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Invacare® Xterra™GT™ Wheelchair

1. esent 72 REMOVING INSTALLING MKIV RII WIRING HARNESS eere 74 REMOVING INSTALLING MKIV A JOYSTICK eese eterne tntentens 76 REMOVING INSTALLING MKIV RII JOYSTICK 79 REMOVING INSTALLING THE MKIV A CONTROLLER eee 81 REMOVING INSTALLING THE MKIV RII CONTROLLER eene tentent 83 SECTION 10 MOTORS WHEELS REMOVING INSTALLING DRIVE WHEELS eese tentent tette tentent tentent 87 REMOVING INSTALLING DRIVE WHEEL HUB ettet tenentes 87 REMOVING INSTALLING 2 0 88 REMOVING INSTALLING MOTOR GEARBOX SUSPENSION ARM ASSEMBLY AND SUSPENSION SPRING HARDWARE 91 REMOVING INSTALLING 8 5 20 2 402 94 XTERRA GT 4 Part No 1110516 LABEL LOCATIONS LABEL LOCATIONS Pinch Point Pinch Point Label Label Note Located on the Seat Prop Pinch Point Label Label Battery Removing Installing Label Part No 1110516 5 XTERRA GT o 2 2 4 d 2 2 lt 2 U a 7 SPECIFICATIONS SPECIFICATIONS Seat Depth 4 to 20 inches 14 to 22 inches Back Angle Range 80 to 100 in 5 increments Seat to Floor approximate 18 inches
2. Mounting Screw SECTION 9 of this manual Locknut 5 Install the controller Refer to REMOVING Battery Tray INSTALLING CONTROLLER in SECTION FIGURE 6 REMOVING 9 of this manual INSTALLING BATTERY TRAY 6 Install the front shroud Refer to REMOVING INSTALLING FRONT AND REAR SHROUDS in SECTION 9 of this manual 7 Install the seat Refer to REMOVING INSTALLING SEAT FRAME in SECTION 6 of this manual 8 Install che batteries Refer to REMOVING INSTALLING BATTERIES in SECTION 6 of this manual XTERRA GT 58 Part No 1110516 BASE FRAME SECTION 7 REPLACING COMPONENTS OF THE FLIP UP SEAT PLATE AND OR CHANGING FROM 3 TILT TO O TILT AND VICE VERSA FIGURE 7 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 flip up seat plate Refer to REMOVING INSTALLING FLIP UP SEAT PLATE in this section of the manual BASE FRAME 4 Lay flip up seat plate upside down on flat surface as shown in FIGURE 7 Remove the two 2 mounting screws that secure the handle release bracket to the seat plate and prop threaded plate 6 Remove the two 2 mounting screws that secure the remaining handle release bracket to the threaded plate 7 Remove the three 3 mounting screws that secure the release handle to the flip up seat plate 8 Remove the release handle fr
3. RED battery cable ring terminal between the mounting plate and battery clamp of POSITIVE battery terminal post A Secure the battery cable s ring terminal s to the battery clamp s BLACK to NEGATIVE and RED to POSITIVE with existing hex screws Securely Tighten DETAIL Verify battery cable ring terminal s are correctly installed and securely tightened o Slide battery clamp covers down battery cables and onto battery terminals DETAIL S Secure each terminal in place with a tie wrap Use tie wraps 1 2 inches long DETAIL NOTE It will be necessary to trim excess tie wrap in order to install the battery box top s 8 Install the battery with lid into the wheelchair Refer to INSTALLING REMOVING BATTERIES in this section NOTE New battery ies MUST be fully charged BEFORE using otherwise the life of the battery ies will be reduced 9 f necessary charge the battery ies Refer to CHARGING BATTERIES in this procedure XTERRA GT 70 Part No 1110516 BATTERIES SECTION 8 CONNECTING BATTERY CABLE S TO BATTERY IES TERMINAL S POST S POSITIVE Battery Terminal Post and 22NF Battery Battery Clamp NEGATIVE Battery Terminal Post and Battery Clamp Negative BLACK Battery Cable Positive RED Battery Cable TOP VIEW BATTERIES Positive RED Battery Cable Hex Screw EXPLODED VIEW Nega
4. Reposition the battery clamp on the POSITIVE battery terminal post as shown in FIGURE 6 Securely tighten the hex nut that secures the battery clamp to the positive battery FIGURE 6 CONNECTING BATTERY CABLES BATTERY 1 CLAMP METHOD terminal post B If the battery clamp on the POSITIVE battery terminal post is positioned as shown in FIGURE 6 proceed to STEP 2 2 Install battery clamp covers onto battery cables as follows FIGURE 7 A RED battery clamp cover onto RED battery cable B BLACK battery clamp cover onto BLACK battery cable NOTE Only 1 battery cable and battery clamp cover are shown for clarity Both battery clamp covers install in the same manner INSTALLING BATTERY CLAMP COVERS Battery Clamp Cover Battery Cable FIGURE 7 CONNECTING BATTERY CABLES BATTERY CLAMP METHOD Part No 1110516 69 XTERRA GT BATTERIES BATTERIES SECTION 8 BATTERIES When connecting the battery cable ring terminal s to the battery ies 5 the battery cable s MUST be connected in the position shown in DETAIL of FIGURE 8 otherwise damage may occur to the battery cable and or battery clamp covers 199 Connect battery cable s to battery ies terminal s post s as follows DETAIL A A NEGATIVE BLACK battery cable ring terminal between the mounting plate and battery clamp of NEGATIVE battery terminal post B POSITIVE
5. 3 17 1 4 inches 0 Seat Width Range 14 to 20 inches Overall Width of Base w o joystick 25 inches Overall Height 36 1 4 inches 36 1 2 std 40 inches max Overall Length 4 Pole Motor Without Batteries 179 lbs With Batteries With ASBA Seat 280 Ibs With Van Style Seat 300 Ibs Drive Wheels Tires Foam Filled or Pneumatic 16 x3 inches Pneumatic std 16 x 3 inches foam filled opt 22NF batteries Battery Type 1 inch increments measured without front riggings XTERRA GT PHYSICAL DIMENSIONS Casters w Precision Sealed Bearings Semi Pneumatic Front 8 x 2 inches Rear 6 x 2 inches Footrests Telescoping Front Rigging Supports Swing Away Heavy Duty 2 in and 4 in longer Pivot Slide Tube Cage Armrests Flip Back Fixed or Adjustable Height Desk and Full Length A S B A Seat Angle Adjustment Adjust able 0 and 3 A S B A Back Angle Adjustment Adjust able 80 to 100 in 5 increments A S B A Seat Cushion Cushion Optional A S B A Chair Upholstery Options Nylon or Vinyl Van Style Seat Cloth or Vinyl Operating Temperature 0 122 degrees F Storage Temperature 10 152 degrees F Curb Climbing 2 inches Weight Limitations 250 Ibs NOTE A S B A stands for Adjustable Seat and Back Angle PERFORMANCE Up to 21 Miles RATING 250 LBS Up to 7 5 Range wi
6. DETAIL DETAIL D NOTE View is top right side of chair Joystick Controller Connector This area is to be used Connector to feed the controller connector through Wire Harness Wrap Motor Cable Joystick Tie Wra Mounting Tube NOTE Controller seat is removed for clarity Cable for 2 The portion of controller cable located between Joystick rear tie wrap on motor mount plate and central tie See NOTE 2 wrap on rear seat frame tube MUST have enough slack in it so as to allow full up and down travel of motor during chair operation FIGURE 8 REMOVING INSTALLING MKIV RII CONTROLLER Part No 1110516 87 XTERRA GT ELECTRONICS SECTION 9 ELECTRONICS DETAIL Right Motor Connector Left Motor Connector i ES mm ea E Left Controller Connector jx Tie Wraps Connector DETAIL Power Take Off Lead Blue Controller Connector Controller Connector FIGURE 9 REMOVING INSTALLING THE MKIV RII CONTROLLER XTERRA GT 88 Part No 1110516 ELECTRONICS SECTION 9 INSTALLING 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 in FIGURE 9 3 Connect the power take off lead to the other powered accessory connectors if
7. This puts a heavy load on the batteries as they try to push through the stationary object Read the meter while the motors are straining to deter mine the voltage under load NOTE If the voltage drops to less than 23 5 volts from a pair of fully charged batteries while under load they should be replaced regardless of the unloaded voltages Part No 1110516 9 XTERRA GT 2 O I 7 m e a E SECTION 2 TROUBLESHOOTING USING HYDROMETER TO CHECK BATTERY CELLS LEAD ACID FIGURE 2 NOTE Perform this procedure when a digital voltmeter is not available NOTE Use of Lead Acid wet batteries is not recommended NEVER smoke or strike a match near the batteries If the caps of the battery cells are removed NEVER look directly into them when charging the battery The use of rubber gloves and chemical goggles or face shields is recommended when working with batteries When reading a hydrometer DO NOT allow any liquid to come in contact with your eyes or skin It is a form of acid and can cause serious burns and in some cases blindness If you do get battery acid on you flush the exposed areas with cool water IMMEDIATELY If the acid comes into contact with eyes or causes serious burns get medical help IMMEDIATELY The battery acid can damage your wheelchair clothing and household items Therefore take readings cautiously and only in designated areas ONLY use distilled water when topping of
8. 3 Remove caster INSTALLING Install caster as shown 2 Secure the caster to the fork with the locknut and washers 3 Secure the hub cab onto the caster with the two 2 mounting screws and locknuts Torque 40 in Ibs 20 Mounting Fork Screw mc Caster Q Washer Locknut Hub Cap Mounting Screw Locknuts FIGURE 7 REMOVING INSTALLING CASTERS Part No 1110516 97 XTERRA v I 2 2 0 gt GT NOTES NOTES XTERRA GT NOTES 98 Part No 1110516 WARRANTY LIMITED WARRANTY PLEASE NOTE THEWARRANT Y BELOW HAS BEEN DRAFTED TO COMPLY WITH FEDERAL LAW APPLICABLE TO PRODUCTS MANUFACTURED AFTER JULY 4 1975 This warranty is extended only to the original purchaser user of our products This warranty gives you specific legal rights and you may also have other legal rights which vary from state to state Invacare warrants seat frame to be free from defects in materials and workmanship for a period of three 3 years from date of purchase that electrical components are warranted for a period of one 1 year gearbox motors for a period of 18 months and gearless brushless motors for five 5 years from the date of purchase and the base frame for the life of the product all remaining components including gas cylinders and motor lock pads for one 1 year from the date of purchase except upholstered materials padded materials and tires whe
9. 3 for the opposite flip back armrest Part No 1110516 19 XTERRA GT BACK SECTION 5 BACK This Procedure Includes the Following Replacing Seat Positioning Strap Changing Back Height Removing Installin Back Upholstery Back Angle Adjustment After ANY adjustments repair or service and BEFORE use make sure that all attaching hardware is tightened securely otherwise injury or damage may result STANDARD ADJUSTABLE SEAT FRAMES FIGURE 2 Remove the seat cushion from the seat pan 2 Move the flip back armrests out of the way Refer to USING ADJUSTING FLIP BACK ARMRESTS in PROCEDURE 5 of the Owner s manual 1106627 3 Remove the two 2 mounting screws quick release pin tabs spacers and locknuts that secure the seat pan and seat positioning straps to the seat frame 4 Remove the two 2 halves of the seat positioning strap from the rear seat frame Mounting age DT Screw Mur OM ED ES E Ses nis m en Seat eye H Positioning Strap Rear of Arh Seat Frame ck UI a D A E iu i lt Front of Quick MES Seat Frame NOTE Quick release pin tabs are positioned unfelease Pin derneath the seat positioning strap 5 Reposition the two 2 NEW seat posi tioning strap halves underneath seat rails Tab Locknut spacer Seat Rail FIGURE 2 REPLACING SEAT POSITIONING STRAP REPLACING SEAT POSITIONING STRAP VAN STYLE SEAT FIGURE 1 Remo
10. FIGURE 5 and 6 depending on battery type otherwise damage to the battery cable may result when installing battery terminal caps M Connect battery cable s to battery ies terminal s post s as follows DETAIL or DETAIL B of FIGURE 3 depending on battery type NEGATIVE BLACK battery cable to NEGATIVE battery terminal post B POSITIVE RED battery cable to POSITIVE battery terminal post Secure the battery cable s ring terminal s to the battery terminal s post s BLACK to NEGATIVE and RED to POSITIVE with the provided 1 4 20 x 7 8 inch hex flange screw and hex flange locknut Securely tighten DETAIL A or DETAIL B of FIGURE 3 depending on battery type 199 gt Verify all battery cable s ring terminal s are correctly installed and securely tightened Slide terminal cap s down battery cable s and onto battery clamps FIGURE 3 Part No 1110516 67 XTERRA GT BATTERIES SECTION 8 BATTERIES 6 Secure each terminal in place with a tie wrap Use tie wraps 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 NOTE New battery ies MUST be fully charged BEFORE using otherwise the life of the battery ies will be reduced 8 If necessary charge the battery ies Refer to CHARG
11. Gearbox Assembly 3 1 2 inch Mounting Screw FIGURE 4 REMOVING INSTALLING MOT OR GEARBOX SUSPENSION ARM ASSEMBLY AND SUSPENSION SPRING HARDWARE XTERRA GT 94 Part No 1110516 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 9 Remove the 3 1 2 long mounting screw washer and locknut that secures the rear of the motor mount to the base frame 10 For motor gearbox FIGURE 5 Remove the two 2 short mounting screws three 3 long mounting screws that secure the motor mount bracket to the motor gearbox assembly INSTALLING FIGURES 4 5 AND 6 NOTE This procedure will require 5 inch mounting screw with 1 1 2 inches of thread fender washer and locknut l Secure the motor mount bracket to the motor gearbox assembly with two 2 short mounting screws and three 3 long mounting screws Torque mounting screws to 75 in Ibs FIGURE 5 Short Mounting 2 Secure the rear of the motor mount Screws to the suspension arm with the 3 1 2 inch long mounting screw washer 6 Motor Mount and locknut Torque to 13 ft lbs Long Bracket FIGURE 4 Mounting Screws 3 Secure the front of the motor m
12. INCH SEAT WIDTHS D E REMOVING INSTALLING SEAT FRAME FOR 19 AND 20 INCH SEAT WIDTHS INSTALLING REMOVING VAN STYLE SEAT SEAT FRAME ASSEMBLY ONTO FROM FLIP UP SEAT PLATE XTERRA GT 52 Part No 1110516 BASE FRAME SECTION 7 7 8 inch dia Spring Washer Washer 3 8 x 3 4 inch Bushing Mounting 8 inch dia Screw NS Washer AU y Sprin Bushi E g ushing 9 3 8 x l inch Washer Mounting lt Screw i p TH 3I8 inch di 32 Ke JU MEE s Seat Prop lt ashers ee Al 3 8 x l inch E 8 inch dia Mounting amp Washers Screw Adjustment Adjustment Bracket Bracket Locknut 5 8 inch dia Washer Locknut 5 8 inch dia Washer NOTE Top of the Flip up seat plate not shown for clarity of attaching hardware FOR 14 7 SEAT DEPTHS FOR 19 20 INCH SEAT DEPTHS FIGURE REMOVING INSTALLING FLIP UP SEAT PLATE Part No 1110516 53 XTERRA GT BASE FRAME SECTION 7 BASE FRAME REMOVING INSTALLING ADJUSTMENT BRACKET FIGURE 2 NOTE When installing replacing components of the wheelchair refer to the individual section for correct use of LOCTITE 242 and torque specifications or SECTION 3 of this manual REMOVING Remove the flip up seat plate Refer to REMOVING INSTALLING FLIP UP SEAT PLATE this section of the manual 2 Remove the two 2 3 8 x 3 4 inch mounting screw two 2 3 8 inch dia
13. INSTALLING REMOVING VAN STYLE SEAT SEAT FRAME ASSEMBLY FROM FLIP UP SEAT PLATE eed teen iet tee a 50 INSTALLING REMOVING VAN STYLE SEAT FROM SEAT FRAME ASSEMBLY 51 SECTION 7 BASE FRAME REMOVING INSTALLING FLIP UP PLATE eese ettet tentent entente 52 REMOVING INSTALLING ADJUSTMENT 2 0 04 000 54 REMOVING INSTALLING FRONT AND REAR SHROUDS eere 55 REMOVING INSTALLING TORSION 56 REMOVING INSTALLING PORT 2 2 0 57 REMOVING INSTALLING BATTERY 200 2222 2 58 REPLACING COMPONENTS OF THE FLIP UP SEAT PLATE AND OR CHANGING FROM 3 TILT TO 0 TILT 59 Part No 1110516 3 XTERRA GT 4 2 H 2 O le m lt TABLE CONTENTS TABLE OF CONTENTS CONTINUED SECTION 8 BATTERIES REMOVING INSTALLING BATTERIES 20 2 59 DISCONNECTING BATTERY CABLES tiie lian iniii aidi iiia 62 CONNECTING BATTERY CABLES uu sessssssssscsssssssssssssessccssessscssssssssssssssesseessesesesssenssnsnsansaes 64 WHEN CHARGE 5 2 2 2 69 CHARGING BAT IERIES 5 69 SECTION 9 ELECTRONICS REMOVING INSTALLING MKIV A WIRING HARNESS
