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Invacare Power 9000 Service Manual

Invacare wheelchair service manual
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Service Manual
Excel and P9000

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Summary of Contents for Invacare Power 9000

  • Page 1 Service Manual Excel and P9000...

  • Page 2: Special Notes

    THE INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE. WHEELCHAIR USER As a manufacturer of wheelchairs, Invacare endeavors to supply a wide variety of wheelchairs to meet many needs of the end user. However, final selection of the type of wheelchair to be used by an individual rests solely with the user and his/her healthcare professional capable of making such a selection.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS The following procedures refer to POWER 9000 and EXCEL wheelchairs except where specified. SPECIAL NOTES ......... 2 REPLACING SEAT POSITIONING STRAP .... 23 REPLACING CAPTAIN'S SEAT ......23 SPECIFICATIONS ........4 REPOSITIONING MKIV JOYSTICK PROCEDURE 1 - GENERAL GUIDELINES ..

  • Page 4: Specifications

    SPECIFICATIONS SPECIFICATIONS NOTE: All specifications are EXCEL approximate. INTEGRATED SLING SEAT CAPTAIN'S SEAT BACK TYPE LOW SOLID SEAT HIGH (LOB) (LOBSS) (HIB) Seat Width Range: 16, 18 or 20-in. 19-in. 19-in. 19-in. Seat Depth Range: 16, 17 or 18-in. - In 1-in. increments 17-in.
  • Page 5 SPECIFICATIONS SPECIFICATIONS POWER 9000 NOTE: All specifications are approximate. Seat Width Range: 14, 16, 18 or 20-in. - ADULT FRAME 16, 18 or 20-in. - LOW SEAT FRAME Seat Depth Range: 16, 17 or 18-in. (17 and 18-in. by extension) Back Height Range Standard: 16, 17, 18, 19 or 20-in.

  • Page 6: Procedure 1 General Guidelines

    DO NOT remove these tags. BATTERIES The warranty and performance specifications contained in this manual are based on the use of deep cycle gel cell or sealed lead acid batteries. Invacare strongly recom- mends their use as the power source for this unit.

  • Page 7: Procedure 2 - Troubleshooting

    If the caps of the battery cells are removed, NEVER look directly into NOTE: Invacare recommends that ONLY qualified ser- them when charging the battery. vice personnel perform this test. The use of rubber gloves and safety 1.

  • Page 8: Motor Testing

    A reading of 0 ohms ( Ω ) or in excess of 15 ohms ( Ω ) Number of Floating Balls indicates a problem. High readings are generally caused Discharged by bad connections and/or damaged brushes. Contact 25% Charged authorized dealer or Invacare. 50% Charged 75% Charged 100% Charged Overcharged * Check charging system.

  • Page 9: Motor Brush Inspection

    If either with the commutator. 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.

  • Page 10: Procedure 3 Upholstery

    PROCEDURE 3 UPHOLSTERY This Procedure Includes the Following: Back Upholstery Washer Replacing Back Upholstery WARNING After ANY adjustments, repair or service and BEFORE use, make sure that all attaching hardware is tightened securely - otherwise injury or damage may result. Phillips Screw REPLACING BACK UPHOLSTERY...

  • Page 11: Procedure 4 - Seat Frame

    SEAT FRAME PROCEDURE 4 ADJUSTING BACK HEIGHT/ This Procedure Includes the Following: REPLACING BACK CANES Adjusting Seat Depth (FIGURE 2) Adjusting Back Height /Replacing Back Canes 1. Remove the four (4) hex screws, washers and locknuts that secure the two (2) back canes to the WARNING wheelchair frame.

  • Page 12: Procedure 5 - Electronics

    PROCEDURE 5 ELECTRONICS REPOSITIONING MKIV JOYSTICK This Procedure Includes the Following: (FIGURE 2) Preparing MKIV Joystick for Use Repositioning MKIV Joystick 1. Turn the lever on the adjustment lock to release the adjustment lock from joystick mounting tube (tube). 2. Remove the joystick from the wheelchair. WARNING 3.

  • Page 13: Procedure 6 - Wheels

    Washer If tires are pneumatic, replacement of tire or tube MUST be performed by an Invacare dealer or qualified technician. NOTE: If drive wheels or casters are pneumatic, under-inflation causes excessive wear which results in Washer poor performance of the tires.

  • Page 14: Replacing Casters

    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 7.

