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Invacare Xterra GT Service Manual

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Service Manual
Invacare
Xterra
GT
™
™
®
Wheelchair
DEALER: KEEP THIS MANUAL. THE PROCEDURES IN
THIS MANUAL MUST BE PERFORMED BY A QUALI-
FIED TECHNICIAN ONLY

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Summary of Contents for Invacare Xterra GT

  • Page 1 Service Manual Invacare Xterra ™ ™ ® Wheelchair DEALER: KEEP THIS MANUAL. THE PROCEDURES IN THIS MANUAL MUST BE PERFORMED BY A QUALI- FIED TECHNICIAN ONLY...

  • Page 2: Special Notes

    WITHOUT FIRST READING AND UNDERSTANDING THIS MANUAL AND THE OWNER’S MANUAL SUPPLIED WITH THE WHEELCHAIR. IF YOU ARE UNABLE TO UNDERSTAND THE WARNINGS, CAUTIONS, AND INSTRUCTIONS, CONTACT INVACARE TECHNICAL SUPPORT BEFORE ATTEMPTING TO SERVICE OR OPERATE THIS EQUIPMENT - OTHERWISE INJURY OR DAMAGE MAY RESULT.
  • Page 3 TABLE OF CONTENTS TABLE OF CONTENTS Part No. 1110516 XTERRA™ GT™...
  • Page 4 TABLE OF CONTENTS TABLE OF CONTENTS (CONTINUED) XTERRA™ GT™ Part No. 1110516...

  • Page 5: Label Locations

    LABEL LOCATIONS LABEL LOCATIONS Pinch Point Pinch Point Label Label Seat Prop Label Pinch Point Label Battery Removing/Installing Label Part No. 1110516 XTERRA™ GT™...

  • Page 6: Specifications

    SPECIFICATIONS SPECIFICATIONS Seat Width Range: Seat Depth Range: Back Height Range Back Angle Range Weight** 4-Pole Motor Without Batteries: 179 lbs. With Batteries: With ASBA Seat 280 lbs. With Van Style Seat 300 lbs. PERFORMANCE RATING SPEED RANGE 250 LBS Up to 7.5 Up to 21 M.P.H.

  • Page 7: General Guidelines

    SECTION 1 GENERAL GUIDELINES This Section Includes the Following: Repair or Service Information Operating Information GENERAL WARNINGS Part No. 1110516 XTERRA™ GT™...
  • Page 8 SECTION 1 GENERAL GUIDELINES GENERAL WARNINGS (CONTINUED) XTERRA™ GT™ Part No. 1110516...

  • Page 9: Troubleshooting

    TROUBLESHOOTING SECTION 2 This Procedure Includes the Following: Field Load Test Motor Brush Inspection Using Hydrometer To Check Battery Electro-Mechanical Parking Brake Testing Cells (Lead Acid) Motor Testing FIELD LOAD TEST (FIGURE 1) CONTROLLER MANUAL READ CAREFULLY ONLY Battery Charger Connector Digital Voltmeter FIGURE 1 - FIELD LOAD TEST...
  • Page 10 SECTION 2 TROUBLESHOOTING USING HYDROMETER TO CHECK BATTERY CELLS (LEAD ACID) (FIGURE 2) WARNING Number of Floating Balls Will Vary Accord- DO NOT ing to Charge NUMBER OF FLOATING BALLS FIGURE 2 - USING HYDROMETER TO CHECK BATTERY CELLS (LEAD ACID) XTERRA™...
  • Page 11 TROUBLESHOOTING SECTION 2 MOTOR TESTING (FIGURE 3) Ω Ω Ω Ω Ohmmeter Motor Connector FIGURE 3 - MOTOR TESTING MOTOR BRUSH INSPECTION (FIGURE 4) MUST Motor 4 Pin Motor Connector FIGURE 4 - MOTOR BRUSH INSPECTION Part No. 1110516 XTERRA™ GT™...

  • Page 12: Electromechanical Parking Brake Testing

    SECTION 2 TROUBLESHOOTING ELECTROMECHANICAL PARKING BRAKE TESTING (FIGURE 5) Motor Ω Ω Ω FIGURE 5 - ELECTROMECHANICAL PARKING BRAKE TESTING XTERRA™ GT™ Part No. 1110516...

  • Page 13: Hardware Torque Specifications

    HARDWARE TORQUE SPECIFICATIONS SECTION 3 HARDWARE TORQUE SPECIFICATIONS STANDARD SEAT FRAME Torque to 60 in-lbs Loctite and Torque to 75 in-lbs Torque to 60 in-lbs Seat Frame ® Loctite Torque to 75 in-lbs SEAT FRAME WITH CJ BACK BRACKETS TO OBTAIN 14 AND 15-INCH SEAT DEPTHS Loctite and Torque to...