14. SEAT FRAME ASSEMBLY Part No 1110516 51 XTERRA GT BASE FRAME SECTION 7 BASE FRAME This Section Includes the Following Removing Installing Flip up Seat Plate Removing Installing Port Bracket Removing Installing Adjustment Bracket Removing Installing Battery Tray Removing Installing Front Rear Shrouds Replacing Components of Flip up Seat Removing Installing Torsion Bar Plate Changing from 3 tilt to 0 tilt After ANY adjustments repair or service and BEFORE use make sure that all attaching hardware is tightened securely otherwise injury or damage may result REMOVING INSTALLING FLIP UP SEAT PLATE FIGURE 1 NOTE When installing replacing components of the wheelchair refer to the individual procedure for correct use of LOCTITE 242 and torque specifications or SECTION 3 of this manual NOTE Right and Left are determined from the user s seated position REMOVING Remove the seat frame Refer to one 1 of the procedures in SECTION 6 of this manual REMOVING INSTALLING SEAT FRAME FOR 14 AND 15 SEAT WIDTHS REMOVING INSTALLING SEAT FRAME FOR 16 SEAT WIDTHS REMOVING INSTALLING SEAT FRAME FOR 17 AND 18 INCH SEAT WIDTHS REMOVING INSTALLING SEAT FRAME FOR 19 AND 20 SEAT WIDTHS INSTALLING REMOVING VAN STYLE SEAT SEAT FRAME ASSEMBLY ONTO FROM FLIP UP SEAT PLATE mm D gt M Remove the 3 8 x l inch mounting screw two 2 3 8 diameter washers 5 8
15. XTERRA GT 62 Part No 1110516 BATTERIES Release Lever Seat Prop Battery Retention Battery Strap Disconnect KCN S Nd FIGURE REMOVING INSTALLING BATTERIES INSTALLING FIGURE 2 N A When lowering the seat ensure that hands and fingers clear from under neath seat before lowering otherwise injury may result Install the rear battery into the base frame in the orientation shown in DETAIL B in FIGURE 2 Slide the rear battery rearward Install the front battery into the base frame in the orientation shown in DETAIL A in FIGURE 2 Connect the battery retention strap FIGURE 1 Connect the battery wiring harness to the rear battery FIGURE 1 Connect the battery wiring harness to the front battery FIGURE 1 After lowering seat ensure that seat is locked securely in place before operat ing chair otherwise serious personal injury damage to the wheelchair and or damage to surrounding property may occur 7 To lower seat Lift up on seat with one hand While holding seat pull prop toward the Part No 1110516 63 XTERRA GT front of the seat Lower seat SECTION 8 BATTERIES BATTERIES SECTION 8 Front Battery SE SM m DETAIL SELE ERNA DETAIL FIGURE 2 REMOVING INSTALLING BATTERIES Part No 1110516 64 XTERRA GT BATTERIES SECTION 8 DISCONNECTING BATTERY CABLES FIGURE 3 NOTE Perform this
16. clothes or other possessions It is a form of acid and harmful or damaging burns result Should the liquid touch your skin wash the area IMMEDIATELY and thoroughly with cool water In serious cases or if eye contact is made seek medical attention IMMEDIATELY I Examine battery clamps and terminals for corrosion M Verify the plastic caps are in place over battery cell holes Clean terminals and inside battery clamps by using a battery cleaning tool wire brush or medium grade sand paper NOTE Upon completion areas should be shiny not dull 4 Carefully dust off all metal particles XTERRA GT 74 Part No 1110516 ELECTRONICS SECTION 8 is Procedure Includes the Following Installing Removing MKIV A Wiring Harness InstallinglRemoving MKIV RII Wiring Harness Installing Removing MKIV A Joystick InstallinglIRemoving MKIV RII Joystick REMOVING INSTALLING MKIV A WIRING HARNESS FIGURE 1 REMOVING 1 Review DETAIL A in FIGURE and identify each 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 in FIGURE 4 Cut the tie wrap that secures the power take off lead in place DETAIL in FIGURE 1 Disconnect the battery wiring harness blue connector from the controller blue connector DETAIL in FIGURE 1 6 Discon
17. drive over curbs or obstacles Doing so may cause your wheelchair to turn over and cause bodily harm or damage to the chair DO NOT use parts accessories or adapters other than those authorized by Invacare DO NOT leave the power button ON when entering or exiting the wheel chair DO NOT stand on the frame of the wheelchair DO NOT use the footplates as a platform When getting in or out of the wheelchair make sure that the footplates are in the upward position or swing footrests towards the outside of the chair ALWAYS wear your seat positioning strap TIRE PRESSURE DO NOT use your wheelchair unless it has the proper tire pressure P S l DO NOT over inflate the tires Failure to follow these suggestions may cause the tire to explode and cause bodily harm The recommended tire pressure is listed on the side wall of the tire ISS a ae Part No 1110516 7 XTERRA GT v m Q gt m 0 Z SECTION I GENERAL GUIDELINES GENERAL WARNINGS CONTINUED ELECTRICAL Grounding Instructions DO NOT under any circumstances cut or remove the round grounding prong from any plug used with or for Invacare products Some devices are equipped with three prong grounding plugs for protection against possible shock hazards Where a two prong wall receptacle is encountered it is the personal responsibility and obligation of the customer to contact a qualified electrician and have the two prong r
18. is replaced it must be burned in This is accomplished by running the motor for one hour 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 replaced will only carry a small percentage of its rated load capacity until the NEW brush is burned in Part No 1110516 11 Motor AS Ep d 4 Pin Motor Connector FIGURE 4 MOTOR BRUSH INSPECTION XTERRA GT 2 O I 7 m e ac E SECTION 2 TROUBLESHOOTING ELECTROMECHANICAL PARKING BRAKE TESTING FIGURE 5 NOTE This procedure should only be performed on wheelchairs with conventional motor gearbox assembly On the four pin motor connector locate the side by side connectors in the black housings Set the digital multimeter to read ohms Q Measure the resistance between the two 2 brake contacts A normal reading is 100 ohms A reading of 0 ohms or a very high reading MEG ohms or O L out of limit indicates a shorted brake or an open connection respec tively If either condition exists send the motor to Invacare Technical Service for inspection repair Motor 4 Pin Motor Connector FIGURE 5 ELECTROMECHANICAL PARKING BRAKE TESTING NOTE A bad motor can dam
19. motor sensor cables 4 Feed motor sensor cable with wire harness wrap down through base frame 5 Connect the motor connector to the controller connector and the sensor cable to the power take off lead NOTE Re install the tie wraps to secure the cables in place 6 Secure the wire harness wrap around the motor sensor cable with two 2 tie wraps 7 Secure the motor cable and sensor cable together with a tie wrap 8 Secure the wire harness wrap to the battery tray with tie wrap 9 Secure the motor cable and sensor cable to the motor mount with tie wrap 10 Secure the motor cable to the motor with tie wrap Install the front shroud Refer to REMOVING INSTALLING FRONT AND REAR SHROUDS in SECTION 7 of this manual 12 Install batteries Refer to REMOVING INSTALLING BATTERIES in SECTION 6 of this manual 13 If necessary reinstall the seat and or the drive wheels Refer to REMOVING INSTALL ING DRIVE WHEELS in this section or REMOVING INSTALLING SEAT FRAME in SECTION 6 of this manual XTERRA GT 92 Part No 1110516 MOTORS WHEELS SECTION 10 DETAIL Tie Wrap STEP 6 Tie Wrap STEP 8 2 l I 2 uv oc ie H O Tie Wrap STEP 4 TOP VIEW OF BASE FRAME DETAIL FRONT VIEW OF BASE FRAME A aa 1 1 MIL IIIJ 1 U AH L DETAIL Motor Coupling Motor Connector Sensor Connect
20. neces sary DETAIL B in FIGURE 10 4 Secure the power take off lead in place with NEW tie wrap DETAIL B in FIGURE 10 5 Connect the controller connector to the wiring harness connector Detail B FIG URE 10 6 Connect the left motor connector to the left controller connector DETAIL A in FIGURE 10 7 Connect the right motor connector to the right controller connector DETAIL A in FIGURE 10 8 Secure controller cables up against the controller with four 4 NEW tie wraps DETAIL A in FIGURE 10 9 Feed controller connector for joystick down through base frame DETAIL D in FIGURE 9 10 Secure the controller connector cable for joystick and motor cable together DETAIL D in FIGURE 9 Secure the wire harness wrap around the controller connector cable for joystick and motor cable DETAIL D in FIGURE 9 12 Secure the controller connector cable for joystick to the arm tube and seat frame DETAIL C in FIGURE 9 13 Secure the controller joystick connection to the joystick mounting tube DETAIL in FIGURE 9 4 Connect joystick connector to the controller connector DETAIL in FIGURE 9 ELECTRONICS 15 Secure the front shroud in place with the two 2 mounting screws washers DETAIL A in FIGURE 9 Torque to 40 in Ibs 16 Install che batteries Refer to REMOVING INSTALLING THE BATTERIES in SECTION 8 of this manual Part No 1110516 89
21. of this manual Perform one 1 of the following A For 14 and 5 seat depths Remove the back upholstery from the back brackets Refer to REMOVING INSTALL ING BACK UPHOLSTERY in SECTION 5 of this manual Remove the two 2 washers and locknuts that secure each CJ bracket to the seat frame B For 16 17 18 19 and 20 inch seat depths Remove the back upholstery from the seat frame REMOV ING INSTALLING BACK UPHOLSTERY in SECTION 5 of this manual NOTE When performing STEP 7 note the mount ing location of the mounting screws on the flip up seat plate for proper reinstallation of the seat frame Figure 8 illustrates various configurations of how the seat frame is attached to the flip up seat plate Back Bracket SER t Washer a Torque to 75 in Ibs FIGURE 7 REMOVING SEAT FRAME 19 AND 20 INCH SEAT WIDTHS 7 Remove the four 4 mounting screws and tube spacers if applicable and locknuts that secure the seat frame to the flip up seat plate 8 Remove the existing seat frame Part No 1110516 35 XTERRA GT SEAT FRAME SEAT FRAME SECTION 6 SEAT FRAME 14 15 16 AND 17 SEAT DEPTHS 18 AND 19 SEAT DEPTHS Mounting Standard Mounting Standard 9s ews A Seat Frame Screws Seat Frame orque to 156 inch to 56 inch pounds bound 3 4 inch Tube Spacers Use these gt Mounting USC Holes ira th
22. seat pan 8 Secure the bottom of the back upholstery to the CJ back brackets with new tie wraps 9 Use LOCTITE 242 and torque the mounting screws to 75 inch pounds 10 Repeat the STEPS 1 9 for the opposite back cane Reinstall the armrests onto the wheelchair Refer to INSTALLING REMOVING FLIP BACK ARMRESTS in SECTION 4 of this manual CHANGING SEAT WIDTH OF FIXED SEAT FRAMES 16 17 18 19 AND 20 INCH WIDE NOTE If desired seat width is below 16 wide you must use an adjustable seat frame When doing so remember to transfer the CJ back brackets from the existing fixed seat frame and install onto the NEW adjustable seat frame For all fixed seat width changes above 16 wide or fixed seat frame perform the following Perform one 1 of the following A Remove the existing l6 inch width seat frame B Remove the existing 17 18 inch width seat frame C Remove the existing 19 20 inch width seat frame Part No 1110516 45 XTERRA GT SEAT FRAME SECTION 6 SEAT FRAME Perform one 1 of the following A Install the NEW 16 inch width seat frame B Install the NEW 17 18 inch width seat frame C Install the NEW 19 20 inch width seat frame NOTE Remember when changing the seat width NEW back upholstery spreader bar if applicable and seat pan are required CHANGING SEAT WIDTH OF ADJUSTABLE SEAT FRAMES 14 15 AND 16 INCH WIDE FIGURES AND 14 NOTE If desired seat wi
23. the Department of Transportation has not approved any tie down systems for transportation of a user while in a wheelchair in a moving vehicle of any type It is Invacare s position that users of wheelchairs should be transferred into appropriate seating in vehicles for transportation and use be made of the restraints made available by the auto industry Invacare cannot and does not recommend any wheelchair transportation systems AS REGARDS TO RESTRAINTS SEAT POSITIONING STRAPS IT IS THE OBLI GATION OF THE DME DEALER THERAPISTS AND OTHER HEALTHCARE PRO FESSIONALS TO DETERMINE IF A SEATING POSITIONING STRAP IS REQUIRED TO ENSURE THE SAFE OPERATION OF THIS EQUIPMENT BY THE USER SERI OUS INJURY CAN OCCUR IN THE EVENT OF A FALL FROM A WHEELCHAIR SAVE THESE INSTRUCTIONS XTERRA GT 2 Part No 1110516 TABLE CONTENTS TABLE OF CONTENTS SPECIAL NOTES LABEL LOCATIONS v SPECIFICATIONS 2 SECTION GENERAL GUIDELINES SECTION 2 TROUBLESHOOTING FED LOAD TEST eyen AEN EE E TE 9 USING HYDROMETER CHECK BATTERY CELLS rtn 12n 10 6 MOTOR TESTING ON DUIS 11 MOTOR BRUSH 5 2 1 ttt 11 ELECTROMECHANICAL PARKING BRAKE TESTING rttr rtnr rtn 12 lt SECTION 3 HARDWARE TORQUE SPECIFICATIONS SECTION 4 ARMS REPLACING ARMREST PADS VAN STYLE SEAT eese tnttntent
24. 0516 SEAT FRAME DECREASING SEAT DEPTH amp amp 7 KA Sg CS LRY SVS i ADAE AAA gt amp AS EZ CR lt SKE I S lt gt qm Seat LE KE A mb Depth QATAR S SZ S 4 5 4 3 2 14 15 incn 3 4 5 7 T 1 71413151261 einni 2 5 3 4 6 7 4 3 5 2 6 l 14 15 lI9 inch l 2 5 3 4 7 4 3 5 216 1 I4l5inch 20inch T 2 5 3 4 DL LE Lo SS LE LA l7inn 1 2 6 4 3 5 2 l ich lI amp ich 1 2 5 3 4 6 4 3 5 2 I l ich 19 inch 1 2 5 3 4 6 6 4 3 5 2 i l inh 204811 2 5 3 4 6 6 4 3 5 2 I 17 448 l amp ich 2 5 3 4 6 61 4 3 5 2 I lZich 19 inh I 2 5 3 4 6 6 4 3 5 2 I lIZinh 20 inch 2 5 3 4 6 LLL LE E ELLE LA 2 11 19 142 6 4 3 5 2 1 19 inch 20 inch i 2 5 3 4 6 SECTION 6 INCREASING SEAT DEPTH NOTE All procedures are located in this section PREPARATIONS REMOVING INSTALLING CJ BACK BRACKETS REMOVING INSTALLING SEAT PAN REMOVING INSTALLING SEAT FRAME and REAS SEMBLING THE CHAIR Part No 1110516 XTERRA GT SEAT FRAME SECTION 6 SEAT FRAME PREPARATIONS NOTE When installing replacing components of the wheelchair refer to the individual procedu
25. 2 0 for a pair replace the batteries 2 I 4 m 2 tc LE 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 Use a digital voltmeter to check battery charge level at the charger connector It is located on the base of the wheelchair frame NOTE READ the instructions CAREFULLY before using the digital voltmeter NOTE Invacare recommends that ONLY a qualified service technician perform this test 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 3 Remove the footrests from the wheel chair and place the CASTERS of the Battery Charger wheelchair against a wall workbench or Connector other stationary object 4 Place the voltmeter leads into the NY charger plug on the wheelchair Most digital voltmeters are not affected by A polarity however analog meters S Q 5 meters with swinging needles can be T o AN and should be used carefully A good meter reading should be 25 5 to 26 FIGURE I FIELD LOAD TEST VDC 5 Have two 2 individuals one 1 on each arm apply as much downward pressure as possible on the arms of the wheelchair 6 Turn the wheelchair ON and push the joystick forward trying to drive the wheelchair through the stationary object
26. 8 Install the batteries Refer to REMOVING INSTALLING BATTERIES in SECTION 8 of this manual Part No 1110516 75 XTERRA GT ELECTRONICS ELECTRONICS SECTION 9 ELECTRONICS DETAIL A IDENTIFYING DETAIL BATTERY WIRING HARNESS CONNECTORS To Battery To Battery Front Take Off gt Shroud Lead SU d Washer Battery Charger y ALA Port RS A 2 d os Lc RII Controller PERI i Locknuts b NI 7 d To Controller miem Blue Connector pe Mounting Screws Torque to 40 in Ib d DETAIL Cut Out in Battery Tray Battery Tray Battery Charger Port Mounting Bracket Power Take OfF Lead o UU i Mounting ai 2 Screws Battery Wiring Harness Blue Connetor Tie Wrap Controller Blue Connetor FIGURE REMOVING INSTALLING THE MKIV WIRING HARNESS XTERRA GT 76 Part No 1110516 ELECTRONICS SECTION 9 REMOVING INSTALLING THE MKIV RII WIRING HARNESS FIGURE 2 REMOVING l 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 0 this manual gt 3 Remove the two 2 mounting screws washers that secure the front shroud place Refer to DETAIL in FIGURE 2 4 Disconnect the battery wiring harness con