  • Page 15: Procedure 7 - Batteries

    1. If necessary, remove the battery boxes from the is recommended when working with wheelchair. Refer to INSTALLING/REMOVING batteries. BATTERY BOXES in PROCEDURE 8 - FWD or Invacare strongly recommends that battery PROCEDURE 9 - RWD of this manual. installation battery replacement 2.

  • Page 16: Connecting Battery Cables

    PROCEDURE 7 BATTERIES CONNECTING BATTERY CABLES CAUTION When connecting the battery cables to the WARNING battery(ies), the battery cable(s) MUST be NEVER allow any of your tools and/or connected to the battery terminal(s)/post(s) battery cable(s) to contact BOTH battery as shown in DETAIL “A” or DETAIL “B” of terminal(s)/post(s) at the same time.
  • Page 17 BATTERIES PROCEDURE 7 DETAIL “A” DETAIL “B” DUAL 22NF BATTERIES DUAL U1 BATTERIES POSITIVE (+) Battery Terminal/Post 1/4-20 x 7/8-Inch Negative (-) Hex Flange Screw 1/4-20 x 7/8-Inch Battery Terminal/ POSITIVE (+) Red Hex Flange Screw Post Battery Cable 1/4-20 Hex Flange U1 Battery Locknut...
  • Page 18 PROCEDURE 7 BATTERIES 2. Install battery clamp covers onto battery cables as Battery Clamp Method (FIGURES 4, 5 and 6). follows (FIGURE 5): WARNING A. RED battery clamp cover onto RED battery cable. The battery clamp of the POSITIVE (+) B.
  • Page 19 BATTERIES PROCEDURE 7 9. Install the battery box(es) into the wheelchair. Refer to 10. If necessary, charge the battery(ies). Refer to INSTALLING/REMOVING BATTERY BOX(ES) in the CHARGING BATTERIES in the PROCEDURE PROCEDURE 8 - FWD MODELS or PROCEDURE 8 - FWD MODELS or PROCEDURE 9 - RWD 9 - RWD MODELS of this manual.

  • Page 20: Procedure 8 - Fwd Wheelchairs

    Extreme caution is advised when it is neces- Disconnecting/Connecting Limit Switch sary to move an UNOCCUPIED power wheel- Adjusting Limit Switch chair. Invacare recommends using two (2) assis- tants and making thorough preparations. Make Removing/Installing Shrouds sure to use ONLY secure, non-detachable parts Changing Seat Width - Integrated Sling Seats for hand-hold supports.

  • Page 21: Adjusting Flip-Up Removable Footboard

    FWD WHEELCHAIRS PROCEDURE 8 2. Remove the Captain's Seat. Refer to REMOVING/ FOLDING. INSTALLING CAPTAIN'S SEAT in PROCEDURE 9 1. Remove the batteries and footrests/legrests from of the owner's manual, part number 1080737. the wheelchair. Refer to FIGURE 1. 3. Remove the shrouds. Refer to REMOVING/INSTALL- 2.

  • Page 22: Replacing Armrest Pads

    PROCEDURE 8 FWD WHEELCHAIRS 6. Torque the two (2) hex screws to 156-in/lbs. REPLACING ARMREST PADS 7. Reinstall the two (2) caplug caps. (FIGURE 5) Wheelchair Frame 1. Remove the mounting screws that secures the front of the armrest pad to the armrest plate. Bushing 2.

  • Page 23: Replacing Seat Positioning Strap

    FWD WHEELCHAIRS PROCEDURE 8 5. Position the mounting holes in the two (2) new seat Armrest Plate Armrest Pad positioning strap halves with the mounting holes in the Armrest Insert Lug Bolt seat frame assembly. 6. Reinstall the two (2) hex bolts, washers and locknuts Locknuts that secure the seat positioning strap to the seat frame Phillips Screw...

  • Page 24: Removing/Installing Mkiv Controller

    PROCEDURE 8 FWD WHEELCHAIRS 3. Remove the three (3) hex bolts, spacers and locknuts 17. Install the three (3) hex bolts, spacers and locknuts that secure joystick mounting bracket to armrest plate. that secure joystick mounting bracket to armrest plate. 4.