  • Page 14: Standard Seat Frame

    HARDWARE TORQUE SPECIFICATIONS SECTION 3 TORQUE SPECIFICATIONS STANDARD VAN SEAT SEAT FRAME Torque to 13 ft/lbs. ± 20% Torque to 60 in/lbs. Torque to 60 in/lbs. Torque to 75 in/lbs. Torque to ADJUSTABLE SEAT FRAME 13 ft/lbs. ± 20% Torque to 13 ft/lbs.

  • Page 15: Base Frame Hardware Torque Specifications

    HARDWARE TORQUE SPECIFICATIONS SECTION 3 BASE FRAME HARDWARE TORQUE SPECIFICATIONS Torque to 13 ft/lbs. ± 20% Flip-Up Seat Plate Assembly (Plate removed for clarity) Torque to 40 in/lbs. ± 20% Torque to Torque to 13 ft/lbs. 75 in/lbs. ± 20% ±...
  • Page 16 HARDWARE TORQUE SPECIFICATIONS SECTION 3 BASE FRAME HARDWARE TORQUE SPECIFICATIONS Torque to 75 in/lbs. ± 20% Torque to 40 in/lbs. ± 20% Torque to Torque to 75 in/lbs. ± 20% 75 in/lbs. ± 20% Torque to 75 in/lbs. ± 20% Torque to 40 in/lbs.
  • Page 17 ARMS SECTION 4 This Section Includes the Following: Replacing Armrest Pads - Van Style Seat Replacing Van Style Seat Armrest Plate Installing/Removing Flip Back Armrests Installing/Removing Van Style Seat Armrests WARNING REPLACING ARMREST PADS - VAN STYLE SEAT (FIGURE REAR Armrest Insert Armrest...
  • Page 18 SECTION 4 ARMS Locknut Locknuts Washer Armrest Plate Mounting Screws Armrest Plate Mounting Joystick Mounting Screws Washer Arm Weldment Bracket FIGURE 2 - REPLACING ARMREST PLATE - VAN STYLE SEAT INSTALLING/REMOVING FLIP BACK ARMRESTS (FIGURE 3) WARNING Flip Back REMOVING Armrest Rear Socket...
  • Page 19 ARMS SECTION 4 INSTALLING INSTALLING/REMOVING VAN STYLE SEAT ARMRESTS (FIGURE AND 4) REMOVING Height Adjustment Holes Van Seat Mounting Frame Screw INSTALLING Part No. 1110516 XTERRA™ GT™...

  • Page 20: Replacing Seat Positioning Strap

    SECTION 5 BACK This Procedure Includes the Following: Replacing Seat Positioning Strap Removing/Installin Back Upholstery Changing Back Height Back Angle Adjustment WARNING STANDARD/ADJUSTABLE SEAT FRAMES (FIGURE 2) Mounting Screw Seat Seat Pan Positioning Strap Quick Release Pin Spacer Locknut Seat Rail FIGURE 2 - REPLACING SEAT POSITIONING STRAP REPLACING SEAT POSITIONING STRAP...
  • Page 21 BACK SECTION 5 REMOVING/INSTALLING BACK UPHOLSTERY (FIGURE 3) REMOVING INSTALLING Part No. 1110516 XTERRA™ GT™...

  • Page 22: Standard Models

    SECTION 5 BACK STANDARD MODELS Locknuts Back Cane Spacers Mounting Screw Locknut Washer Spreader Back Upholstery Insert Mounting Screw Torque to 60 in/lbs Mounting Screws Washers Torque to 75 in/lbs FIGURE 3 - REPLACING BACK UPHOLSTERY XTERRA™ GT™ Part No. 1110516...