27. ALLING BACK UPHOLSTERY in SECTION 5 of this manual 2 Remove the two 2 washers and locknuts that secure each C bracket to the seat frame B For 16 17 18 19 and 20 inch seat depths NOTE Note the mounting hole position of the side frame for proper installation of the NEW side frame 7 Remove the two 2 mounting screws coved washers spacers and locknuts that secure the side frame to the center frame 8 Remove the side frame from the Mounting Screws center frame Torque to 13 ft Ibs 9 If the desired seat depth requires Mounting Screws Typ all four 4 screws a new center frame perform Torque to 75 following otherwise proceed to inch pounds STEP 10 Remove the four 4 mount ing screws and spacers if applicable that secure the Coved EXISTING center frame to Washers the flip up seat plate Remove existing center frame from flip up seat plate Secure NEW center frame to flip up seat plate with the existing four 4 mounting screws spacers if applicable and locknuts Torque to 13 Lock ft lbs ocknuts 10 Secure NEW side frame to the Side Frame Center center frame at the position 9 Frame noted previously Torque to 75 Spacers Ec inch pounds NOTE If seat width adjustment is also de sired refer to CHANGING SEAT WIDTH in this section of the manual for mounting hole locations and allowable seat width seat depth combinations amp Locknut
28. ALLING 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 4 Remove the controller Refer to REMOVING INSTALLING CONTROLLER in SECTION 9 of this manual 5 Remove the wiring harness Refer to REMOVING INSTALLING WIRING HARNESS in SECTION 9 of this manual 6 Remove the right drive wheel to gain access to the rear mounting screw that secures the battery tray in place Refer to REMOVING INSTALLING DRIVE WHEELS in SECTION 10 of this manual 7 Remove the two 2 mounting screws washers and locknut that secures the front of the battery tray to the base frame 8 Remove the mounting screw washers and locknut that secures the rear of the battery tray to the base frame 9 Remove battery tray from base frame INSTALLING Mounting Secure the rear of the battery tray to the Screw base frame with the mounting screw washers and locknut Torque mounting screw to 75 in lbs Base Frame 2 Secure the front of the battery tray to the base frame with two 2 mounting screws washers and locknut Torque mounting screws 75 in Ibs 3 Install the right drive wheel Refer to REMOVING INSTALLING DRIVE WHEELS in SECTION 10 of this manual 4 Install the wiring harness Refer REMOV ING INSTALLING WIRING HARNESS in
29. BATTERIES FIGURE 10 NOTE New batteries MUST be fully charged prior to initial use of the wheelchair Never attempt to recharge the batteries by attaching cables directly to the battery terminals or clamps Always use the recharging plug located on the back of the joystick or on the front shroud DO NOT attempt to recharge the batteries and operate the power wheel chair at the same time During use and charging unsealed batteries will vent hydrogen gas which is explosive in the right concentration with air XTERRA GT 72 Part No 1110516 BATTERIES SECTION 8 Always charge new batteries before initial use or battery 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 Plan to recharge the batteries when it is anticipated the wheelchair will not be used for a long period of time 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 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
30. Bracket Orientation for O tilt Springs Mounting Screws CHART B Mounting Handle Release Bracket HANDLE RELEASE BRACKET Screws Orientation for 3 tilt Dimension A 7 8 inch Dimension B 9 16 inch DETAIL CHANGING SEAT DEPTH Large Washer Mount here for 14 and 7 inch Seat Depths Mount here for 18 and 19 inch Seat Depths Mount here for 20 inch Seat Depth Prop Seat Bracket NEW flip up Seat Plate FIGURE 7 COMPONENTS OF THE FLIP UP SEAT PLATE AND OR CHANGING FROM 3 TILT TO 0 TILT AND VICE VERSA Part No 1110516 61 XTERRA GT BATTERIES SECTION 8 BATTERIES This Procedure Includes the Following Installing Removing Batteries Disconnecting Battery Cables Connecting Battery Cables When to Charge Batteries Charging Batteries Replacing Batteries Make sure power to the wheelchair is OFF before performing this procedure 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 This procedure MUST be performed while the wheelchair is unoccupied REMOVING INSTALLING BATTERIES FIGURE 1 Each battery weighs 35 pounds Use proper lifting techniques lift with yo
31. CT 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 THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS WARRANTIES IMPLIED WARRANTIES IF ANY INCLUDING THE IMPLIED WARRAN TIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE SHALL NOT EXTEND BEYOND THE DURATION OF THE EXPRESS 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 CON SEQUENTIAL ORINCIDENTAL DAMAGES WHATSOEVER THIS WARRANTY SHALL BE EXTENDED TO COMPLY WITH STATE PROVINCIAL LAWS AND REQUIREMENTS Part No 1110516 99 XTERRA GT Yes you Invacare Corporation www invacare com USA One Invacare Way Elyria Ohio USA 44035 4190 800 333 6900 Technical Services 1 800 832 4707 Canada 570 Matheson Blvd E Unit 8 Mississauga Ontario 147 4G4 Canada 800 668 5324 Invacare isa registered trademark of Invacare Corporation Yes you can Xterra GT and MKIV are trademarks of Invacare Corporation LOCTITE is a registered trademark of Loctite Corporation 9 2002 Invacare Corporation Part No 1110516 Rev A 6 02
32. CTION 5 3 Remove the mounting screw and washer from the bottom mounting hole of the back angle plate and back cane 4 Reposition the back canes into the correct mounting holes of the back angle plate to obtain a back angle between 80 and 1007 in 5 increments 5 Torque mounting screws to 75 inch pounds 6 Reinstall the armrests onto the wheelchair Refer to INSTALLING REMOVING FLIP BACK ARMRESTS in SECTION 4 of this manual TO ACHEVE A BACKANGLE OF BACK ANGLE ANGLE MOUNTING HOLE PLATE HOLE 80 Top Top Front Bottom Bottom Rear 85 Top s Top Front 2nd From LIN Bottom Center Bottom 90 Top Top Front Bottom Bottom Front Top 959 2nd Erem Top Center Bottom Bottom Front 100 Top Top Reatr Bottom Bottom Front HGURE5 BACKANGLEADJ USIMENT Part No 1110516 25 XTERRA GT SEAT FRAME 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 Seat Widths Removing Installing Seat Frame for 17 and 18 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 Removing Installing CJ Back Brackets Changing Seat Width of Fixed Seat Frames 16 17 18 19 and 20 inch wide Changing Seat Width of Adjustable Seat Frames 14 15 and 16
33. EIGHT FIGURE 4 NOTE If changing the back height new back upholstery may be needed as well Refer to the following chart to determine if new back upholstery is needed 16 17 INCHES range of the original back height only 18 19 INCHES new back canes will be needed 5 20 INCHES If the back height required is NOT lt 21 22 INCHES within the range of the original back height new back upholstery as well as new back canes will be required NOTE Existing hardware and inserts will be reused Remove the flip back armrests from the wheelchair Refer to INSTALLING REMOVING FLIP BACK ARMRESTS in SECTION 4 of this manual NOTE Note the correct mounting screw mounting positions to ensure the proper back angle for rein stallation 2 Remove the two 2 mounting screws and washers that secure the existing back uphol stery to the back canes 3 Remove the four 4 mounting screws washers spacers and locknuts that secure the existing back canes to the seat frame Remove the inserts from the existing back canes 5 Remove the back assembly from the wheelchair 6 If applicable loosen but do not remove the mounting screws and locknuts that secure the spreader bar to the existing back canes 7 Remove existing back canes from the back assembly 8 Slide the inserts into the bottom of the NEW back canes 9 Line up the mounting holes of the inserts with the mounting holes in the back canes NOTE To keep the inserts lined u
34. EMOVING INSTALLING MKIV A OR MKIV A JOYSTICKS ASBA SEAT Part No 1110516 81 XTERRA GT ELECTRONICS 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 an ASBA seat For additional views of other mkiv RII joystick mounting options see FIGURE 7 REMOVING Remove the batteries Refer to REMOVING INSTALLING BATTERIES in SECTION 8 of this manual 2 Cuttie wrap that secures the joystick controller connection to the joystick mounting tube 3 Disconnect the joystick connector from the controller connector 4 Cutthe tie wrap that secures the joystick cable to the joystick mounting tube 5 Rotate adjustment lock lever and remove joystick mounting tube from mounting bracket 6 Remove joystick from wheelchair INSTALLING l Install joystick mounting tube into mounting bracket at the desired position 2 Secure joystick mounting tube in place by rotating adjustment lock lever 3 Plug joystick connector into controller connector Secure connection by tightening screws on the side of controller connector 4 Secure the joystick cable to joystick mounting tube with one 1 tie wrap Install batteries Refer to REMOVING INSTALLING BATTERIES in SECTION 8 of this manual Joystick Mounting Tube Joystick Cable Joystick Controller Cannecion Connector Ad
35. ERRA GT 14 Part 1110516 HARDWARE TORQUE SPECIFICATIONS SECTION 3 BASE FRAME HARDWARE TORQUE SPECIFICATIONS Torque to ft lbs 20 Flip Up Seat Plate Assembly Plate removed for clarity Torque to 40 inllbs 20 Torqu to 13 ftllbs N Z o 4 Q Q a O d gt a lt I lorque to ft lbs Torque to 75 inllbs 20 Torque to 13 f llbs A lt 20 Torque to 75 inllbs 20 Torque to SN 75 inllbs 20 Torque to Ae five 5 screws 40 in Ibs 2096 pres Torque to 45 ft lbs 20 i Torque to e 40 in Ibs 20 Torque to ft lbs 20 Part 1110516 15 XTERRA GT 2 0 4 Q Q a 7 O 4 gt x lt I SECTION 3 HARDWARE TORQUE SPECIFICATIONS BASE FRAME HARDWARE TORQUE SPECIFICATIONS Torque to Torque to 75 inllbs 20 40 in lbs 2096 Torque to 75 in lbs 20 Torque to 75 inllbs 20 Torque to 75 in lbs 20 Torque to 40 inllbs 20 XTERRA GT 16 Part 1110516 ARMS SECTION 4 is Section Includes the Following Replacing Armrest Pads Van Style Seat Replacing Van Style Seat Armrest Plate Installing Removing Flip Back Armrests InstallinglRemoving Van Style Seat Armrests After ANY adjustme
36. IL A 14 Install the batteries Refer to REMOVING INSTALLING BATTERIES in SECTION 8 of this manual DETAIL NOTE The tie wrap locations beyond what is shown in the illustrations below are identical to the ones described in the instructions on the previous page VAN SEAT ASBA SEAT WITH QUAD LINK JOYSTICK MOUNTING VAN SEAT WITH QUAD LINK JOYSTICK MOUNTING FIGURE 3 TIE WRAP LOCATIONS FOR OTHER MKIV JOYSTICK MOUNTING OPTIONS XTERRA GT 80 Part No 1110516 ELECTRONICS SECTION 9 DETAIL FRONT VIEW Tie Wrap Joystick Connector Wire Hamess Wrap ELECTRONICS Right Controller Connector Motor Lead Controller DETAIL B TOP VIEW OF RIGHT DETAIL C SIDE OF CHAIR This area is to be used to feed the motor lead and joystick leads through Tie Wraps STEP 9 Compression Spring Wire Harness Wrap Tie Wraps e Motor Cable Tie Wrap Joystick Tube Tie Wraps Joystick STEP 8 Cable Seat Frame Joystick Cable See NOTE 2 NOTE seat is removed for clarity 2 The portion of joystick cable located between rear tie wrap on motor mount plate and central tie wrap on rear seat frame tube MUST have enough slack in it so as to allow full up and down travel of motor during chair operation FIGURE 4 R
37. ING BACK UPHOLSTERY in SECTION 5 of this manual 2 Remove the two 2 washers and locknuts that secure each bracket to the seat frame B FOR 16 17 18 19 AND 20 INCH SEAT DEPTHS Remove the back upholstery from the seat frame Refer to REMOVING IN STALLING THE BACK UPHOLSTERY in SECTION 5 of this manual NOTE When performing STEP 7 note the mounting location of the mounting screws on the flip up seat plate for proper reinstallation of the seat frame FIGURE 2 illustrates various configurations of how the seat frame is attached to the flip up seat plate 7 Remove the four 4 mounting screws spacers and locknuts that secure the seat frame to the flip up seat plate 8 Remove the existing seat frame INSTALLING FIGURES AND 2 l Secure the seat frame to the flip up seat plate the mounting location previously noted with the existing four 4 mounting screws spacers and locknuts Torque mounting screws to 13 ft Ibs 20 FIGURE 2 2 Perform one 1 of the following A For 4 and 5 seat depths Secure each CJ bracket to the seat frame the two 2 washers and locknuts Torque locknuts to 75 in Ibs FIGURE 1 2 Install the back upholstery onto the CJ back brackets Refer to REMOVING INSTALLING BACK UPHOLSTERY in SECTION 5 of this manual For 16 17 18 19 and 20 inch seat depths Install the back upholstery onto the seat frame Refer REMOVING INSTALLING BACK UPHOLSTE
38. ING BATTERIES in this procedure POSITIVE Battery Terminal Post POSITIVE Red Battery Cable 1 4 20 x 7 8 Inch 1 4 20 Hex Hex Flange Screw Flange Locknut NEGATIVE Black Battery Cable 22NF Battery NEGATIVE Battery Terminal Post CONNECT BATTERY CABLE TO BATTERY TERMINAL AS SHOWN NEGATIVE Battery Terminal Post POSTIVE GEE Tie i Terminal Wrap Post 22 NF Battery BLACK BatteryTerminal Cap FIGURE 5 CONNECTING BATTERY CABLES DIRECT MOUNT METHOD XTERRA GT Part No 1110516 BATTERIES SECTION 8 BATTERY CLAMP METHOD FIGURES 6 7 AND 8 The battery clamps MUST be mounted in the positions shown in FIGURE 6 otherwise the battery box top cannot be installed properly Perform one 1 of the following A If the battery clamp of the POSITIVE battery terminal post is NOT mounted in the orientation shown in FIGURE 5 perform the following Loosen the hex nut that secures the battery clamp to the POSITIVE battery terminal post CAUTION eas 5522 POSITIVE Battery Terminal Post bi ad pes AE Note position of battery clamp Pliers will round off the nuts NEVER wiggle the Es NEGATIVE Battery battery terminal s post s Terminal Post and Battery Clamp when tightening The battery may become damaged Remove the battery clamp from the POSITIVE battery terminal post
39. LING FIGURES 3 AND 4 Secure the seat frame to the flip up seat plate in the mounting location noted in the removal section with the existing four 4 mounting screws spacers if applicable and locknuts Torque mounting screws to 13 ft Ibs 20 FIGURE 4 2 Perform one 1 of the following A FOR I4 AND 5 SEAT DEPTHS Secure each CJ bracket to the seat frame the two 2 washers and locknuts Torque locknuts to 75 in Ibs FIGURE 3 2 Install the back upholstery onto the CJ back brackets Refer to REMOVING INSTALLING BACK UPHOLSTERY in SECTION 5 of this manual SEAT FRAME B FOR l6 17 18 19 AND 20 INCH SEAT DEPTHS Install the back upholstery onto the seat frame Refer REMOVING INSTALLING BACK UPHOLSTERY in SECTION 5 of this manual 4 Install the flip back armrest and secure cable in place with tie wraps Refer to REMOV ING INSTALLING ARMRESTS in SECTION 4 of this manual 5 Install the seat pan Refer to REMOVING INSTALLING SEAT PAN in this section of the manual 6 Install the seat cushion 7 Install the battery box es Refer to INSTALLING REMOVING BATTERY BOXES in SECTION 8 of this manual 8 Install footrest assemblies Refer to PROCEDURE 4 in the Owner s Manual part number 1106627 Part No 1110516 3l XTERRA GT SEAT FRAME SECTION 6 SEAT FRAME REMOVING INSTALLING SEAT FRAME FOR 17 AND 18 INCH SEAT WIDTHS NOTE When installing replacing componen
40. Locknut iis A Progr ammer Blue Wiring Harness A Extension Connector Washer Cable Joystick Connector Fn or Tie Wrap Right Motor Connector t A J EET ll Left Motor neve i HE Connector Controller P Connector ETT 57 Left Controller Connector Locknut and Washer Tie Wrap Tie Wrap Blue Controller Connector Controller NOTE Seat and top portion of base frame removed for clarity FIGURE 7 REMOVING INSTALLING THE MKIV A CONTROLLER Part No 1110516 85 XTERRA GT ELECTRONICS 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 in FIGURE 9 3 To help in removing the controller review DETAIL B in FIGURE 9 and identify each lead and connector 4 Disconnect joystick connector from the controller connector DETAIL in FIGURE 9 Cut the tie wrap that secures the controller joystick connection to the joystick mounting tube Detail in FIGURE 9 6 Cut the three 3 tie wraps that secure the controller cable to the arm tube and seat frame DETAIL in FIGURE 9 7 Cut the two 2 tie wraps that secure the wire harness wrap around the controller cable and motor cable Det