  • Page 25: Replacing Wiring Harness

    PROCEDURE 8 FWD WHEELCHAIRS 6. Remove the two (2) phillips bolts and locknuts that REPLACING WIRING HARNESS secure the front battery connector to wheelchair frame. (FIGURE 11) 7. Remove the two (2) phillips screws that secure the 1. If necessary, remove the front and rear shrouds. wiring harness to the charger cable mounting bracket.

  • Page 26: Disconnecting/Connecting Limit Switch

    PROCEDURE 8 FWD WHEELCHAIRS C. Connect the limit switch. Refer to DISCONNECT- ADJUSTING LIMIT SWITCH ING/CONNECTING LIMIT SWITCH in this (FIGURE 13) procedure of the manual. NOTE: The following procedure is for High Back Captain's 17. Reinstall the battery boxes. Refer to INSTALLING/ seat model wheelchairs only.

  • Page 27: Removing/Installing Shrouds

    FWD WHEELCHAIRS PROCEDURE 8 Back Recline Angle 5-3/4 inches Upper Limit Switch Bracket Phillips Screws, Washers Magnetic Protractor - Seat Angle and Lock- (Will read 61 when back nuts recline angle is at 114 relative to the seat Actuator frame) FIGURE 13 - ADJUSTING LIMIT SWITCH REMOVING/INSTALLING SHROUDS Removing Side Shrouds and Fillers...
  • Page 28 PROCEDURE 8 FWD WHEELCHAIRS Installing Side Shrouds and Fillers B. Reinstall the phono jack nut onto the phono jack and tighten securely. 1. Position side shroud and filler on the wheelchair frame. 6. Perform one (1) of the following: 2. Line up the mounting holes in the side shroud and A.

  • Page 29: Changing Seat Width - Integrated Sling Seats

    FWD WHEELCHAIRS PROCEDURE 8 CHANGING SEAT WIDTH - 4. Remove the existing back and seat upholstery from the wheelchair. Refer to REPLACING BACK UPHOL- INTEGRATED SLING SEATS STERY in PROCEDURE 5 of this manual and (FIGURE 15) REPLACING SEAT UPHOLSTERY in PROCEDURE 5 of the owner's manual, part number 1080737.

  • Page 30: Replacing Crossbraces - Captain's Seat

    PROCEDURE 8 FWD WHEELCHAIRS 6. Remove the dust covers from the bottom of the REPLACING CROSSBRACES - crossbraces. CAPTAIN'S SEAT (FIGURE 16) NOTE: Note position of the tie wraps that secure the wiring harness to the crossbraces. 1. Remove the captain's seat from the wheelchair. Refer to REMOVING/INSTALLING CAPTAIN'S SEAT 7.
  • Page 31 FWD WHEELCHAIRS PROCEDURE 8 20. Reinstall the battery boxes onto the wheelchair. 17. Reinstall the hex bolts, spacers, washers and Refer to INSTALLING/REMOVING BATTERY locknuts that secure the (2) push brackets to the new BOXES in this procedure of the manual. crossbraces and tighten securely.

  • Page 32: When To Charge Batteries

    FWD WHEELCHAIRS PROCEDURE 8 WHEN TO CHARGE BATTERIES Description and Use of Battery Chargers (FIGURE 17) The charger automatically reduces the charge from an initially high rate to a zero reading at a fully charged It is advantageous to recharge frequently rather than only condition.

  • Page 33: Replacing Batteries

    NOTE: When done, these areas should be shiny, not dull. or damage can occur. 4. Carefully dust off all metal particles. NOTE: Invacare recommends that both batteries be replaced if one (1) battery is defective. INSTALLING/REMOVING BATTERY Recommended Battery Types...

  • Page 34: Battery Tray

    PROCEDURE 8 FWD WHEELCHAIRS 2. Lift up on the pin side of the battery tray and rotate UP WARNING towards the battery tray pivot. The Battery Box Retaining Strap MUST be fastened securely and adjusted properly to hold battery 3. Fold the wheelchair. Refer to ASSEMBLING EXCEL boxes in place before using the wheelchair.
  • Page 35 FWD WHEELCHAIRS PROCEDURE 8 Battery Tray Pin Battery Tray Hanger Bracket Washers Battery Tray Hex Bolts Locknuts Battery Tray Pivot Hex Bolts 16-inch Wheelchair Locknuts 18-inch Wheelchair 20-inch Wheelchair Battery Tray FIGURE 23 - BATTERY TRAY - REMOVING/ INSTALLING BATTERY TRAY Replacing Right Battery Tray Hanger Bracket FIGURE 22 - BATTERY TRAY - CHANGING WIDTH OF (FIGURE 24)