  • Page 23: Changing Back Height

    BACK SECTION 5 CHANGING BACK HEIGHT (FIGURE 4) BACK UPHOLSTERY HEIGHT WARNING Part No. 1110516 XTERRA™ GT™...
  • Page 24 SECTION 5 BACK WARNING Locknuts Back Cane Spacers Mounting Screw Locknut Washer Spreader Back Upholstery Mounting Screw Insert Torque 60 in/lbs Mounting Screws Washers Torque to 75 in/lbs FIGURE 4 - REMOVING/ INSTALLING BACK UPHOLSTERY BACK ANGLE ADJUSTMENT (FIGURE 5) XTERRA™...
  • Page 25 BACK SECTION 5 TO ACHIEVE A BACK ANGLE OF: BACK CANE BACK ANGLE ANGLE MOUNTING HOLE PLATE HOLE Top Front Bottom Rear Bottom Top Front 2nd From Bottom Center Bottom Top Front Bottom Bottom Front Top Center 2nd From Bottom Front Bottom Top Reatr 1 0 0...
  • Page 26 SEAT FRAME SECTION 6 This Section includes the following: Removing/Installing Seat Frame for 14 and 15-inch Seat Widths Removing/Installing Seat Frame for 16-inch Seat Widths Removing/Installing Seat Frame for 17 and 18-inch Seat Widths Removing/Installing Seat Frame for 19 and 20-inch Seat Widths Installing Seat Frame for 19 and 20-inch Seat Widths Changing Seat Depth Removing/Installing Seat Pan...
  • Page 27 SEAT FRAME SECTION 6 INSTALLING (FIGURES 1 AND 2) Part No. 1110516 XTERRA™ GT™...
  • Page 28 SECTION 6 SEAT FRAME Mounting Mounting Screws Screws (Torque (Torque Adjustable Adjustable to 13 ft/lbs.) to13 ft/lbs.) Seat Frame Seat Frame Spacers Spacers Use these Use these Mounting Mounting Holes Use these Use these Holes Mounting Mounting Holes Holes 16-inch Deep Flip- Locknuts 18-inch Deep Flip-...
  • Page 29 SEAT FRAME SECTION 6 REMOVING/INSTALLING SEAT FRAME FOR 16-INCH SEAT WIDTHS REMOVING (FIGURES 3 AND 4) FIXED SEAT FRAME CJ Back Bracket Washer Locknut ADJUSTABLE SEAT FRAME CJ Back Washer Bracket Locknut FIGURE 3 - REMOVING SEAT FRAME (16-INCH SEAT WIDTHS) Part No.
  • Page 30 SECTION 6 SEAT FRAME Mounting Screws *Fixed Mounting *Fixed (Torque to 13-ft/ Seat Frame Screws Seat Frame lbs) (Torque to 13-ft/lbs) these Mounting Holes these Mounting Holes 16-inch 18-inch Deep Flip- Locknuts Deep Flip- up Seat up Seat Locknuts Plate Plate Mounting Screws *Fixed...
  • Page 31 SEAT FRAME SECTION 6 INSTALLING (FIGURES 3 AND 4) Part No. 1110516 XTERRA™ GT™...
  • Page 32 SECTION 6 SEAT FRAME REMOVING/INSTALLING SEAT FRAME FOR 17 AND 18- INCH SEAT WIDTHS REMOVING (FIGURES 5 AND 6) CJ Back Bracket Washer Torque to 75-in./lbs. Locknut FIGURE 5 - REMOVING SEAT FRAME (17 AND 18-INCH SEAT WIDTHS) XTERRA™ GT™ Part No.
  • Page 33 SEAT FRAME SECTION 6 Mounting Screws Adjustable Mounting Standard (Torque to Seat Frame Screws Seat Frame 13 ft/lbs) (Torque to 13 ft/lbs) Use these Mounting Holes these Mounting Holes 16-inch 18-inch Deep Flip- Locknuts Deep Flip- up Seat up Seat Locknuts Plate Plate...
  • Page 34 SECTION 6 SEAT FRAME INSTALLING (FIGURES 5 AND 6) XTERRA™ GT™ Part No. 1110516...
  • Page 35 SEAT FRAME SECTION 6 REMOVING/INSTALLING SEAT FRAME FOR 19 AND 20- INCH SEAT WIDTHS REMOVING (FIGURES 7 AND 8) CJ Back Bracket Washer Torque to 75-in./lbs. Locknut FIGURE 7 - REMOVING SEAT FRAME (19 AND 20-INCH SEAT WIDTHS) Part No. 1110516 XTERRA™...
  • Page 36 SECTION 6 SEAT FRAME Mounting Standard Standard Mounting Screws Seat Frame Seat Frame Screws (Torque (Torque to 156-inch to 156-inch pounds) pounds) 3/4-inch Tube Spacers Use these Mounting these Holes Mounting Holes 16-inch 18-inch Deep Flip- Deep Flip- up Seat up Seat Locknuts Plate...
  • Page 37 SEAT FRAME SECTION 6 INSTALLING SEAT FRAME FOR 19 AND 20-INCH SEAT WIDTHS (FIGURES 7 AND 8) Part No. 1110516 XTERRA™ GT™...
  • Page 38 SECTION 6 SEAT FRAME CHANGING SEAT DEPTH - FIXED SEAT FRAME AND ADJUSTABLE SEAT FRAME FIXED SEAT FRAME COMPONENT IDENTIFICATION TABLE FOR STANDARD SEAT FRAME SEAT FRAME COMPONENTS CJ BACK SEAT SEAT BRACKETS SEAT FRAME DEPTH REQUIRED DEPTH 14-inches 17-inch 16-inch deep 15-inches 16-inches...
  • Page 39 SEAT FRAME SECTION 6 DECREASING SEAT DEPTH INCREASING SEAT DEPTH Part No. 1110516 XTERRA™ GT™...