41. N 8 of this manual 2 Remove the front shroud Refer to REMOVING INSTALLING FRONT AND REAR SHROUD in SECTION 7 of this manual 3 Disconnect the joystick connector from the controller DETAIL A ELECTRONICS 4 Disconnect the right motor lead from the right controller connector DETAIL A NOTE There is a section of joystick cable and right motor lead that is covered with a wire harness wrap 5 Cut tie wrap that secure the wire harness wrap to the battery tray DETAIL A 6 Press wire harness wrap down in between suspension arm battery box and controller DETAIL B 7 Feed joystick cable and right motor lead up through the base frame in between the suspension arm and battery box DETAIL B 8 Cut the tie wraps that secures the wire harness wrap to the joystick motor cable DE TAIL B 9 Cut the two 2 tie wraps that secure the joystick cable to the joystick tube DETAIL 10 Cut the remaining three 3 tie wraps that secure the joystick cable to the armrest and seat frame DETAIL Rotate adjustment lock lever and remove joystick tube from mounting bracket DETAIL 12 Pull the joystick and mounting tube with cable from the wheelchair DETAIL INSTALLING FIGURE 4 Install joystick tube into mounting bracket DETAIL Feed the joystick cable through the back of the chair underneath the seat frame Route joystick cab
42. RY in SECTION 5 of this manual 3 Install the flip back armrest and secure cable in place with tie wraps Refer to REMOV ING INSTALLING ARMRESTS in SECTION 4 in this manual 4 Install the seat pan Refer to REMOVING INSTALLING SEAT PAN in this section of the manual 5 Install the seat cushion 6 Install the battery box es Refer to INSTALLING REMOVING BATTERIES in SECTION 8 of this manual 7 Install footrest assemblies Refer to SECTION 8 in the Owner s Manual 1106627 Part No 1110516 27 XTERRA GT SEAT FRAME SEAT FRAME SECTION 6 SEAT FRAME NOTE 16 deep seat frame and CJ back brackets are used to obtain 14 and 15 depths 14 15 16 AND 7 SEAT DEPTHS 18 AND 19 SEAT DEPTHS Mounting Mounting Screws Screws Torque Adjustable 2 Seat Frame Saat Frame 1013 ft lbs Spacers Spacers Use these Use these Mounting 7 Mounting Use these Holes 2 Use these Mounting Ho Holes Mounting Holes l 6 inch Deep up Seat Locknuts Plate 18 Deep Flip Locknuts up Seat Plate Mounting Screws Torque to Adjustable ft lbs Seat Frame SEAT DEPTHS D OF 20 INCH O Spacers Use these Munang s a Use these Holes gt 7 2 Mounting 20 inch Deep lt
43. SEAT FRAMES ADJUSTABLE SEAT FRAME FIGURE 15 Remove footrest assemblies Refer to PROCEDURE 4 in of the Owner s Manual part number 106627 Remove battery box es Refer to INSTALLING REMOVING BATTERIES in SECTION 8 of this manual Remove the seat cushion Remove the seat pan Refer to REMOVING INSTALLING SEAT PAN in this section of the manual Remove flip back armrest Refer to REMOVING INSTALLING ARMRESTS in SECTION 4 of this manual Perform one 1 of the following A For 4 5 seat depths Remove the back upholstery from the back brackets Refer to REMOVING INSTALLING BACK UPHOLSTERY in SECTION 5 of this manual 2 Remove the two 2 washers and locknuts that secure each bracket to the seat frame For 16 17 18 19 and 20 inch seat depths Remove the back upholstery from the seat frame REMOVING INSTALLING BACK UPHOLSTERY in SECTION 5 of this manual XTERRA GT 48 Part No 1110516 SEAT FRAME SECTION 6 REPLACING ONE 1 SIDE FRAME NOTE Note the mounting hole position of the current side frame for proper installation of the NEW side rame f Mounting Screws I Remove the two 2 mounting screws Torque to 13 ft Ibs coved spacers spacers and locknuts that Typical all four 4 secure the side frame to the center frame sgrews o Mounting Screws 2 Install new side frame into existing center Torque to 75 frame at the mounting position previo
44. Service Manual Invacare Xterra Wheelchair DEALER KEEP THIS MANUAL THE PROCEDURES IN THIS MANUAL MUST BE PERFORMED BY A QUALI FIED TECHNICIAN ONLY WARNING v E 2 d 4 Q 72 WARNING THE PROCEDURES IN THIS MANUAL SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN DO NOT SERVICE OR OPERATE THIS EQUIPMENT 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 SPECIAL NOTES WARNING CAUTION notices as used in this manual apply to hazards or unsafe practices which could result in personal injury or property damage 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 WHEELCHAIR TIE DOWN RESTRAINTS AND SEAT POSITIONING STRAPS Invacare recommends that wheelchair users NOT be transported in vehicles of any kind while in wheelchairs As of this date
45. XTERRA GT I gt 0 gt 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 I Remove the batteries Refer to REMOV Motor Gearbox ING INSTALLING BATTERIES in Assembly SECTION 8 in this manual Reference 2 Remove the hub from drive wheel 3 Remove the four 4 beveled hex nuts Wheel that secure the hub cap spring and drive wheel to the drive wheel hub Beveled INSTALLING Hex Nuts Secure the drive wheel and hub cap spring to the drive wheel hub with the four 4 beveled hex nuts Torque to 13 ft Ibs 2 Install the hub cap 3 Install the batteries Refer to RE Hub Cap MOVING INSTALLING BATTERIES Hub Cap Spring in SECTION 8 in this manual FIGURE REMOVING INSTALLING THE DRIVE WHEEL REMOVING INSTALLING DRIVE WHEEL HUB Motor Gearbox Assembly FIGURE 2 REMOVING l Remove the locknut that secures the drive wheel hub washer and keystock to the motor gearbox assembly 2 Remove the drive wheel hub Washer INSTALLING 524 l Install the drive wheel hub onto the o9 Drive Wheel motor gearbox assembly Hub 2 Secure the drive
46. age the controller module but a bad controller will NOT damage a motor XTERRA GT Part No 1110516 HARDWARE TORQUE SPECIFICATIONS SECTION 3 HARDWARE TORQUE SPECIFICATIONS STANDARD SEAT FRAME V ON 1 MUN Torque to wae 60 in lbs Loctite and Torque to 75 in lbs 2 o 4 Q m Q 7 Oo d gt a lt I Torque to 60 in Ibs Seat Loctite and Frame Torque to 75 in lbs Ew SEAT FRAME WITH CJ BACK BRACKETS TO OBTAIN 14 AND 15 INCH SEAT DEPTHS Loctite and NOTE Adjustable seat Torque to frame shown CJ back 75 in lbs brackets attach to the standard seat frame in the same manner Seat Loctite and Frame Torque to 75 in lbs Part No 1110516 13 XTERRA GT SECTION 3 HARDWARE TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS STANDARD p SEAT FRAME VAN SEAT Torque to ft lbs 20 2 Z 4 Q Q a O n 4 gt a lt I Torque to 2 60 inllbs ES 60 in lbs d ENS 553 2 orque to D Y 75 inllbs Torque to ft lbs ADJUSTABLE SEAT FRAME 2096 Torque to Torque to Torque to e 13 Dos 75 inllbs 75 in Ibs T 20 Typ both 3 sides Tube Spacers may not be lt T Te required ke gt depending ace EN S on seat AM o width and depth i i XT
47. ail C in FIGURE 9 8 Cut all tie wraps that secure the controller connector cable and motor cable together DETAIL D in FIGURE 9 9 Pull controller connector through base frame DETAIL D in FIGURE 9 10 Cut the four 4 tie wraps that secure controller cables up against the controller DE TAIL A in FIGURE 10 Disconnect the right motor connector from the right controller connector DETAIL A in FIGURE 10 12 Disconnect the left motor connector from the left controller connector DETAIL in FIGURE 10 13 Disconnect the controller connector from the wiring harness connector DETAIL in FIGURE 10 4 Cut the tie wrap that secures the power take off lead in place DETAIL in FIGURE 10 15 Disconnect the power take off lead from any of the other powered accessory connec tors DETAIL B in FIGURE 10 16 Remove the two 2 washers and locknuts that secure the MKIV RII controller to the battery tray DETAIL A in FIGURE 9 17 Remove the MKIV RII controller from the front of the battery tray DETAIL in FIGURE 9 XTERRA GT 86 Part No 1110516 ELECTRONICS SECTION 9 DETAIL DETAIL IDENTIFYING MKIV RII CONTROLLER CONNECTORS Battery Wire Harness Power Connector Take Off Motor Connector __ RII Controller ELECTRONICS Connector Controller Connector Mounting Screws Lead for Joystick Torque to 40 in Ib
48. ame mounting hole position to main tain proper weight balance of user and seat frame If weight is not balanced injury to the assistant and or user and damage to the wheelchair may result 4 Install existing side frame s into NEW center frame at the mounting position previously noted with two 2 mounting screws coved spacers spacers and locknuts Torque to 75 inch pounds Part No 1110516 49 XTERRA GT SEAT FRAME SECTION 6 SEAT FRAME INSTALLING REMOVING VAN STYLE 5 5 FRAME ASSEMBLY ONTO FROM FLIP UP SEAT PLATE FIGURE 16 REMOVING 1 Remove footrest assemblies Refer to PROCEDURE 4 in of the Owner s Manual part number 1106627 2 Remove battery box es Refer to IN STALLING REMOVING BATTERIES in SECTION 8 of this manual 3 Remove armrests Refer to REMOVING INSTALLING ARMRESTS in PROCE DURE 4 in this manual 4 Remove the four 4 locknuts from the mounting screws that secure the van style seat and seat frame assembly to the flip up seat plate Seat Frame Torque to 13 Assembly ft Ibs 5 Remove van style seat and seat frame assembly ie Seat Plate INSTALLING Position the van style seat seat frame assembly on the flip up seat plate at the mounting position shown Locknuts 2 Secure the van style seat seat frame Assembly to the flip up seat plate with FIGURE 16 REMOVING four 4 mounting screws and locknuts INSTALLING VAN STYLE SEAT Tor
49. brackets Refer to REMOVING INSTALLING BACK UPHOLSTERY in SECTION 5 of this manual B FOR l6 17 18 19 AND 20 INCH SEAT DEPTHS Install the back upholstery onto the seat frame Refer REMOVING INSTALLING BACK UPHOLSTERY in SECTION 5 of this manual Install the flip back armrest and secure cable in place with tie wraps Refer to REMOV ING INSTALLING THE ARMRESTS in SECTION 4 of this manual Install the seat pan Refer to REMOVING INSTALLING SEAT PAN in this section of the manual Install the seat cushion Install the battery box es Refer to INSTALLING REMOVING BATTERIES in SECTION 8 of this manual Install footrest assemblies Refer to PROCEDURE 4 in the Owner s Manual part number 1106627 XTERRA GT 34 Part 1110516 SEAT FRAME SECTION 6 REMOVING INSTALLING SEAT FRAME FOR 19 AND 20 INCH SEAT WIDTHS NOTE When installing replacing components of the wheelchair refer to the individual procedure for correct use of LOCTITE 242 and torque specifications or SECTION 3 of this manual REMOVING FIGURES 7 AND 8 l 2 Remove footrest assemblies Refer to PROCEDURE 4 in the Owner s manual 1106627 Remove battery box es Refer to INSTALLING REMOVING BATTERIES in SECTION 8 of this manual Remove the seat cushion Remove the seat pan Refer to REMOVING INSTALLING SEAT PAN this section of the manual Remove flip back armrest Refer to REMOVING INSTALLING ARMRESTS in SECTION 4
50. cable and lock nuts that secure the seat frame to the flip up seat plate 8 Remove the existing seat frame XTERRA GT 32 Part No 1110516 SEAT FRAME 14 15 16 AND 7 SEAT DEPTHS Mounting Screws Torque to 13 ft Ibs Standard f5 Seat Frame Use these Mounting Holes 6 inch Deep Flip up Seat Plate Locknuts Mounting Screws Torque to ft Ibs SEAT DEPTHS OF 20 INCH Use these Mounting Holes 20 inch Deep Flip up Seat Plate SECTION 6 18 AND 19 INCH SEAT DEPTHS Mounting Screws Torque to 13 ft Ibs Use these Mounting Holes Deep up Seat Plate Adjustable Seat Frame SEAT FRAME Locknuts Adjustable Seat Frame 3 4 inch Tube Spacers Locknuts FIGURE 6 REMOVING SEAT FRAME 17 AND 18 INCH SEAT WIDTHS Part No 1110516 33 XTERRA GT SEAT FRAME SECTION 6 SEAT FRAME INSTALLING FIGURES 5 AND 6 Secure the seat frame to the flip up seat plate in the mounting location noted in the removal section with the existing four 4 mounting screws spacers if applicable and locknuts Torque mounting screws to 13 ft Ibs 2076 FIGURE 6 Perform one 1 of the following A FOR I4 AND 5 SEAT DEPTHS Secure each bracket to the seat frame the two 2 washers and locknuts Torque locknuts to 75 in Ibs FIGURE 5 2 Install the back upholstery onto the CJ back
51. ck assembly or changing back height follow these guidelines for spreader bar height where appli Back Cane SW cable Spacers BACK HEIGHT SPREADER BAR Mounting HEIGHT ER 16 inches 5 inches 17 inches 5 inches Locknut 18 19 inches 7 inches Washoe 2 20 22 inches 7 inches NOTE Spreader Bar required on back heights 20 Back 22 inches Spreader bar ONLY required these Upholstery back heights if the width or depth of the chair ex Mounting ceeds 19 Insert Screw Height of Spreader Bar from Bottom of Torque Back Canes to Top of Spreader Bar Clamp to 60 in Ibs 17 If necessary reposition the spreader bar at the correct height for the corresponding Mounting Screws back height and torque the mounting Torque to 75 inllbs Washers hardware to 60 inch pounds 18 Reinstall the armrest onto the wheelchair FIGURE 4 REMOVING Refer to INSTALLING REMOVING FLIP INSTALLING BACK UPHOLSTERY BACK ARMRESTS in SECTION 4 of this manual BACK ANGLE ADJUSTMENT FIGURE 5 Remove armrests from the wheelchair Refer to INSTALLING REMOVING FLIP BACK ARM RESTS in this manual 2 Remove the mounting screw and washer from the top mounting hole of back angle plate and back cane NOTE To avoid losing the insert in each back cane thread the mounting screw through the cane from the inside of wheelchair to hold the insert in place XTERRA GT 24 Part No 1110516 SE
52. ck bracket Secure the quick release pin seat positioning strap and CJ back bracket to the seat frame Torque to 75 inch pounds 4 Install washers and locknuts onto the threaded studs of the back bracket Torque to 75 inch pounds 5 Perform the steps outlined in REASSEMBLE THE CHAIR XTERRA GT 40 Part No 1110516 SEAT FRAME SECTION 6 Mounting Back Seat Screw Bracket Positioning Back Threaded Angle Studs Locknuts lt Torque to 75 in Ibs ul Pan Quick Release Pin Locknut FIGURE 9 REMOVING INSTALLING CJ BACK BRACKETS REMOVING INSTALLING SEAT PAN FIGURE 10 Removing Remove the seat cushion from the seat pan 2 Remove the flip back armrests from the wheelchair Refer to INSTALLING REMOVING FLIP BACK ARMRESTS in SECTION 4 of this manual 3 Remove the six 6 mounting screws locknuts and spacers that secure the seat pan seat positioning strap and quick release pin to the seat frame NOTE When removing seat pan note tab position of quick release pin in relation to the seat position ing strap for reinstallation Installing I Position the NEW seat pan on the seat frame aligning the mounting holes of the seat pan and the mounting holes of the seat frame 2 Position the seat positioning strap and quick release pin tab onto the seat frame and secure with mounting screw and locknut See FIGURE 9 for proper orientation Repeat for other seat position
53. dth is above 16 wide a fixed seat frame is required For all changes below 16 wide perform the outlined steps below Remove footrest assemblies Refer to PROCEDURE 4 in of the owner s manual part no 1106627 Remove battery box es Refer to INSTALLING REMOVING BATTERIES in SECTION 8 of this manual Back Remove the seat cushion Wash asner Bracket Remove the seat pan Refer to REMOV ING SEAT PAN in this section of the manual Locknut Remove flip back armrest Refer to REMOVING INSTALLING ARMRESTS in SECTION 4 of this manual Perform one 1 of the following A For 14 and 5 seat depths Remove the back upholstery from the back brackets Refer to REMOVING INSTALLING BACK UPHOLSTERY in SECTION 5 of this manual 2 Remove the two 2 washers and FIGURE 13 REMOVING locknuts that secure each CJ INSTALLING SEAT FRAME FOR 14 bracket to the seat frame AND 5 SEAT WIDTHS B For 16 17 18 19 and 20 inch seat depths Remove the back upholstery from the seat frame Refer to REMOVING IN STALLING BACK UPHOLSTERY in SECTION 5 of this manual XTERRA GT 46 Part No 1110516 SEAT FRAME SECTION 6 7 Review the chart below for the allowable seat width and seat depth combinations for the adjustable seat frame NOTE The seat widths and seat depths enclosed in the outlined box will require the use of CJ back brackets and a 7 inch dee