  • Page 36: Repositioning Motors

    PROCEDURE 8 FWD WHEELCHAIRS B. WHEELCHAIR NOT EQUIPPED WITH FLIP-UP 7. Perform one (1) of the following: REMOVABLE FOOTBOARD - Reinstall the front A. WHEELCHAIR EQUIPPED WITH FLIP-UP hex screw that secures the new right battery tray REMOVABLE FOOTBOARD - Reinstall the hex hanger bracket to the wheelchair frame.
  • Page 37 FWD WHEELCHAIRS PROCEDURE 8 NOTE: If motors are repositioned, the front riggings may STEPS 2, 4, 10, 11, 12 Spacers need to be repositioned. Refer to ADJUSTING/REPLAC- Dust Cover (Not Shown) ING TELESCOPING FRONT RIGGING SUPPORT in PROCEDURE 9 of the owner's manual, 1080737. Battery Tray Hanger FACTORY SETTINGS...

  • Page 38: Replacing Clutch Handles

    PROCEDURE 8 FWD WHEELCHAIRS 9. Connect the clutch handle to the motor/gearbox and CAUTION line up the mounting holes in the clutch handle and The longer socket screws must be positioned in motor/gearbox. the mounting holes on the OUTSIDE of the wheelchair frame and the short socket screws 10.
  • Page 39 FWD WHEELCHAIRS PROCEDURE 8 5. Rotate battery tray hanger bracket up. 10. Remove the six (6) socket screws that secure the existing motor/gearbox to the wheelchair frame. 6. Left side of wheelchair only - Remove the front dust cover from the end of the crossbrace. 11.

  • Page 40: Procedure 9 - Rwd Wheelchairs

    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...

  • Page 41: When To Charge Batteries

    RWD WHEELCHAIRS PROCEDURE 9 WHEN TO CHARGE BATTERIES Description and Use of Battery Chargers (FIGURE 4) The charger automatically reduces the charge from an initially high rate to a zero reading at a fully charged condition. If left NOTE: As a general rule, batteries should be recharged unattended, the charger should automatically shut-off when daily to assure the longest possible life and minimize the full charge is obtained.

  • Page 42: Replacing Batteries

    Read them carefully, otherwise injury or damage may occur. 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.

  • Page 43: Battery Tray

    RWD WHEELCHAIRS PROCEDURE 9 BATTERY TRAY (FIGURE 7) 2. Secure the hanger brackets to the battery tray in the mounting holes that the hex screws are mounted. NOTE: To remove the battery tray from the wheelchair, 3. Attach the key slot bracket located at the front of the reverse the following procedure.

  • Page 44: Adjusting Seat-To-Floor Height

    FIGURE 8 - CHANGING SEAT WIDTH Fastening Straps ADJUSTING SEAT-TO-FLOOR Nylon Boot HEIGHT WARNING Adjusting seat-to-floor height MUST be performed by Invacare Technical Support, 1-800-832-4707. DISCONNECTING/CONNECTING Battery Lead MKIV CONTROLLER, MOTOR AND Leads From BATTERY LEADS (FIGURE 9) Controller NOTE: To connect MKIV controller motor and battery leads, reverse the following procedure.

  • Page 45: Removing/Installing Mkiv Controller

    RWD WHEELCHAIRS PROCEDURE 9 REMOVING/INSTALLING MKIV REPLACING WIRING HARNESS CONTROLLER (FIGURE 10) (FIGURE 11) 1. Disconnect the left/right motor leads and battery Disassembly leads. Refer to DISCONNECTING/CONNECTING 1. Remove the battery boxes. Refer to INSTALLING/ MKIV CONTROLLER, MOTOR AND BATTERY REMOVING BATTERY BOXES in this procedure of LEADS in this procedure of the manual.

  • Page 46: Replacing Motor/Gearbox

    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. 4. Re-secure the wiring harness and motor cables to the 11. Reinstall the battery boxes. Refer to INSTALLING/ crossbraces with new tie wrap.

  • Page 47: Limited Warranty

    Invacare warrants the side frames and crossbraces to be free from defects in materials and workmanship for a period of five (5) years from date of purchase; electronics for a period of one (1) year from the date of purchase;...
  • Page 48 Invacare Corporation Canada...

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