  • Page 40: Removing/Installing Cj Back Brackets

    SECTION 6 SEAT FRAME PREPARATIONS REMOVING/INSTALLING CJ BACK BRACKETS (FIGURE 9) Removing. Installing. WARNING Always wear your seat positioning strap. XTERRA™ GT™ Part No. 1110516...
  • Page 41 SEAT FRAME SECTION 6 Mounting Seat CJ Back Screw Positioning Bracket Strap Back Threaded Angle Studs Plate Washers Locknuts (Torque to 75-in./lbs.) Seat Quick Release Locknut FIGURE 9 - REMOVING/INSTALLING CJ BACK BRACKETS REMOVING/INSTALLING SEAT PAN (FIGURE 10) Removing. Installing. Part No.
  • Page 42 SECTION 6 SEAT FRAME Mounting Screws Seat Seat Positioning Strap Spacer Seat Frame Locknut Locknut Quick Release Pin FIGURE 10 - REMOVING/INSTALLING SEAT PAN RE-ASSEMBLING THE CHAIR XTERRA™ GT™ Part No. 1110516...
  • Page 43 SEAT FRAME SECTION 6 ADJUSTABLE SEAT FRAME (FIGURE 11) COMPONENT IDENTIFICATION TABLE FOR STANDARD SEAT FRAME SEAT FRAME COMPONENTS CJ BACK SEAT BRACKETS SEAT SIDE CENTER DEPTH REQUIRED FRAME FRAME 14-inches 17-inch Short Short 15-inches 16-inches 16-inch Short Short 17-inches 17-inch Short Short...
  • Page 44 SECTION 6 SEAT FRAME Mounting Screws (Torque to 13 ft/lbs) (Typ all four (4) screws) Mounting Screws (Torque to 75- inch pounds) Side Frame Coved Washers Spacers Locknuts Side Frame Center Frame Spacers CHANGING SEAT WIDTH Locknuts FIGURE 11- CHANGING SEAT DEPTH - ADJUSTABLE SEAT FRAME XTERRA™...
  • Page 45 SEAT FRAME SECTION 6 CHANGING SEAT DEPTH BETWEEN 14 AND 15-INCHES (FIGURE 12) Coved Washers Back Cane CJ Back Bracket Mounting Threaded Screws Insert Seat Frame Washers FIGURE 12 - ADJUSTING SEAT DEPTH - CHANGING SEAT DEPTH BETWEEN 14 AND 15-INCHES CHANGING SEAT WIDTH OF FIXED SEAT FRAMES (16, 17, 18, 19, AND 20-INCH WIDE) Part No.
  • Page 46 SECTION 6 SEAT FRAME CHANGING SEAT WIDTH OF ADJUSTABLE SEAT FRAMES (14, 15, AND 16-INCH WIDE) (FIGURES 13 AND 14) CJ Back Washer Bracket Locknut Seat Frame FIGURE 13 - REMOVING/ INSTALLING SEAT FRAME FOR 14 AND 15-INCH SEAT WIDTHS XTERRA™...
  • Page 47 SEAT FRAME SECTION 6 DETAIL “A” ALLOWABLE SEAT WIDTH AND DEPTH COMBINATIONS FOR ADJUSTABLE SEAT FRAME 14-inches 15-inches 16-inches STEPS 3-6 Side Coved Frame Mounting Washers Screws Side Center Frame Spacers Frame Locknut FIGURE 14 -CHANGING SEAT WIDTH - ADJUSTABLE SEAT FRAME Part No.
  • Page 48 SECTION 6 SEAT FRAME COMPONENT REPLACEMENT FOR 14-INCH, 15-INCH, AND 16-INCH SEAT FRAMES (ADJUSTABLE SEAT FRAME) (FIGURE 15) XTERRA™ GT™ Part No. 1110516...
  • Page 49 SEAT FRAME SECTION 6 REPLACING ONE (1) SIDE FRAME Mounting Screws (Torque to 13 ft/lbs) (Typical all four (4) screws) Mounting Screws (Torque to 75- inch pounds) Side REPLACING BOTH SIDE FRAMES Frame Coved Washers Spacers Locknuts Side Frame Center Frame Spacers REPLACING CENTER FRAME...
  • Page 50 SECTION 6 SEAT FRAME INSTALLING/REMOVING VAN STYLE SEAT/SEAT FRAME ASSEMBLY ONTO/ FROM FLIP-UP SEAT PLATE (FIGURE 16) Van Style Seat REMOVING Mounting Screws Seat Frame (Torque to 13 Assembly ft/lbs.) Flip-Up Seat Plate INSTALLING Locknuts FIGURE 16 - REMOVING/ INSTALLING VAN STYLE SEAT/ SEAT FRAME ASSEMBLY XTERRA™...
  • Page 51 SEAT FRAME SECTION 6 INSTALLING/REMOVING VAN STYLE SEAT ONTO/FROM SEAT FRAME ASSEMBLY (FIGURE 17) REMOVING INSTALLING Style Seat Seat Frame Assembly Washer Spacers Mounting Screws FIGURE 17 - INSTALLING/REMOVING VAN STYLE SEATONTO/ FROM SEAT FRAME ASSEMBLY Part No. 1110516 XTERRA™ GT™...
  • Page 52 SECTION 7 BASE FRAME This Section Includes the Following: Removing/Installing Port Bracket Removing/Installing Flip-up Seat Plate Removing/Installing Battery Tray Removing/Installing Adjustment Bracket Replacing Components of Flip-up Seat Removing/Installing Front/Rear Shrouds Plate - Changing from 3 tilt to 0 tilt Removing/Installing Torsion Bar WARNING REMOVING/INSTALLING FLIP-UP SEAT PLATE (FIGURE 1) REMOVING...
  • Page 53 BASE FRAME SECTION 7 Spring 7/8-inch dia. Washer Washer Bushing 3/8 x 1-3/4-inch 7/8-inch dia. Mounting Washer Screw Bushing Spring Washer 3/8 x 1-inch Mounting Screw 3/8-inch dia. Seat Prop Washers 3/8-inch dia. 3/8 x 1-inch Washers Mounting Screw 5/8-inch Adjustment dia.