54. eceptacle replaced with a properly grounded three prong wall receptacle in accordance with the National Elec trical Code If you must use an extension cord use ONLY a three wire exten sion cord having the same or higher electrical rating as the device being connected addition Invacare has placed RED ORANGE WARNING TAGS on some equipment DO NOT remove these tags o 2 l 2 5 2 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 recommends their use as the power source for this unit Carefully read battery battery charger information prior to installing servicing or operating your wheelchair RAIN TEST INVACARE has tested it s power wheelchairs in accordance with ISO 7176 Rain Test This design provides the user or his her attendant time to remove the power wheelchair from a rain storm and retain wheelchair operation DO NOT leave power wheelchair in a rain storm of any kind DO NOT use power wheelchair in a shower DO NOT leave power wheelchair in a damp area for extended period of time Direct exposure to rain or dampness will cause the chair to malfunction electri cally and mechanically and may cause the chair to rust prematurely Check to ensure that the battery covers are secured in place joystick boot is NOT torn or cracked where water can enter and that all elect
55. efer to REMOVING SEAT PANI in this section of the manual Install the seat cushion Install che battery box es Refer to INSTALLING REMOVING BATTERIES in SECTION 8 of this manual Install footrest assemblies Refer to PROCEDURE 4 in the Owner s Manual part num 106627 Part 1110516 37 XTERRA GT SEAT FRAME SECTION 6 SEAT FRAME CHANGING SEAT DEPTH FIXED SEAT FRAME AND ADJUSTABLE SEAT FRAME FIXED SEAT FRAME Find current seat depth in left hand column in the chart below 2 Follow that row across underneath SEAT FRAME COMPONENTS 3 Verify and note the components of the current seat depth COMPONENTIDENTIAC ATION TABLE FOR 4 Repeat STEPS 1 3 and note the SIANDARD SEATFRAME components for the desired seat SEAT FRAME COMPONENTS depth 5 Compare existing components of BRACKETS SEAT the current seat depth and the REQUIRED required components for the 14 inches desired Sede depu to 17 inch 16 inch deep 6 Perform one 1 ofthe following 15 inches amp inches 16 inch 16 inch deep A If the current seat depth and HTinches NO 17 inch 16 inch deep odreda Hinchee NO Bind T8inch deen within she 14 IS inch seat Tigvinches No 19 men 18 deep eos gt 20 inches 20 inch 20 inch deep be accomplished by reposi tioning the back canes on the back brackets Refer to CHANGING SEAT DEPTH BETWEEN 14 15 5 this section of
56. elease pin that secures the flip back armrest to the rear arm socket Quick 3 Perform one 1 of the following Release Pin A ARMREST WITH JOYSTICK Cut the tie wraps that secure the joystick cable to the seat frame Flip Back Armrest Release Lever Front Arm Socket MKIV A joystick Pull up on the flip back armrest and remove the armrest LOCKED from the arm sockets and lay on floor VERTICAL MKIV RII joystick Disconnect joystick lead from controller lead at junction point UNEOCKEB on joystick tube Pull up on the flip back HORIZONTAL armrest and remove the armrest from the arm sockets FIGURE 3 INSTALLING REMOVING B ARMREST W O JOYSTICK FLIP BACK ARMRESTS Pull up on the flip back armrest and remove the armrest from the arm sockets 4 Remove the remaining flip back armrest from the wheelchair XTERRA GT 18 Part No 1110516 ARMS SECTION 4 INSTALLING Visually inspect to ensure flip back armrest release lever is in the unlocked HORIZONTAL position 2 Slide the flip back armrest into the arm sockets on the seat frame Install the quick release pin through the rear arm socket and flip back armrest 4 Lock the flip back armrest by pressing the flip back armrest release lever into the VERTI CAL position 5 FOR ARMREST WITH JOYSTICK MKIV A joystick Secure the joystick cable to the seat frame with new tie wraps MKIV RII joystick Connect joystick lead and controller lead and secu
57. els If within such warranty period any such product shall be proven to be defec tive such product shall be repaired or replaced at Invacare s option This warranty does not include any labor or shipping charges incurred in replacement part installation or repair of any such product Invacare s sole obligation and your exclusive remedy under this warranty shall be limited to such repair and or replacement WARRANTY This warranty pertains to Xterra GT power wheelchair Only For warranty service please contact the dealer from whom you purchased your Invacare product In the event you do not receive satisfactory warranty service please write directly to Invacare at the address at the bottom of the back cover Provide dealer s name address date of purchase indicate nature of the defect and if the product is serialized indicate the serial number Do not return products to our factory without our prior consent LIMITATIONS AND EXCLUSIONS THE FOREGOING WARRANTY SHALL NOT APPLY TO SERIAL NUMBERED PRODUCTS IF THE SERIAL NUMBER HAS BEEN REMOVED OR DEFACED PRODUCTS SUBJECTED TO NEGLIGENCE ACCIDENT IMPROPER OPERA TION MAINTENANCE OR STORAGE COMMERCIAL OR INSTITUTIONAL USE PROD UCTS MODIFIED WITHOUT INVACARE S EXPRESS WRITTEN CONSENT INCLUDING BUT NOT LIMITED TO MODIFICATION THROUGH THE USE OF UNAUTHORIZED PARTS ORATTACHMENTS PRODUCTS DAMAGED BY REASON OF REPAIRS MADE TO ANY COMPONENT WITHOUT THE SPECIFIC CONSENT OF INVACARE ORTOA PRODU
58. ension 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 9 Install the front shroud Refer to REMOVING INSTALLING FRONT AND REAR SHROUD in SECTION 7 of this manual 10 Install the flip up seat plate Refer REMOVING INSTALLING FLIP UP SEAT PLATE SECTION 7 of this manual Install the seat from the base frame Refer to REMOVING INSTALLING SEAT in SEC TION 6 of this manual 12 Install the batteries Refer to REMOVING INSTALLING BATTERIES in SECTION 8 of this manual EXPLODED VIEW Base Frame Locknut ASSEMBLED VIEW IET 5 Flat Washers 5 inch aes Mounting Screw Locknut Base Frame Weldments EN Flat Washers Me Spring Spacer Suspension Arm T pring a Weldment Spring Spacer RE Spring Retainer Spring Retainer a Spring eo Flat Washers Flat Washers 2 inches of thread 2 26 Suspension 5 inch Arm Mounting Screw FIGURE 6 REMOVING INSTALLING MOTOR GEARBOX SUSPENSION ARM ASSEMBLY AND SUSPENSION SPRING HARDWARE XTERRA GT 96 Part No 1110516 MOTORS WHEELS SECTION 10 REMOVING INSTALLING CASTERS FIGURE 7 REMOVING I Remove the two 2 mounting screws locknuts that secure the hub cab onto the caster 2 Remove the locknut and washers that secures the caster to the fork
59. ensor cable 9 Disconnect the motor connector from the controller connector and the sensor cable from the power take off lead NOTE There may be some tie wraps that need to be cut before disconnecting Note location of tie wraps for proper reinstallation 10 Feed motor sensor cable up through base frame 11 Remove the wire harness wrap from around the motor sensor cables 12 Remove the two 2 allen screws and washers that secure the motor to the gearbox 13 Carefully pull the motor away from the gearbox Part No 1110516 91 XTERRA GT v I 2 2 0 gt v I gt o 0 gt SECTION 10 MOTORS WHEELS INSTALLING FIGURE 3 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 Install coupling onto gearbox input shaft inserting coupling drive plate onto slot on shaft C Carefully align motor and coupling and place motor against gearbox D With motor against gearbox turn gearbox drive shaft until the coupler seats into gearbox NOTE When properly aligned motor will be seated into gearbox 2 Install two 2 allen screws Use Loctite 242 tighten allen screws evenly and then torque to 75 inch 165 3 Install the wire harness wrap around the
60. entnnent 17 REPLACING VAN STYLE SEAT ARMREST 2 000 00 11 17 5 24 rto Uia 18 SECTION 5 BACK REPLACING SEAT POSITIONING 5 22 2 20 REMOVING INSTALLING BACK UPHOLSTERY 20 0 21 23 BACK ANGLEESADIUSTMENT 22 be eee descanso unco 24 SECTION 6 SEAT FRAME REMOVING INSTALLING SEAT FRAME FOR 14 AND 15 SEAT WIDTHS 26 REMOVING INSTALLING SEAT FRAME FOR 16 SEAT WIDTHS 29 REMOVING INSTALLING SEAT FRAME FOR 17 AND 18 INCH SEAT WIDTHS 32 REMOVING INSTALLING SEAT FRAME FOR 19 AND 20 INCH SEAT WIDTHS 35 CHANGING SEAT DEPT El iit ttt t trt er ee eres 38 REMOVING INSTALLING CJ BACK BRACKETS eerte entente nte tnnt tenentes 40 REMOVING INSTALLING SEAT 2 2 2 41 CHANGING SEAT WIDTH OF FIXED SEAT FRAMES 16 17 18 19 AND 20 INCH WIDE eene 45 CHANGING SEAT WIDTH OF ADJUSTABLE SEAT FRAMES 14 15 AND 16 WIDE eere tette 46 COMPONENT REPLACEMENT FOR 14 15 INCH AND I6 INGH SEAT FRAMES neret eroe eoe eor reet rt 48
61. ese X Mounting Holes 5 8 inch 1 ia gt Deep Flip BS po up Seat Locknuts Plate Locknuts Plate Mounting Screws Torque to 56 inch pounds Adjustable Seat Frame 20 INCH SEAT DEPTHS Use these d I Tube Mounting pacers Holes 20 inch Deep Flip up Seat Plate Locknuts FIGURE 8 REMOVING INSTALLING SEAT FRAME 19 20 INCH SEAT WIDTHS XTERRA GT 36 Part No 1110516 SEAT FRAME SECTION 6 INSTALLING SEAT FRAME FOR 19 AND 20 INCH SEAT WIDTHS FIGURES 7 AND 8 Secure the seat frame to the flip up seat plate the mounting location noted in the removal section with the existing four 4 mounting screws spacers if applicable and locknuts Torque mounting screws to 13 ft Ibs 20 FIGURE 8 Perform one 1 of the following A For 4 and 15 inch seat depths Secure each bracket to the seat frame with the two 2 washers and locknuts Torque locknuts to 75 in Ibs FIGURE 7 2 Install the back upholstery onto the CJ back brackets Refer to REMOVING INSTALLING BACK UPHOLSTERY in SECTION 5 of this manual SEAT FRAME For 16 17 18 19 and 20 inch seat depths Install the back upholstery onto the seat frame Refer to REMOVING INSTALL ING BACK UPHOLSTERY in SECTION 5 of this manual Install the flip back armrest and secure cable in place with tie wraps Refer to REMOV ING INSTALLING ARMRESTS in this section of the manual Install the seat pan R
62. f the manual 4 Install the seat cushion Install battery box es Refer to INSTALLING REMOVING BATTERIES in SECTION 8 of this manual 6 Install footrest assemblies Refer to SECTION 4 in of the owner s manual part number 1106627 XTERRA GT 42 Part No 1110516 SEAT FRAME SECTION 6 ADJUSTABLE SEAT FRAME FIGURE I 1 UM Find current seat depth in left hand column in the chart Follow that row across to underneath seat frame components Verify and note the components of the current seat depth Repeat STEPS 1 3 and note components for the desired seat depth gt ts of 22022 coute COMPONENT IDENTIFICATION TABLE lt required components for the FOR STANDARD SEAT FRAME desired seat depth SEAT FRAME COMPONENTS 4 To adjust the depth of the seat CJ BACK the wheelchair use the SEAT BRACKETS SEAT following guidelines DEPTH REQUIRED PAN A If the current seat depth and 14 inches the desired seat depth are or 17 inch within the 14 15 inch seat 15 depth range this change can 16 inches NO 16 inch Short Short be accomplished by reposi 17 NO 17 Shot Shot tioning the back canes on the amp inches NO 18inch Medium Short CJ back brackets Refer to 19 inches NO 19 inch Medium Short CHANGING SEAT DEPTH 20 20Hnch Long Long BETWEEN 14 15 INCHES i this sectionof the
63. f the battery cells Most batteries are not sold with instructions However warnings are frequently noted on the cell caps Read them carefully Remove the battery box es Refer to INSTALLING REMOVING BATTERIES SECTION 8 of this manual 2 Remove the battery caps from the battery 3 Squeeze the air from the hydrometer 4 Place the hydrometer into a battery cell NOTE DO NOT fill hydrometer more than 3 4 full Number of Floating Balls Will Vary Accord ing to Charge 5 Draw up sufficient acid to cover float balls 6 Tap lightly to remove air bubbles 7 Number of floating balls indicates charge NUMBER OF FLOATING BALLS 0 Discharged 2576 Charged FIGURE 2 USING HYDROMETER TO CHECK BATTERY CELLS 2 50 Charged LEAD ACID 3 7576 Charged 4 10076 Charged 5 Overcharged Check charging system 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 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 Reinstall battery boxes Refer to INSTALLING REMOVING BATTERIES in SECTION 8 of XTEHRA Mag yal 10 Part No 1110516 TROUBLESHOOTING MOTOR TESTING FIGURE 3 l On the 4 pin motor connecto
64. help you understand this automatic process They are The amount of electrical current drawn within a given time to charge a battery is called the 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 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 SS SSS NOTE If performing the charging procedures independently READ and CAREFULLY follow the indi vidual instructions for each charger supplied or purchased NOTE If charging instructions are not supplied consult a qualified service technician for proper proce dures REQUIRED ITEMS TOOL QUANTITY COMMENTS Battery Charger Extension Cord Not Supplied 3 prong plug 15 ampere current rating industrial type l Perform one 1 of the following A WHEELCHAIRS EQUIPPED WITH MKIV A OR MKIV A JOYSTICK Attach the battery charger connector to the charger cable battery harness NOTE The battery charger connector is factory ins
65. hreaded plate with two 2 mounting screws at same degree of tilt determined in STEP 13 Hand tighten 18 Securely tighten mounting screws from STEPS 15 and 17 Part No 1110516 59 XTERRA GT BASE FRAME 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 Re secure the prop seat bracket in the proper mounting hole of the prop threaded 20 Install the flip up seat plate Refer to REMOVING INSTALLING FLIP UP SEAT PLATE in this section of the manual 21 Install the seat Refer to REMOVING INSTALLING SEAT FRAME in SECTION 6 of this manual 22 Install the batteries Refer to REMOVING INSTALLING BATTERIES in SECTION 8 of this manual XTERRA GT 60 Part No 1110516 BASE FRAME SECTION 7 CHART A SPRING RELEASEHANDLE Use this mounting fA Use this mounting Hook hole for 0 tilt Sey hole for O tilt Release Assembly Use this mounting N Use this mounting hole for 3 hole for 3 tilt 2 Handle Release Bracket x lt i Orientationfor 3 tilt 7 Mounting Screws BASE FRAME Prop Threaded oy Bottom of Plate 7 i Flip up Seat Plate Handle Release Bracket Orientation for O tilt Release Handle Handle Release
66. 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 Remove the two 2 mounting screws that secure the battery charger port to the port bracket 4 Remove the locknut that secures the program extension cable to the charger port Remove the two 2 locknuts that secure the spade rod battery retention strap and charger port bracket to the front of the battery tray INSTALLING Secure the program extension cable to the charger port with locknut 2 Secure the spade rod battery retention strap and charger port bracket to the front of the battery tray with two locknuts Torque locknuts to 75 in Ibs 3 Secure the battery charger port to the port bracket with two 2 mounting screws Securely tighten 4 Install the front shroud Refer to REMOVING INSTALLING FRONT AND REAR SHROUDS in this section of the manual 5 Install the batteries Refer to REMOVING INSTALLING BATTERIES in SECTION 8 of this manual Battery Retention Battery Tray Strap Spade is Locknuts Battery Charger Port Mounting Screws for Battery charger Port Program Extension Locknut Cable Port Bracket FIGURE 5 REMOVING INSTALLING PORT BRACKET Part No 1110516 57 XTERRA GT BASE FRAME BASE FRAME SECTION 7 BASE FRAME REMOVING INSTALLING BATTERY TRAY FIGURE 6 REMOVING 1 Remove the batteries Refer to REMOVING INST
