS 6, 17) Locknut (STEPS 8, 14) Push Bracket Cross[...]

  • Page 32

    32 Description and Use of Battery Chargers The charger automatically reduces the charge from an initially high rate to a zero reading at a fully charged condition. If left unattended, the charger should automatically shut-off when full charge is obtained. There are some basic concepts which will help you understand this automatic process: The amoun[...]

  • Page 33

    33 Cleaning Battery Terminals W ARNING DO NOT allow the liquid in the battery to come in contact with skin, clothes or other possessions. It is a form of acid and harmful or damaging burns may result. Should the liquid touch your skin, wash the area immediately and thor oughly with cool water. In serious cases or if eye contact is made, seek medica[...]

  • Page 34

    34 PROCEDURE 8 FWD WHEELCHAIRS W ARNING The Battery Box Retaining Strap MUST be fastened securely and adjusted pr operly to hold battery boxes in place before using the wheelchair. 6 . Position retaining straps around each battery box as shown in FIGURE 19 , clip retaining strap together a n d adjust if necessary . NOTE: If wheelchair is equipped w[...]

  • Page 35

    35 FIGURE 23 - BA TTERY TRA Y - REMOVING/ INST ALLING BA TTERY TRA Y Battery T ray Hanger Bracket Battery T ray Hex Bolts Locknuts Washers Replacing Right Battery Tray Hanger Bracket (FIGURE 24 ) NOTE: Right and left is determined by sitting in the wheel- chair . 1. Remove the battery boxes from the wheelchair . Refer to INST ALLING/REMOVING BA TTE[...]

  • Page 36

    36 PROCEDURE 8 FWD WHEELCHAIRS B. WHEELCHAIR NOT EQUIPPED WITH FLIP-UP REMOV ABLE FOOTBOARD - Reinstall the front hex screw that secures the new right battery tray hanger bracket to the wheelchair frame. Use Loctite 242 and torque to 156-in/lbs. 8. Reinstall the rear hex screw . Use Loctite 242 and torque to 156-in/lbs. 9. Reinstall the battery tra[...]

  • Page 37

    37 REAR MOTOR MOUNTING POSITION MIDDLE MOTOR MOUNTING POSITION FRONT MOTOR MOUNTING POSITION FIGURE 26 - REPOSITIONING MOTORS Wheelchair Frame LONG Socket Screws (Apply Loctite 242 and torque to 60-inch pounds) (STEPS 6, 8) Motor/ Gearbox SHOR T Socket Screws (Apply Loctite 242 and torque to 60- inch pounds) (STEPS 6, 8) STEPS 2, 4, 10, 1 1, 12 Spa[...]

  • Page 38

    38 PROCEDURE 8 FWD WHEELCHAIRS F W D W H E E L C H A I R S CAUTION The longer socket screws must be positioned in the mounting holes on the OUTSIDE of the wheelchair frame and the short socket screws must be in the mounting holes on the INSIDE of the wheelchair frame. Otherwise damage to the gearbox may result. 8 . Use Loctite 242 and tighten the m[...]

  • Page 39

    39 FIGURE 28 - REPLACING MOTOR/GEARBOX Wheelchair Frame LONG Socket Screws (Apply Loctite 242 and torque to 60-inch pounds) (STEPS 10, 12) Motor/ Gearbox Pin (STEP 14) Detent Ball Motor/Gearbox (STEP 14) DET AIL "B" Clutch Handle (STEP 13) Pin (STEP 7) SHORT Socket Screws (Apply Loctite 242 and torque to 60- inch pounds) (STEPS 10, 12) Cl[...]

  • Page 40

    40 PROCEDURE 9 R WD WHEELCHAIRS R W D W H E E L C H A I R S ASSEMBLING POWER 9000 (FIGURE 1) W ARNING The weight of the wheelchair without the user and batteries is approximately 82 lbs. Use proper lifting techniques (lift with your legs) to avoid injury. Extreme caution is advised when it is necessary to move an UNOCCUPIED power wheelchair. Invaca[...]

  • Page 41

    41 1. Attach the battery charger connector to the charger cable/battery harness. 2. Plug the charger ’ s AC power cord, or extension, into the grounded 120 V AC 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 requ[...]

  • Page 42

    42 PROCEDURE 9 R WD WHEELCHAIRS Retaining Strap Clip Battery Connections on Side of Wheelchair Frame Retaining Strap FIGURE 6 - INST ALLING/REMOVING BA TTERY BOXES Battery Boxes 3. Clean the terminals and inside the battery clamps by using a battery cleaning tool, wire brush, or medium grade sand paper . NOTE: When done, these areas should be shiny[...]

  • Page 43

    43 2. Secure the hanger brackets to the battery tray in the mounting holes that the hex screws are mounted. 3 . Attach the key slot bracket located at the front of the battery tray over the crossbrace bolt bushing under the seat upholstery of the wheelchair . NOTE: If wheelchair is 14-inch wide and equipped with MKIV RII electronics, it may be nece[...]

  • Page 44

    44 PROCEDURE 9 R WD WHEELCHAIRS FIGURE 8 - CHANGING SEA T WIDTH Locknut Wheelchair Frame Hex Screw Locknut Pivot Link Hex Screws Washer Dust Cover Crossbrace Note orientation of hex screw , bushing, washers, coved washers and locknut for in- stallation of new crossbraces. 14 . Reinstall the battery tray and battery boxes/batteries onto the wheelcha[...]

  • Page 45

    45 REPLACING WIRING HARNESS (FIGURE 11) Disassembly 1. Remove the battery boxes. Refer to INST ALLING/ REMOVING BA TTER Y BOXES in this procedure of the manual. 2. Disconnect the wiring harness (BLUE) from the controller connector (BLUE). 3. Remove the four (4) phillips screws that secure the battery connectors and battery connector spacers to the [...]

  • Page 46

    46 FIGURE 12 - REPLACING MOTOR/GEARBOX DET AIL "A" Alignment Pin Wheelchair Frame Alignment Hole Long Socket Screws (Apply Loctite 242 and torque to 60-inch pounds) Short Socket Screws (Apply Loctite 242 and torque to 60- inch pounds) Motor/Gearbox Support T ube Underside of Motor Mount Plate Motor Mount Plate 3. Connect the wring harness[...]

  • Page 47

    47 LIMITED WARRANTY PLEASE NOTE: THE W ARRANTY BELOW HAS BEEN DRAFTED TO COMPL Y WITH FEDERAL LA W APPLICABLE TO PRODUCTS MANUF ACTURED AFTER JUL Y 4, 1975. This warranty is extended only to the original pur chaser/user of our products. This warranty gives you specific legal rights and you may also have other legal rights which vary fr om state to [...]

  • Page 48

    In vacare Corporation www .invacar e.com USA Canada One Invacare W ay 5970 Chedw orth W a y Invacar e and "Y es, you can" are trademarks of Invacare Elyria, Ohio USA Mississauga, Ontario Co rporation. 44036-2125 L5R 3T9, Canada © 2000 Invacare Corporation 800-333-6900 905-890-8838 Form No. 98-271 Par t N o. 1085397 Re v B (1) 7/00[...]