  • Page 54 SECTION 7 BASE FRAME REMOVING/INSTALLING ADJUSTMENT BRACKET (FIGURE 2) REMOVING INSTALLING 3/8-inch dia Left Adjustment Locknut Washer 3/8-3/4-inch Bracket Mounting Screw 3/8-inch dia Washer 5/8-inch dia Washer ADJUSTMENT BRACKET FOR 14-17-INCH Locknut SEAT DEPTHS 5/8-inch dia Washer Right Adjustment Bracket FOR 19-20-INCH SEAT DEPTHS FIGURE 2 - REMOVING/INSTALLING ADJUSTMENT BRACKET...
  • Page 55 BASE FRAME PROCEDURE 7 REMOVING/INSTALLING THE FRONT AND REAR SHROUDS (FIGURE 3) REMOVING 1. Remove the two (2) mounting screws and washers that secure the front or rear shroud to the base frame. 2. Remove shroud. INSTALLING 1. Position shroud in place and secure with two (2) mounting screws and washers. Torque mounting screws to 40-in./lbs.
  • Page 56 SECTION 7 BASE FRAME REMOVING/INSTALLING TORSION BAR (FIGURE 4) Definition: The torsion bar serves two purposes 1.) it keeps the right and left suspension arms in alignment and 2.) provides a more defined driving performance. REMOVING DETAIL “A” 1. Because of the tight tolerance, removing the hitch pin clip from both ends of the torsion bar must be performed by the following: A.
  • Page 57 BASE FRAME SECTION 7 REMOVING/INSTALLING PORT BRACKET (FIGURE 5) REMOVING 1. Remove the batteries. Refer to REMOVING/INSTALLING BATTERIES in SECTION 8 of this manual. 2. Remove the front shroud. Refer to REMOVING/INSTALLING FRONT AND REAR SHROUDS in this section of the manual. 3.
  • Page 58 SECTION 7 BASE FRAME REMOVING/INSTALLING BATTERY TRAY (FIGURE 6) REMOVING 1. Remove the batteries. Refer to REMOVING/INSTALLING BATTERIES in SECTION 8 of this manual. 2. Remove the seat. Refer to REMOVING/INSTALLING SEAT FRAME in SECTION 6 of this manual. 3. Remove the front shroud. Refer to REMOVING/INSTALLING FRONT AND REAR SHROUD in this section of the manual.
  • Page 59 BASE FRAME SECTION 7 REPLACING COMPONENTS OF THE FLIP-UP SEAT PLATE AND/OR CHANGING FROM 3 TILT TO 0 TILT AND VICE VERSA (FIGURE 7) 1. Remove the batteries. Refer to REMOVING/INSTALLING BATTERIES in SECTION 8 of this manual. 2. Remove the seat. Refer to REMOVING/INSTALLING SEAT FRAME in SECTION 6 of this manual.
  • Page 60 SECTION 7 BASE FRAME 19. If a NEW flip-up seat plate is being used with a different seat depth, then perform the following: (DETAIL”A”) A. Remove the mounting screw, small washer, two (2) large washers that secures the prop seat bracket to the prop threaded plate. B.
  • Page 61 BASE FRAME SECTION 7 CHART A RELEASE HANDLE SPRING Use this mounting Use this mounting Hook hole for 0 tilt hole for 0 tilt Release Assembly Use this mounting Use this mounting hole for 3 tilt hole for 3 tilt Handle Release Bracket (Orientationfor 3 tilt)
  • Page 62 The use of rubber gloves and chemical goggles is recommended when working with batteries. Invacare strongly recommends that battery installation and battery replace- ment always be done by a qualified technician. After ANY adjustments, repair or service and BEFORE use, make sure all attaching hardware is tightened securely - otherwise injury or damage may result.
  • Page 63 BATTERIES SECTION 8 Release Lever Seat Prop Battery Retention Strap Battery Disconnect FIGURE 1 - REMOVING/INSTALLING BATTERIES INSTALLING (FIGURE 2) 1. Install the rear battery into the base frame in the orientation shown in DETAIL “B” in FIGURE 2 . 2.
  • Page 64 SECTION 8 BATTERIES DETAIL “A” Front Battery DETAIL “B” Rear Battery FIGURE 2 - REMOVING/INSTALLING BATTERIES XTERRA™ GT™ Part No. 1110516...
  • Page 65 BATTERIES SECTION 8 DISCONNECTING BATTERY CABLES (FIGURE 3) WARNING 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 chemical goggles is recommended when working with batteries.
  • Page 66 SECTION 8 BATTERIES DEATIL “A” - DIRECT MOUNT DETAIL “B” - BATTERY CLAMP METHOD METHOD Terminal Cap Installation Terminal Cover Installation NEGATIVE (-) POSITIVE (+) Battery RED Battery POSITIVE (+) Battery Battery Terminal/ Battery Clamp Cover Tie- Terminal/Post Terminal/ Post Terminal Wrap Post...