67. inch diameter washer and locknut that secures the right side of the flip up seat plate to the adjustment bracket Remove the 3 8 x l inch mounting screw two 2 3 8 inch diameter washers 5 8 inch diameter washer and locknut that secures the left side of the flip up seat plate to the adjustment bracket A Remove the 3 4 inch mounting screw two 2 bushings two 2 7 8 inch dia washer two 2 spring washers 5 8 inch dia washer and locknut that secures the seat prop to adjustment bracket INSTALLING Secure the seat prop to adjustment bracket with one 1 1 3 4 inch mounting screw two 2 bushings two 2 7 8 inch diameter washer two 2 spring washers 5 8 inch diam eter washer and locknut Torque to 13 ft lbs M Secure the left side of the flip up seat plate to the adjustment bracket with one 1 3 8 x 1 inch mounting screw two 2 3 8 inch diameter washers 5 8 inch diameter washer and locknut Torque to 13 ft Ibs 199 Secure the right side of the flip up seat plate to the adjustment bracket with one 1 3 8 x l inch mounting screw two 2 3 8 inch diameter washers 5 8 inch diameter washer and locknut Torque to 13 ft Ibs gt Install the seat frame Refer to one 1 of the procedures SECTION 6 of this manual A REMOVING INSTALLING SEAT FRAME FOR 14 AND 15 SEAT WIDTHS B REMOVING INSTALLING SEAT FRAME FOR 16 SEAT WIDTHS C REMOVING INSTALLING SEAT FRAME FOR 17 AND 18
68. inch wide Component Replacement for 14 15 and 16 inch Seat Frames Installing Removing Van Style Seat Seat Frame Assembly from Flip up Seat Plate InstallinglRemoving Van Style Seat from Seat Frame Assembly After ANY adjustments repair or service and BEFORE use make sure that all attach ing hardware is tightened securely otherwise injury or damage may result REMOVING INSTALLING SEAT FRAME FOR 14 AND 15 INCH SEAT WIDTHS NOTE When installing replacing components of the wheelchair refer to the individual procedure for correct use of LOCTITE 242 and torque specifications or SECTION 3 of this manual REMOVING FIGURES AND 2 Back ac 1 Remove footrest assemblies Refer to Washer Bracket nc PROCEDURE 4 in the owner s manual Locknut part number 1106627 Torque to 2 Remove battery box es Refer to IN 75 in Ibs STALLING REMOVING BATTERIES in SECTION 8 of this manual Remove the seat cushion 4 Remove the seat pan Refer to REMOV ING THE SEAT PAN in this section of the manual 5 Remove flip back armrest Refer to REMOVING INSTALLING THE ARM Frame RESTS in SECTION 4 of this manual FIGURE REMOVING SEAT FRAME 14 15 INCH SEAT WIDTHS XTERRA GT 26 Part No 1110516 SEAT FRAME SECTION 6 6 Perform one 1 of the following A FOR 14 AND 5 SEAT DEPTHS Remove the back upholstery from the back brackets Refer to REMOVING INSTALL
69. ing strap NOTE Check seat positioning strap for proper length The width range for the four 4 seat positioning straps are 12 16 wide Junior 16 19 wide 20 22 inches wide and 23 24 inches wide 3 Reinstall the remaining mounting screws locknuts and spacers Torque all mounting screws to 75 inch pounds 4 Remove the protective strips from new seat pan and reinstall the seat cushion onto the seat pan 5 Perform one 1 of the following A When changing the seat width or depth refer back to that procedure to complete the desired change Part No 1110516 41 XTERRA GT SEAT FRAME SECTION 6 SEAT FRAME Mounting Screws Seat Positioning Strap SD Seat Frame Tab Locknut Locknut Quick Release Pin NOTE Illustration shows fixed frame only for clarity The seat pan removes installs onto the adjustable seat frame the way FIGURE 10 REMOVING INSTALLING SEAT PAN RE ASSEMBLING THE CHAIR NOTE When installing replacing components of the wheelchair refer to the individual procedure for correct use of LOCTITE 242 and torque specifications or SECTION 3 of this manual 1 Install the back upholstery Refer to REMOVING INSTALLING BACK UPHOLSTERY in SECTION 5 of this manual 2 Install the flip back armrests onto the wheelchair Refer to INSTALLING REMOVING FLIP BACK ARMRESTS in SECTION 4 of this manual 3 Install the seat pan Refer to REMOVING INSTALLING SEAT PAN in this section o
70. ius inch Deep Flip up SS Seat Plate Xe FIGURE 2 REMOVING SEAT FRAME 14 15 SEAT WIDTHS XTERRA GT 28 Part No 1110516 SEAT FRAME SECTION 6 REMOVING INSTALLING SEAT FRAME FOR 16 SEAT WIDTHS NOTE When installing replacing components of the wheelchair refer to the individual procedure for correct use of LOCTITE 242 and torque specifications or SECTION 3 of this manual REMOVING FIGURES 3 AND 4 Lu I Remove footrest assemblies Refer to PROCEDURE 4 in the Owner s Manual part no 1106627 lt 2 Remove battery box es Refer to INSTALLING REMOVING BATTERY BOX in SEC TION 8 of this manual m Remove the seat cushion FIXED SEAT FRAME v 4 Remove the seat pan Refer to REMOV Back ING SEAT PAN in this section of the Bracket manual 5 Remove flip back armrest Refer to REMOVING INSTALLING ARMRESTS in SECTION 4 in this manual 6 Perform one 1 of the following A For 14 and 5 seat depths Remove the back upholstery from the CJ back brackets Refer to REMOVING INSTALLING BACK UPHOLSTERY in SEC TION 5 of this manual 2 Remove the two 2 washers and locknuts that secure each CJ bracket to the fixed or adjustable seat frame B For 16 17 18 19 and 20 inch seat depths Remove the back upholstery from the seat frame Refer to REMOVING INSTALLING BACK UPHOLSTERY in SECTION 5 of this manual NOTE When performing STEP 7 no
71. justment Lock Lever FIGURE 5 REMOVING INSTALLING THE MKIV RII JOYSTICK XTERRA GT 82 Part 1110516 ELECTRONICS SECTION 9 VAN SEAT ASBA SEAT WITH QUAD LINK JOYSTICK MOUNTING ELECTRONICS VAN SEAT WITH QUAD LINK JOYSTICK MOUNTING FIGURE 6 TIE WRAP LOCATIONS FOR OTHER MKIV RII JOYSTICK MOUNTING OPTIONS Part 1110516 83 XTERRA GT ELECTRONICS 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 in FIGURE 8 3 Cut the three 3 tie wraps that secure controller cables up against the controller Refer to DETAIL B in FIGURE 8 4 Disconnect the right motor connector from the right controller connector Refer to DETAIL B in FIGURE 8 5 Disconnect the left motor connector from the left controller connector Refer to DETAIL B in FIGURE 8 6 Disconnect the blue controller connector from the blue wiring harness connector Refer to DETAIL B in FIGURE 8 7 Disconnect the joystick connector from the controller Refer to DETAIL B in FIGURE 8 Disconnect the programmer extension cable from the controller Refer to DETAIL B in FIGURE 8 9 Remove the two 2 washers and locknuts that secure the MKIV A controller
72. lack battery cable to the battery clamp of the positive battery terminal post Remove the hex screw that secures the POSITIVE red battery cable to the battery clamp of the positive battery terminal post NOTE To transfer battery clamps to new battery perform the following Remove the hex screw and locknut that secures the battery clamp to the negative battery terminal post Remove battery clamp Remove the hex screw and locknut that secures the battery clamp to the positive battery terminal post Remove battery clamp Part No 1110516 65 XTERRA GT BATTERIES SECTION 8 DEATIL DIRECT MOUNT METHOD Terminal Cap Installation NEGATIVE Battery RED Terminal Post POSITIVE Battery Terminal Post Battery Terminal le Wrap 55 BLACK Battery 22NF Battery Terminal Cap Terminal Cable Connection POSITIVE Red Battery Cable 114 20 Hex Flange 1 4 20 Hex Screw Flange Locknut NEGATIVE Battery Terminal Post BATTERIES DETAIL BATTERY CLAMP METHOD Terminal Cover Installation RED Battery positive Battery Clamp Cover Terminal Post NEGATIVE Battery Terminal Post Tie Wrap BLACK Battery 22NF Battery Camp Corer Tie Wrap Terminal Cable Connection Positive RED Battery Cable Hex Screw DW Mounting Plate F Negative BLACK D Battery Cable POSITIVE Battery 22NF Bat
73. le as shown in DETAIL Secure the joystick cable with tie wraps as shown in DETAIL Ur he oun Join joystick cable and motor lead together with tie wraps The joystick cable must extend approximately 5 1 2 beyond end of motor lead in order to connect to the controller DETAIL B 6 Position wire harness wrap around joystick cable motor cable lead leaving approximately 6 inches from end of motor lead DETAIL B Secure the wire harness wrap in place with one tie wrap on each end DETAIL Feed joystick cable and right motor lead down through the base frame in between the suspension arm and battery box DETAIL B Part No 1110516 79 XTERRA GT BASE FRAME 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 10 Secure wire harness wrap to battery tray with tie wrap DETAIL B Connect the right motor lead from the right controller connector DETAIL A 12 Connect the joystick connector from the controller DETAIL A 13 Install the front shroud Refer to REMOVING INSTALLING FRONT AND REAR SHROUD in SECTION 7 of this manual DETA
74. ll vary with battery conditions surface terrain and operator s weight Part No 1110516 SECTION I GENERAL GUIDELINES This Section Includes the Following Repair or Service Information Operating Information REPAIR OR SERVICE INFORMATION Set up of the Electronic Control Unit is to be performed ONLY by individuals certified by Invacare The final tuning adjustments of the controller may affect other activities of the wheelchair Damage to the equipment could occur under these circumstances The warranty is void if non certified indi viduals perform any work on these units OPERATING INFORMATION GENERAL WARNINGS Performance adjustments should only be made by professionals of the healthcare field or persons fully conversant with this process and the driver s capabilities Incorrect settings could cause injury to the driver bystanders damage to the chair and to surrounding property After the wheelchair has been set up check to make sure that the wheelchair performs to the specifications entered during the set up procedure If the wheelchair does NOT perform to specifications turn the wheelchair OFF immediately and reenter set up specifications Repeat this procedure until the wheelchair performs to specifications DO NOT operate on roads streets or highways DO NOT climb go up or down ramps or traverse slopes greater than 9 DO NOT attempt to move up or down an incline with a water ice or oil film DO NOT attempt to
75. manual NOTE Note the four 4 different lengths of side frames i short medium long and X long as well as the two differ B If the desired ch center frames short and long These components Pere o NEW interchanged to obtain the various different seat depths i e changing from 16 to 17 inch or 18 inch to 19 inch refer to REMOVING INSTALLING SEAT PAN in this section of the manual C If the desired change requires the removal installation of CJ back brackets refer to REMOVING INSTALLING CJ BACK BRACKETS in this section of the manual D If the desired change requires a new side frame and or new center frame perform the following steps ay Remove footrest assemblies Refer to PROCEDURE 4 in the Owner s manual part number 1106627 Remove battery box es Refer to INSTALLING REMOVING BATTERIES in SECTION 8 of this manual Remove the seat cushion Remove the seat pan Refer to REMOVING INSTALLING SEAT PAN in this section of the manual Remove flip back armrest Refer to REMOVING INSTALLING ARMRESTS in SECTION 4 of this manual Remove the back upholstery from the seat frame Refer to REMOVING IN STALLING BACK UPHOLSTERY in SECTION 5 of this manual Part No 1110516 43 XTERRA GT SEAT FRAME SECTION 6 SEAT FRAME 6 Perform one 1 of the following A For 14 and 5 seat depths Remove the back upholstery from the CJ back brackets Refer to RE MOVING INST
76. nect the power take off lead from the other optional power connectors DETAIL C in FIGURE 1 7 Remove the two 2 mounting screws that secure the battery charger port to the mounting bracket DETAIL in FIGURE 1 8 Remove battery charger port from mounting bracket by pulling forward and feeding cable through cutout in mounting bracket DETAIL in FIGURE 1 9 Remove battery wiring harness from base frame by feeding power take off lead blue battery connector and battery charger port up through cutout in battery tray INSTALLING Install battery wiring harness into base frame by feeding power take off lead blue battery connector and battery charger port down through cutout in battery tray DETAIL in FIGURE 1 2 Position battery charger port into mounting bracket by feeding cable up through cutout and push backward DETAIL in FIGURE 1 3 Secure the battery charger port to the mounting bracket with two 2 mounting screws DETAIL in FIGURE 1 Securely tighten 4 Connect the power take off lead to other optional power connectors if necessary DE C in FIGURE 1 5 Connect the battery wiring harness blue connector to the controller blue connector DETAIL C in FIGURE 1 Secure the power take off lead in place with NEW tie wrap DETAIL in FIGURE 1 Secure the front shroud in place with two 2 NEW mounting screws and washers DE B in FIGURE 1
77. nector from the controller connector 9 Remove battery wiring harness from base frame by feeding the blue lead up through cutout in battery tray INSTALLING Install the battery wiring harness from base frame by feeding controller blue lead down through cutout in battery tray 2 Connect the battery wiring harness connector to the controller connector 3 Secure the front shroud in place with two 2 mounting screws and washers Refer to DETAIL in FIGURE 2 Torque mounting screws to 40 in Ibs 4 Install the batteries Refer to REMOVING INSTALLING BATTERIES in SECTION 8 of this manual Part No 1110516 77 XTERRA GT ELECTRONICS SECTION 9 ELECTRONICS DETAIL A IDENTIFYING DETAIL BATTERY WIRING HARNESS CONNECTORS To Batteries To Batteries S 2 RII Controller Locknuts Mounting Screws Torque to 40 in Ib To Controller DETAIL Battery Wiring Cut out Harness Blue Connector in Battery Tray Controller Connector FIGURE 2 REMOVING INSTALLING THE MKIV WIRING HARNESS XTERRA GT 78 Part No 1110516 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 SECTIO
78. nts repair or service and BEFORE use make sure that all attaching hardware is tightened securely otherwise injury or damage may result REPLACING ARMREST PADS VAN STYLE SEAT FIGURE 1 Remove the mounting screw that secures REAR the front of the armrest pad to the armrest DONE Insert Armrest plate 2 Remove the mounting screw that secures 1 FRONT 1 the rear of the armrest pad and armrest insert to the armrest plate 3 Remove the EXISTING armrest pad and position the NEW armrest pad on the armrest plate Mounting Armrest Plate Screw Mounting Screw FIGURE REPLACING ARMREST PADS VAN STYLE SEAT 4 Line up the mounting holes in the armrest insert armrest plate and NEW armrest pad 5 Reinstall the rear mounting screw through the armrest insert armrest plate and armrest pad and tighten securely 6 Reinstall the front mounting screw into the armrest plate and NEW armrest pad and tighten securely REPLACING ARMREST PLATE VAN STYLE SEAT FIGURE 2 l If necessary remove the three 3 mounting screws spacers and locknuts that secure the joystick mounting bracket to the armrest plate 2 Remove armrest pad Refer to REPLACING ARMREST PADS VAN STYLE SEAT in this section of the manual 3 Remove the mounting screw washers and locknut that secure the EXISTING armrest plate to the arm weldment 4 Position the NEW armrest plate on the armrest weldment and
79. om the hook release assembly by squeezing the two ends together 9 Remove the end of the spring from the hook release assembly NOTE If replacing any components discard existing component and use new component when reassem bling 10 Install spring in desired hole location of hook release assembly for 0 or 3 tilt Refer to CHART A in FIGURE 7 for proper mounting hole location Secure the release handle to the flip up seat plate with three 3 mounting screws Torque to 25 in Ibs NOTE The degree of tilt for mounting of the spring and the release handle must correspond otherwise flip up seat plate will not work properly EX if the spring is mounted for O tilt then the release handle must also be mounted for 0 tilt 12 Position the ends of the release handle in the desired hole location of hook release assembly for 0 or 3 tilt Refer to CHART A in FIGURE 7 for proper mounting hole location 13 Determine proper mounting orientation of the handle release bracket for 0 or 3 tilt Refer to CHART B in FIGURE 7 for proper mounting orientation 14 Install end of hook release assembly with flanged bushing in proper mounting hole of release handle bracket 15 Secure handle release bracket to prop threaded plate with two 2 mounting screws Hand tighten 16 Install end of hook release assembly with flanged bushing in proper mounting hole of release handle bracket 17 Secure remaining handle release bracket to t
80. or Gearbox FIGURE 3 REMOVING INSTALLING MOTOR Part No 1110516 93 XTERRA GT SECTION 10 MOTORS WHEELS REMOVING INSTALLING MOTOR GEARBOX SUSPENSION ARM ASSEMBLY AND SUSPENSION SPRING HARDWARE REMOVING FIGURE 4 NOTE This procedure will require 5 inch mounting screw with 1 1 2 of thread fender washer and locknut 1 Remove the batteries Refer to REMOVING INSTALLING BATTERIES in SECTION 8 of this manual 2 Remove the seat from the base frame Refer to REMOVING INSTALLING SEATFRAME in SECTION 6 of this manual 3 Remove the flip up seat plate Refer to REMOVING INSTALLING FLIP UP SEAT PLATE in SECTION 7 of this manual 4 Remove the front shroud Refer to REMOVING INSTALLING FRONT AND REAR SHROUDS in SECTION 7 of this manual 5 Disconnect the motor connector from the controller connector NOTE A tie wrap around the controller may need to be removed to make the disconnection v I 2 o x NOTE Before performing STEP 6 note the location of the tie wraps removed on the motor cable for proper reinstallation of new tie wraps 6 Cut the tie wraps that secure the motor cable in place 7 Remove the drive wheels Refer to REMOVING INSTALLING DRIVE WHEELS in this section of the manual 8 Remove the drive wheel hub Refer to REMOVING INSTALLING DRIVE WHEEL HUB in this section of the manual Suspension Spring Hardware Motor
81. ount bracket and suspension arm to the base frame with the pivot pin washer and locknut Torque locknut to 75 in Ibs FIGURE 4 4 Install the drive wheel hub Refer to NON 7 REMOVING INSTALLING DRIVE WHEEL HUB in this section of the FIGURE 5 SECURING MOTOR manual GEARBOX TO MOTOR MOUNT 5 Install the drive wheels Refer to REMOVING INSTALLING DRIVE WHEELS in this section of the manual Motor Gearbox Assembly Connect the motor connector to the controller connector Re install all the tie wraps where noted from the REMOVING process of the motor gearbox 8 Install mounting suspension spring components by performing the following FIGURE 6 A Install two 2 flat washers on 5 inch mounting screw with at least 1 1 2 of thread B Thread 5 inch mounting screw through spring retainer spring spacer compression spring and spacer C Take the spring assembly completed in STEP B and feed through hole in suspension arm weldment Continue pushing mounting screw up through base frame crossmember ensuring that screw end is protruding through the top D Install two 2 flat washers and locknut onto mounting screw Part No 1110516 95 XTERRA GT v I 2 2 0 gt v I gt o 0 gt SECTION 10 MOTORS WHEELS E Tighten locknut down drawing spring upward until there is a space wide enough between retainer and susp
82. p for reinstallation onto the wheelchair start one 1 of the mounting screws through the back cane from inside of the wheelchair to hold the insert in place 10 Slide the NEW back canes through the existing NEW back upholstery and spreader bar If applicable loosely tighten the mounting screws that secure the spreader bar to the NEW back canes 12 Line up the mounting holes in the back canes with the mounting holes in the seat frame NOTE Refer to BACK ANGLE ADJUSTMENT in this section of the manual to determine the proper mounting holes for the desired back angle The back canes MUST be fastened securely to the seat frame BEFORE using the wheelchair Torque to 75 inch pounds EE 13 Secure the two 2 NEW back canes to the seat frame with the existing four 4 mount ing screws washers spacers and locknuts Use Loctite 242 and torque to 75 in Ibs Part 1110516 23 XTERRA BACK SECTION 5 BACK 14 Secure the top of the existing new back upholstery to the back canes with the two 2 existing mounting screws and washers 15 Secure bottom of the existing new back upholstery to rear of the seat pan 16 Secure the bottom of the existing new back upholstery to the back canes with new tie wraps NOTE Clean upholstery with warm DAMP cloth and mild detergent to remove superficial soil Laundering or moisture will reduce flame retardancy of the upholstery NOTE When replacing the back upholstery ba
83. p seat pan 8 Remove the two 2 mounting screws coved washers spacers and locknuts that secure the side frame to the center frame 9 Adjust side frame to desired width determined from STEP 7 See DETAIL for proper mounting hole position IO Secure side frame to center frame with existing mounting screws coved washers spacers and locknuts Torque mounting screws to 75 inch pounds Remove flip back armrest Refer to REMOVING INSTALLING ARMRESTS in SECTION 4 in this manual 12 Remove the seat pan Refer to REMOVING SEAT PAN in this section of the manual 13 Remove the seat cushion 14 Remove battery box es Refer to INSTALLING REMOVING BATTERIES in SECTION 8 of this manual SEAT FRAME 15 Remove footrest assemblies Refer to PROCEDURE 4 in of the owner s manual part no 1106627 DETAIL ALLOWABLE SEAT WIDTH AND _ NR DEPTH COMBINATIONS FOR 3 ADJUSTABLE SEAT FRAME 14 inches 15 Seat Seat Width 16 inches Depth 2 13 44 15 16 en 12 _ 13 NA 5 53 6 Side 14 NA Mounting Coved f 15 N A 4 V V Washers 17 18 19 20 21 22 7 Screws gt Center Spacers gt Frame Locknut FIGURE 14 CHANGING SEAT WIDTH ADJUSTABLE SEAT FRAME Part No 1110516 47 XTERRA GT SEAT FRAME SECTION 6 SEAT FRAME COMPONENT REPLACEMENT FOR 14 15 AND 16
84. procedure on one 1 battery and battery box at a time Repeat procedure for other battery box A won 199 NEVER allow 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 BATTERIES Disconnect the strap that secures the lid to the battery Lift up on battery box lid to expose underlying cables Cut the tie wraps that secure the battery covers to the terminals Perform one 1 of the following A Direct Mount Method Peel back battery covers to expose ring terminal on each battery cable as follows RED battery cover from RED battery cable BLACK battery cover from BLACK battery cable B Battery Clamp Method Peel back battery covers to expose battery clamp on each battery cable as follows RED battery clamp cover from RED battery cable BLACK battery clamp cover from BLACK battery cable Perform one 1 of the following A Direct Mount Method Remove the hex screw and locknut that secures the NEGATIVE black battery cable to the negative battery terminal post Remove the hex screw and locknut that secures the POSITIVE red battery cable to the positive battery terminal post B Battery Clamp Method Remove the hex screw that secures the NEGATIVE b
85. que to 13 ft Ibs SEAT FRAME ASSEMBLY 3 Install armrests Refer to REMOVING INSTALLING ARMRESTS in PROCE DURE 4 in this manual 4 Install battery box es Refer to STALLING REMOVING BATTERIES in SECTION 8 of this manual 5 Install footrest assemblies Refer to PROCEDURE 4 in of the Owner s Manual part number 106627 XTERRA GT 50 Part 1110516 SEAT FRAME SECTION 6 INSTALLING REMOVING VAN STYLE SEAT ONTO FROM SEAT FRAME ASSEMBLY FIGURE 17 REMOVING Remove the van style seat seat frame assembly from the flip up seat plate Refer to INSTALLING REMOVING VAN STYLE SEAT SEAT FRAME ASSEMBLY ONTO FROM FLIP UP SEAT PLATE in this section of the manual 2 Remove the four 4 mounting screws spacer and washers that secure the van style seat to the seat frame assembly SEAT FRAME 3 Remove van style seat INSTALLING 1 Position the van style seat on seat frame assembly at the mounting position shown 2 Secure the van style seat to the seat frame assembly with four 4 mounting screws spacers and washers Torque to 13 ft Ibs 3 Install the van style seat seat frame assembly from the flip up seat plate Refer to STALLING REMOVING VAN STYLE SEAT SEAT FRAME ASSEMBLY ONTO FROM FLIP UP SEAT PLATE in this section of the manual Van Style Seat Seat Frame Assembly Washer Spacers Mounting Screws FIGURE 17 INSTALLING REMOVING VAN STYLE SEATONTO FROM
86. r locate the two 2 contacts in the red and black housings 2 Set the digital multimeter to measure ohms 3 Measure the resistance between the two 2 motor contacts NOTE A normal reading is between and 5 ohms A reading of 0 ohms Q or in excess of 15 ohms indicates a problem High readings are generally caused by bad connections and or damaged brushes Contact authorized dealer or Invacare SECTION 2 Ohmmeter 2 0 I l m Motor Connector FIGURE 3 MOTOR TESTING MOTOR BRUSH INSPECTION FIGURE 4 There are two 2 contact brushes on the motors located under the brush caps on the motor housing If these caps are hard to remove they are either overtightened or the motor has become very hot Let motors cool If caps still cannot be removed it is recommended that the motor be sent to Invacare Technical Services at 800 832 4707 for inspection repair 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 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
87. re for correct use of LOCTITE 242 and torque specifications or SECTION 3 of this manual I Remove footrest assemblies Refer to PROCEDURE 4 in of the owner s manual part number 106627 2 Remove battery box es Refer to INSTALLING REMOVING BATTERIES in SECTION 8 of this manual Remove the seat cushion 4 Remove the seat pan Refer to REMOVING INSTALLING SEAT PAN in this section of the manual 5 Remove the flip back armrests from the wheelchair Refer to INSTALLING REMOV ING FLIP BACK ARMRESTS in SECTION 4 of this manual 6 Remove the back upholstery Refer to REMOVING INSTALLING BACK UPHOLSTERY in SECTION 5 of this manual REMOVING INSTALLING BACK BRACKETS FIGURE 9 Removing Perform the steps outlined in PREPARATIONS above 2 Remove the locknuts and washers that secure the back bracket to the back angle plate 3 Remove the mounting screw and locknut that secures the quick release pin and back bracket and seat positioning strap to the seat frame Remove the existing CJ back bracket 5 Repeat procedure for opposite CJ back bracket Installing Install the threaded studs of the CJ back bracket through the back angle plates as shown FIGURE NOTE Ensure the CJ back bracket is mounted in the front holes of the back angle plates as shown in FIGURE 9 Always wear your seat positioning strap 2 Position the seat positioning strap and quick release pin under the CJ ba
88. re the joystick cable to the seat frame with new tie wraps 6 Repeat STEPS 1 5 for the opposite flip back armrest INSTALLING REMOVING VAN STYLE SEAT ARMRESTS FIGURE AND 4 REMOVING NOTE The MKIV A joystick is one continuous cable that runs from the joystick to the controller The mkiv RIl joystick can be disconnected at the point directly underneath the armrest Remove the mounting screw that secures the armrest to the van seat frame 2 Perform one 1 of the following A ARMREST WITH JOYSTICK Cut the tie wraps that secure the joystick cable Height l2 X to the seat frame Adjustment 6 lt MKIV A joystick Pull up on the Holes armrest and remove the armrest from the van seat frame and lay on floor MKIV RII joystick Disconnect Seat Mounting joystick lead from controller lead at Screw junction point on joystick tube Pull up on the armrest and remove the armrest from the van seat frame B ARMREST W O JOYSTICK Pull up on the armrest and remove the armrest from the van seat frame INSTALLING FIGURE 4 INSTALLING REMOVING OF ARMREST VAN STYLE SEAT l Slide the armrest into the van seat frame 2 Secure with mounting screw 3 FOR ARMREST WITH JOYSTICK MKIV joystick Secure the joystick cable to the seat frame with new tie wraps RII joystick Connect joystick lead and controller lead and secure the joystick cable to the seat frame with new tie wraps 4 Repeat STEPS 1
89. rical connections are secure at all times DO NOT use the joystick if the boot is torn or cracked If the joystick boot becomes torn or cracked replace IMMEDIATELY WEIGHT LIMITATION The weight limitation for the Xterra GT wheelchair is 250 Ibs WEIGHT TRAINING Invacare DOES NOT recommend the use of its wheelchairs as a weight training apparatus Invacare wheelchairs have NOT been designed or tested as a seat for any kind of weight training If occupant uses said wheelchair as a weight training apparatus INVACARE SHALL NOT BE LIABLE FOR BODILY INJURY AND THE WARRANTY IS VOID XTERRA GT 8 Part No 1110516 TROUBLESHOOTING SECTION 2 This Procedure Includes the Following Field Load Test Motor Brush Inspection Using Hydrometer To Check Battery Cells Lead Acid Motor Testing Electro Mechanical Parking Brake Testing 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 wheel chair Old batteries lose their ability to store and release power due to increased internal resistance This means that as you try to take power from the battery some of that power is used up in the process of passing through the battery resulting in less voltage at the posts The more power drawn the lower the voltage available When this lost voltage drops the output 1 0 volts under load
90. s FIGURE 11 CHANGING SEAT DEPTH ADJUSTABLE SEAT FRAME XTERRA GT 44 Part No 1110516 SEAT FRAME SECTION 6 CHANGING SEAT DEPTH BETWEEN 14 AND I 5 INCHES FIGURE 12 Remove the armrests from the wheelchair Refer to INSTALLING REMOVING FLIP BACK ARMRESTS in SECTION 4 of this manual 2 Cutthe tie wraps that secure the back upholstery to the CJ back brackets Pull the bottom of the back upholstery away from the rear of the seat pan T 4 Remove mounting screw washer and 20028 4 lt coved washer from the top mounting hole Wash ue of the back bracket and back cane e IE Pi gt NOTE Before removing the back canes from the 9 Back es T back brackets note the BACK ANGLE for reinstalla Mounting Bracket Hon Threaded Screws Insert NOTE To avoid losing the insert in each back cane line up the holes in the insert with the holes in the back cane and start one of the screws through the cane from the inside of the wheelchair to hold the insert in place Seat 5 Remove the mounting screw washer and Washers Frame coved washer from the bottom mounting hole of the CJ back bracket and the back FIGURE 12 ADJUSTING SEAT cane DEPTH CHANGING SEAT DEPTH 6 Reposition the back cane to the desired BETWEEN 14 AND 15 5 seat depth and angle If changing the back angle as well refer to BACK ANGLE ADJUST MENT in SECTION 5 of this manual 7 Secure bottom of the back upholstery to the
91. secure with the mounting screw washers and locknut Refer to FIGURE 2 for correct hardware orientation 5 Reinstall van style armrest pad Refer to REPLACING ARMREST PADS VAN STYLE SEAT in this section of the manual 6 If necessary reinstall the three 3 mounting screws spacers and locknuts that secure the joystick mounting bracket to the armrest plate 7 Repeat STEPS 1 6 for the opposite armrest plate if necessary Part No 1110516 17 XTERRA GT SECTION 4 ARMS C a Locknut PW gt NN 2 oS amp P d E ES AL Armrest Plate Mounting t He 2 Screws Ch Armrest Cae Plate Mounting AY Joystick Mounting Screws Arm Weldment Bracket FIGURE 2 REPLACING ARMREST PLATE VAN STYLE SEAT INSTALLING REMOVING FLIP BACK ARMRESTS FIGURE 3 Make sure the flip back armrest release and height adjustment levers are in the locked position before using the wheelchair NOTE Flip back armrest release lever must be in the unlocked UP HORIZONTAL position when placing the armrest into the arm sockets Flip Back REMOVING Armrest Note The MKIV A joystick is one continuous cable that runs from the joystick to the controller The MKIV RII joystick can Bear be disconnected at the point directly undemeath the armrest Ar 1 Unlock the flip back armrest by positioning the Socket flip back armrest release lever into the HORI ZONTAL position 2 Remove the quick r