  • Page 67: Connecting Battery Cables

    BATTERIES SECTION 8 CONNECTING BATTERY CABLES WARNING 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 chemical goggles is recommended when working with batteries.
  • Page 68 SECTION 8 BATTERIES 6. Secure each terminal cap in place with a tie-wrap (Use tie-wraps 11-1/2-inches long). NOTE: It will be necessary to trim excess tie-wrap in order to install the battery box top(s). 7. Install the battery with lid into the wheelchair. Refer to INSTALLING/REMOVING BAT- TERIES in this procedure.
  • Page 69 BATTERIES SECTION 8 BATTERY CLAMP METHOD (FIGURES 6, 7 AND 8). CAUTION The battery clamps MUST be mounted in the positions shown in FIGURE 6, otherwise the battery box top cannot be installed properly. 1. Perform one (1) of the following: A.
  • Page 70 SECTION 8 BATTERIES CAUTION When connecting the battery cable/ring terminal(s) to the battery(ies) clamp(s), the battery cable(s) MUST be connected in the position shown in DETAIL “A” of FIGURE 8, otherwise damage may occur to the battery cable and/or battery clamp covers. 3.

  • Page 71: Top View

    BATTERIES SECTION 8 CONNECTING BATTERY CABLE(S) TO BATTERY(IES) TERMINAL(S)/ POST(S) 22NF Battery POSITIVE (+) Battery Terminal/Post and Battery Clamp NEGATIVE (-) Battery Terminal/Post and Battery Clamp Negative (-) BLACK Positive (+) RED Battery Cable Battery Cable TOP VIEW Fuse Box Positive (+) RED Battery Cable Battery Clamp...
  • Page 72 SECTION 8 BATTERIES WHEN TO CHARGE BATTERIES (FIGURE 9) The Battery Discharge Indicator (BDI) is a bar graph display located on the MKIV joystick. It will keep you informed as to power availability. A visual warning is given before the power becomes too low to operate the wheelchair.

  • Page 73: Description And Use Of Battery Chargers

    NEVER leave the charger unattended when the charger circuit breaker is tripping ON and OFF. A condition between the battery charger and batteries exists. Unplug immediately. Contact an Invacare dealer. NOTE: If performing the charging procedures independently, READ and CAREFULLY follow the indi- vidual instructions for each charger (supplied or purchased).

  • Page 74: Cleaning Battery Terminals

    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 Invacare dealer for service. Front View of...

  • Page 75: Electronics Section

    ELECTRONICS SECTION 8 This Procedure Includes the Following: Installing/Removing MKIV-A Wiring Harness Installing/Removing MKIV-RII Wiring Harness Installing/Removing MKIV-A Joystick Installing/Removing MKIV-RII Joystick REMOVING/INSTALLING MKIV-A WIRING HARNESS (FIGURE 1) REMOVING 1. Review DETAIL “A” in FIGURE 1 and identify each connector. 2.
  • Page 76 SECTION 9 ELECTRONICS DETAIL “A” - IDENTIFYING DETAIL “B” BATTERY WIRING HARNESS CONNECTORS To Battery To Battery Front Power Shroud Take-Off Lead Washer Washer Battery Charger Port RII Controller Locknuts To Controller Washer Blue Connector Mounting Screws (Torque to 40-in/lb.) DETAIL “C”...
  • Page 77 ELECTRONICS SECTION 9 REMOVING/INSTALLING THE MKIV-RII WIRING HARNESS (FIGURE 2) REMOVING 1. Review DETAIL “A” in FIGURE 12 and identify each battery wiring harness connector. 2. Remove the batteries. Refer to REMOVING/INSTALLING BATTERIES in SECTION 8 of this manual. 3. Remove the two (2) mounting screws and washers that secure the front shroud in place. Refer to DETAIL “A”...
  • Page 78 SECTION 9 ELECTRONICS DETAIL “A” -IDENTIFYING DETAIL “B” BATTERY WIRING HARNESS CONNECTORS Front To Batteries To Batteries Shroud Washer Washer RII Controller Locknuts Washer Mounting Screws (Torque to 40-in/lb.) To Controller DETAIL “C” Battery Wiring Harness Blue Connector Cut-out in Battery Tray Controller Connector FIGURE 2 - REMOVING INSTALLING THE MKIV WIRING HARNESS XTERRA™...
  • Page 79 ELECTRONICS SECTION 9 REMOVING/INSTALLING THE MKIV-A JOYSTICK NOTE: The instructions outlined below are for the removal/installation of the MKIV-A joystick on an ASBA seat. For additional views of other MKIV mounting options see FIGURE 3. REMOVING (FIGURE 4) 1. Remove the batteries. Refer to REMOVING/INSTALLING BATTERIES in SECTION 8 of this manual.
  • Page 80 ELECTRONICS SECTION 9 9. Cables are to be routed between battery box and compression spring. This can be accomplished by lifting wire harness wrap up in between suspension arm, battery box, and controller (DETAIL “B”). NOTE: Wire harness wrap to be secured against battery tray with tie-wrap so as to provide clearance between wire harness wrap and compression springs.
  • Page 81 ELECTRONICS SECTION 9 DETAIL “A” - FRONT VIEW Joystick Connector Tie-Wrap Battery Tray Wire Harness Wrap Right Controller Right Connector Motor Lead Controller DETAIL “B” - TOP VIEW OF RIGHT DETAIL “C” SIDE OF CHAIR This area is to be used Tie-Wraps to feed the motor lead (STEP 9)
  • Page 82 SECTION 9 ELECTRONICS REMOVING/INSTALLING THE MKIV-RII JOYSTICK (FIGURES 5 AND 6) NOTE: The instructions outlined below are for the removal/installation of the MKIV-RII joystick with offset mounting tube on an ASBA seat. For additional views of other mkiv-RII joystick mounting options see FIGURE 7.
  • Page 83 ELECTRONICS SECTION 9 VAN SEAT ASBA SEAT WITH QUAD LINK JOYSTICK MOUNTING VAN SEAT WITH QUAD LINK JOYSTICK MOUNTING FIGURE 6 - TIE-WRAP LOCATIONS FOR OTHER MKIV-RII JOYSTICK MOUNTING OPTIONS Part No. 1110516 XTERRA™ GT™...
  • Page 84 SECTION 9 ELECTRONICS REMOVING/INSTALLING THE MKIV-A CONTROLLER (FIGURE 7) REMOVING 1. Remove the batteries. Refer to REMOVING/INSTALLING BATTERIES in SECTION 8 of this manual. 2. Remove the two (2) mounting screws and washers that secure the front shroud in place. Refer to DETAIL “A”...
  • Page 85 ELECTRONICS SECTION 9 DETAIL “A” Washer *Controller Locknuts Front Shroud Washer Mounting Screws *NOTE: MKIV-RII controller shown. MKIV-A con- (Torque to 40-in/ troller removes and installs in the same manner. lb.) Washer DETAIL “B” FRONT VIEW Locknut Programmer Blue Wiring Harness Extension Connector Washer...
  • Page 86 SECTION 9 ELECTRONICS REMOVING/INSTALLING THE MKIV-RII CONTROLLER REMOVING (FIGURES 8 AND 9) 1. Remove the batteries. Refer to REMOVING/INSTALLING BATTERIES in SECTION 8 of this manual. 2. Remove the two (2) mounting screws and washers that secure the front shroud in place. Refer to DETAIL “A”...
  • Page 87 ELECTRONICS SECTION 9 DETAIL “B” - IDENTIFYING MKIV- DETAIL “A” RII CONTROLLER CONNECTORS Battery Wire Harness Power Take-Off Connector Lead Motor Front Connector Shroud Washer RII Controller Washer RII Controller Motor Locknuts Connector Washer Controller Connector Mounting Screws Lead for Joystick (Torque to 40-in/lb.) DETAIL “D”...
  • Page 88 SECTION 9 ELECTRONICS DETAIL “A” Right Motor Connector Left Motor Connector Left Controller Connector Wraps Right Controller Connector Tie-Wraps DETAIL “B” Blue Controller Connector Power Take-Off Lead Wrap Controller Connector FIGURE 9 - REMOVING/INSTALLING THE MKIV-RII CONTROLLER XTERRA™ GT™ Part No. 1110516...
  • Page 89 ELECTRONICS SECTION 9 INSTALLING 1. Position the MKIV-RII controller on the front of the battery tray as shown in DETAIL “A” in FIGURE 9. 2. Secure the MKIV-RII controller to the battery tray with the two (2) washers and lock- nuts (Detail “A”...

  • Page 90: Removing/Installing Drive Wheel Hub

    SECTION 10 MOTORS/WHEELS This Procedure Includes the Following: Removing/Installing Drive Wheel Removing/Installing Drive Wheel Hub Removing/Installing Motor Removing/Installing Motor/Gearbox, Suspension Arm Assembly, Suspension Spring Hardware Removing/Installing Casters REMOVING/INSTALLING DRIVE WHEEL (FIGURE 1) REMOVING 1. Remove the batteries. Refer to REMOV- Motor/Gearbox ING/INSTALLING BATTERIES in Assembly...
  • Page 91 MOTORS/WHEELS SECTION 10 REMOVING/INSTALLING MOTOR (FIGURE 3) REMOVING 1. If necessary, the seat and/or the drive wheels can be removed to make this procedure easier. Refer to REMOVING/INSTALLING DRIVE WHEEL in this section or REMOV- ING/INSTALLING SEAT FRAME in SECTION 6 of this manual. 2.
  • Page 92 SECTION 10 MOTORS/WHEELS INSTALLING (FIGURE 3) WARNING Wiring MUST be routed and secured properly to ensure that wiring does NOT be- come entangled and damaged during normal operation of wheelchair operation. 1. Perform the following: A. Inspect the coupling for wear and damage. If damage is evident, replace coupling. B.
  • Page 93 MOTORS/WHEELS SECTION 10 Tie -Wrap DETAIL “A” (STEP 6) Tie -Wrap (STEP 8) Tie -Wrap (STEP 7) Motor Mount Tie -Wrap (STEP 5) Tie -Wrap (STEP 4) Sensor Cable TOP VIEW OF BASE FRAME Motor Cable DETAIL “B” - FRONT VIEW OF BASE FRAME DETAIL “C”...
  • Page 94 SECTION 10 MOTORS/WHEELS REMOVING/INSTALLING MOTOR/GEARBOX, SUSPENSION ARM ASSEMBLY, AND SUSPENSION SPRING HARDWARE REMOVING (FIGURE 4) NOTE: This procedure will require a 5-inch mounting screw (with 1-1/2-inches of thread), fender washer, and locknut. 1. Remove the batteries. Refer to REMOVING/INSTALLING BATTERIES in SECTION 8 of this manual.
  • Page 95 MOTORS/WHEELS SECTION 10 NOTE: Note that after performing STEPS 8 and 9 that the suspension spring hardware will come off with the suspension arm assembly. Save for reinstallation of motor/gearbox assembly. 8. Remove the pivot pin, washer and locknut that secures the front of the motor mount and suspension arm to the base frame.

  • Page 96: Assembled View

    SECTION 10 MOTORS/WHEELS E. Tighten locknut down, drawing spring upward, until there is a space wide enough between retainer and suspension arm weldment to slide in lower retainer. F. Once lower retainer is installed, remove mounting screw, washers and locknut. Spring is contained within weldments of base frame crossmember and suspension arm.
  • Page 97 MOTORS/WHEELS SECTION 10 REMOVING/INSTALLING CASTERS (FIGURE 7) REMOVING 1. Remove the two (2) mounting screws and locknuts that secure the hub cab onto the caster. 2. Remove the locknut and washers that secures the caster to the fork. 3. Remove caster. INSTALLING 1.
  • Page 98 NOTES NOTES XTERRA™ GT™ Part No. 1110516...

  • Page 99: Warranty

    WARRANTY LIMITED WARRANTY Part No. 1110516 XTERRA™ GT™...
  • Page 100 Invacare Corporation Canada Invacare is a registered trademark of One Invacare Way 570 Matheson Blvd E. Invacare Corporation. Elyria, Ohio USA Unit 8 Mississauga, Ontario Yes, you can., Xterra, GT, and MKIV 44035-4190 L4Z 4G4, Canada are trademarks of Invacare Corporation.

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