92. talled on the front shroud side of the wheelchair 1 Part No 1110516 73 XTERRA GT BATTERIES BATTERIES SECTION 8 BATTERIES 2 Plug the charger s AC power cord or extension into 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 equal ized If 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 NOTE 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 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 Joystick Joystick ms NN L Charger Port for Wheelchairs Equipped with MKIV RII Joystick Charger Port for Wheelchairs Equipped With MKIV A or MKIV A Joystick FIGURE 10 CHARGING BATTERIES CLEANING BATTERY TERMINALS Most batteries are not sold with instructions However warnings are frequently noted on the cell caps Read them carefully DO NOT allow the liquid in the battery to come in contact with skin
93. te the mount ing location of the mounting screws on the flip up seat plate for proper reinstallation of the seat frame FIGURE 4 illustrates various configurations of how NOTE 16 inch seat widths can have either a fixed the seat frame is attached to the flip up seat plate frame or adjustable seat frame 7 Remove the four 4 mounting screws and FIGURE 3 REMOVING SEAT tube spacers if applicable and locknuts that FRAME 16 INCH SEAT WIDTHS secure the seat frame to the flip up seat plate ADJUSTABLE SEAT FRAME Back 8 Remove the existing fixed adjustable seat frame Part No 1110516 29 XTERRA GT SEAT FRAME SECTION 6 SEAT FRAME 14 15 16 AND 7 SEAT DEPTHS 18 AND 19 SEAT DEPTHS Mounting Screws Torque to 13 ft Ibs Fixed Mounting Fixed f gt Seat Frame Screws j Torque to 13 ft Ibs Mounting E Mounting Holes 6 inch 8 inch Deep Flip Locknuts Deep Flip up Seat up Seat TE Plate Plate Mounting Screws Torque to Fixed ft Ibs Seat Frame 20 INCH SEAT DEPTHS 3 4 inch Tube Use these 5 Mounting P pacers Holes lt 20 inch Deep Flip up Seat Plate NOTE Fixed seat frame is shown for darity Adjustable seat frame is secured in the same way Locknuts FIGURE 4 REMOVING INSTALLING SEAT FRAME 16 INCH SEAT WIDTHS XTERRA GT 30 Part No 1110516 SEAT FRAME SECTION 6 INSTAL
94. tery Terminal Post NEGATIVE Battery Terminal Post FIGURE 3 DISCONNECTING BATTERIES XTERRA GT 66 Part No 1110516 BATTERIES SECTION 8 CONNECTING BATTERY CABLES 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 Perform one 1 of the following methods for connecting the battery cable s A FOR 22 NF BATTERIES THAT INSTALLING BATTERY TERMINAL HAVE MOUNTING HOLES IN CAPS THE BATTERY TERMINAL S POST S Use direct mount method Refer to FIGURES 4 AND 5 B FOR 22 NF BATTERIES THAT DO NOT HAVE MOUNTING BATTERIES Battery Cable HOLES IN THE BATTERY Battery Terminal Cap TERMINAL S POST S Use battery clamp method Refer to NOTE Only one 1 battery cable and terminal cap FIGURES 6 7 AND 8 shown for darity Both caps install in the same manner FIGURE 4 CONNECTING DIRECT MOUNT METHOD BATTERY CABLES DIRECT FIGURES 4 AND 5 MOUNT METHOD Install battery terminal cap s onto battery cable s as follows FIGURE 3 A RED battery terminal cap onto RED battery cable B BLACK battery terminal cap onto BLACK battery cable When connecting the battery cables to the battery ies the battery cable s MUST be connected to the battery terminal s post s as shown in
95. the manual B For all other seat depth changes follow the instructions outlined below INCREASING SEAT DEPTH In the chart on the following page find the current seat depth on the left side of the middle column Scroll down and find desired seat depth on right side of middle column Perform the procedures in numerical order listed in the RIGHT hand side of the chart DECREASING SEAT DEPTH In the chart on the following page find the current seat depth on the right side of the middle column Scroll down and find desired seat depth on left side of middle column Perform the procedures in numerical order listed in the LEFT hand side of the chart Example of decreasing seat depth Changing from a l6 inch seat depth to a 4 inch seat depth The required steps are located on the left side of the chart in row I STEP is PREPARATIONS which includes removal of footrests battery boxes armrests and back upholstery STEP 2 is Installing the CJ Back brackets CJ back brackets are required to obtain either seat depth of 14 or 5 deep STEP 3 Removing the l6 inch seat pan which was determined in the COMPONENT IDENTIFI CATION TABLE STEP 4 Install NEW seat pan 17 inch deep seat pan is required for seat depths of 14 and 15 inches deep Refer to the COMPONENT IDENTIFICATION TABLE STEP 5 Reassemble chair which includes installing footrests battery boxes armrests and back upholstery XTERRA GT 38 Part No 111
96. tive BLACK Battery Cable POSITIVE Battery Terminal Post NEGATIVE Battery 6 Wwe Terminal Post H NOTE Battery clamps exploded away for clarification purposes only DETAIL POSITIVE Battery Terminal RED Battery Clamp Cover Battery Termina Post NEGATIVE Battery Terminal Post Tie Wrap 22NF Battery BLACK Battery Clamp Cover FIGURE 8 CONNECTING BATTERY CABLES BATTERY CLAMP METHOD Part 1110516 71 XTERRA GT BATTERIES 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 At full charge the two 2 LEFT segments and the farthest RIGHT segment of the bar graph will be illuminated As the battery becomes discharged the farthest RIGHT segment will progressively move to the LEFT until only the last two 2 bars LEFT are illuminated At this level the last two 2 bars LEFT will start to Flash ON and OFF to indicate that the end user should charge the batteries as soon as possible Battery Discharge Indicator MKIV RII JOYSTICK STANDARD Battery Discharge Indicator Battery Discharge Indicator BDI LCD Readout BDI MKIV A JOYSTICK MKIV A JOYSTICK FIGURE 9 WHEN TO CHARGE BATTERIES CHARGING
97. to the battery tray Refer to DETAILS A and B in FIGURE 8 10 Remove the MKIV A controller from the front of the battery tray INSTALLING Position MKIV A controller on front of battery tray as shown in DETAIL A in FIGURE 8 2 Secure MKIV A controller to front of battery tray as shown in DETAIL A in FIGURE 8 with two 2 mounting screws and one 1 washer Torque locknuts 75 in Ib 3 Connect the programmer extension cable to the controller Refer to DETAIL B in FIGURE 8 4 Connect the joystick connector to the controller Refer to DETAIL B in FIGURE 8 Connect the blue controller connector to the blue wiring harness connector Refer to DETAIL B in FIGURE 8 6 Connect the left motor connector to the left controller connector Refer to DETAIL B in FIGURE 8 7 Connect the right motor connector to the right controller connector Refer to DETAIL B in FIGURE 8 Secure the cables to the controller as shown in DETAIL in FIGURE 8 Secure the front shroud in place with two 2 mounting screws and washers Torque mounting screws to 40 in Ib XTERRA GT 84 Part No 1110516 ELECTRONICS SECTION 9 DETAIL Washer Controller Locknuts Front 0 Shroud 2 Washer c p Mounting NOTE MKIV RII controller shown MKIV A con Lie Screws troller removes and installs in the same manner Torque to 40 in Washer DETAIL FRONT VIEW
98. ts of the wheelchair refer to the individual procedure for correct use of LOCTITE 242 and torque specifications or SECTION 3 of this manual REMOVING FIGURES 5 AND 6 Remove footrest assemblies Refer to PROCEDURE 4 in the Owner s Manual part no 1106627 Remove battery box es Refer to INSTALLING REMOVING BATTERY BOX in SEC TION 8 of this manual Remove the seat cushion Remove the seat pan Refer to REMOVING INSTALLING SEAT PAN in this section of the manual Remove flip back armrest Refer to REMOVING INSTALLING ARMRESTS in SECTION 4 in this manual Perform one 1 of the following A For 14 and 5 seat depths Remove the back upholstery from the CJ back brackets Refer to REMOVING INSTALLING BACK UPHOLSTERY in SEC TION 5 of this manual Remove the two 2 washers and locknuts that secure each bracket to the seat frame B For 16 17 18 19 and 20 inch seat depths Remove the back upholstery from the seat frame Refer to REMOVING INSTALLING BACK UPHOLSTERY in SECTION 5 of this manual FIGURE 5 REMOVING SEAT FRAME 17 AND 18 INCH SEAT WIDTHS NOTE When performing STEP 7 note the mounting location of the mounting screws on the flip up seat plate for proper reinstallation of the seat frame FIGURE 6 illustrates various configurations of how the seat frame is attached to the flip up seat plate 7 Remove the four 4 mounting screws spacers or tube spacers if appli
99. two 2 mounting screws and washers that secure the existing back upholstery to the back canes 4 Cut the tie wraps that secure the bottom of the existing back upholstery to the back canes NOTE Note the back angle before disassembly for proper reinstallation 5 On the side of the wheelchair that the armrest was removed remove one 1 of the mounting screws washer spacer and locknut that secures the back cane to the seat frame or back brackets NOTE back brackets are used to obtain depths of 14 and15 inch seat depths NOTE To avoid losing the insert in each back cane thread the mounting screw just removed through the cane from the inside of the wheelchair to hold the insert in place 6 Remove the other mounting screw washer spacer and locknut that secures the back cane to the seat frame 7 Slide the back cane out of the spreader bar if applicable and the existing back uphol stery 8 Remove other armrest from the chair Refer to INSTALLING REMOVING FLIP BACK ARMRESTS in PROCEDURE 4 of this manual 9 Repeat STEPS 5 7 for the opposite side of the wheelchair 10 Slide the other back cane out of the spreader bar if applicable and the existing back upholstery INSTALLING I Slide one 1 back cane into NEW back upholstery and through spreader bar if appli cable 2 Secure back cane to the seat frame or back brackets from the outside of the wheel chair with the existing two 2 mounting screws
100. ur legs to avoid injury Failure to use the correct battery size and or voltage may cause damage to your wheelchair and give you unsatisfactory performance ALWAYS use a battery lifting strap when lifting a battery It is the most conve nient method and assures that the battery acid will not spill It also helps to prolong the life of the battery DO NOT tip the batteries Keep the batteries in an upright position NOTE If there is battery acid in the bottom of the battery tray or on the sides of the 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 tray or battery ies REMOVING FIGURE 1 l Place the wheelchair in a well ventilated area where work can be performed without risking damage to carpeting or floor covering Verify the joystick ON OFF switch is in the OFF position Pull release lever located underneath the front of the seat to disengage FIGURE 1 Tilt seat backward and lock seat in upward position with seat prop FIGURE 1 Disconnect the battery wiring harness from the front battery FIGURE 1 Disconnect battery wiring harness from the rear battery FIGURE 1 Disconnect the battery retention strap FIGURE 1 Lift the front battery out of the base frame DETAIL A in FIGURE 2 Slide rear battery forward and lift out of base frame DETAIL B in FIGURE 2 20 250 74 708 Ri t
101. usly i inch pounds noted Torque to 75 inch pounds REPLACING BOTH SIDE FRAMES NOTE Note the mounting hole position of the cur Coved rent side frame s for proper installation ofthe NEW Washers side frame s SEAT FRAME Remove the two 2 mounting screws coved spacers spacers and locknuts that secure the side frame to the center frame Repeat for opposite side frame 2 Install new side frame into existing center frame at the mounting position previ ously noted and secure with two 2 mounting screws coved spacers spacers and locknut Torque to 75 inch pounds Repeat for opposite side frame Locknuts Side Frame Center Frame Spacers REPLACING CENTER FRAME NOTE Note the mounting hole position of the cur rent side frame s for proper installation side frame into the center side frame Remove the two 2 mounting screws Ar coved spacers spacers and locknuts that _Locknuts secure the side frame to the center frame Repeat for opposite side frame FIGURE 15 COMPONENT 2 Remove the four 4 mounting screws REPLACEMENT FOR 14 15 spacers if applicable and locknuts that INCH AND 16 SEAT FRAMES secure the seat frame to the flip up seat ADJUSTABLE SEAT FRAME plate 3 Secure NEW center frame to flip up seat plate with existing four 4 mounting screws and locknuts Torque to 13 ft Ibs Both side frames MUST be adjusted to the s
102. ve the van style seat from the van seat frame Refer to INSTALLING REMOVING VAN STYLE SEAT AS SEMBLY in SECTION 6 of this manual 2 Remove the two 2 mounting screws washers and locknuts that secure the seat positioning straps to the van seat frame NOTE The washer is positioned between the seat positioning strab and the mounting screw 3 Secure the NEW seat positioning strap halves with the mounting screws washers and locknuts to the van seat frame and torque to 75 inch pounds 4 Reinstall the van style seat to the van Seat Positioning Strap Van Seat Frame Seat Positioning Strap Mounting Screw asher FIGURE REPLACING SEAT POSITIONING STRAP VAN STYLE SEAT FRONT seat frame Refer to INSTALLING REMOVING VAN STYLE SEAT ASSEMBLY in SEC TION 6 of this manual XTERRA GT 20 Part No 1110516 SECTION 5 6 Reinstall the two 2 mounting screws quick release pin tabs spacers and locknuts that secure the seat pan and seat positioning straps to the seat frame and torque to 75 inch pounds 7 Reinstall the seat cushion onto the seat pan REMOVING INSTALLING BACK UPHOLSTERY FIGURE 3 REMOVING Remove one 1 armrest from the wheelchair Refer to INSTALLING REMOVING FLIP BACK ARMRESTS in SECTION 4 of this manual 2 If applicable remove the two 2 mounting screws and locknuts that secure the spreader bar to the back canes BACK 3 Remove the
103. washers spacers and locknuts Use Loctite 242 and torque to 75 in Ibs Repeat STEPS 1 2 for opposite back cane 4 Secure the top of the NEW back upholstery to the back canes with the two 2 existing mounting screws Part 1110516 21 XTERRA GT 70 4 5 NOTE When replacing the back upholstery back assembly changing back height follow these guidelines for spreader bar height STANDARD MODELS BACK HEIGHT SPREADER BAR HEIGHT 16 inches 5 inches 17 inches 5 inches 18 19 inches T inches 20 22 inches T inches NOTE Spreader Bar required on ALL back heights between 20 24 inches Spreader bar required on back heights 16 17 18 or 19 ONLY if the width or depth of the chair exceeds 9 inches Height of Spreader Bar from Bottom of Back Canes to Top of Spreader Bar Clamp 5 f applicable reposition the spreader bar at the correct height for the corresponding back height and torque the mounting hardware to 60 in Ibs 6 Reinstall the armrest onto the wheelchair Refer to INSTALLING REMOVING FLIP BACK ARMRESTS in SECTION 4 of this manual Locknuts Back MS D PR Mounting M Screw A Locknut Washer Spreader Bar Back Upholstery Insert Mounting Screw gt Torque to 60 in lbs Mounting Screws Torque to 75 inllbs Washers FIGURE 3 REPLACING BACK UPHOLSTERY XTERRA GT 22 Part No 1110516 SECTION 5 CHANGING BACK H
104. washers two 2 5 8 inch dia washer and locknut that secure the right adjustment bracket to the base frame Remove the right adjustment bracket 4 Remove the 3 8 x 3 4 inch mounting screw 3 8 inch dia washers 5 8 inch dia washer and locknut that secures the left adjustment bracket to the base frame 5 Remove the left adjustment bracket INSTALLING l Secure the left adjustment bracket to the base frame with one 1 3 8 x 3 4 inch mounting screw 3 8 inch dia washers 5 8 inch dia washer and locknut Torque to 13 ft lbs 2 Secure the right adjustment bracket to the base frame with two 2 3 8 x 3 4 inch mounting screws two 2 3 8 inch dia washers two 2 5 8 inch dia washer and locknuts Torque to 13 ft lbs 3 Install the flip up seat plate Refer to REMOVING INSTALLING FLIP UP SEAT PLATE this secction of the manual Left Adjustment 3 8 3 4 inch Bracket Washer ocknut 3 8 inch dia Mounting Screw Washer FOR 14 7 SEAT DEPTHS 5 8 inch dia Right Washer Adjustment Bracket FOR 19 20 INCH SEAT DEPTHS FIGURE 2 REMOVING INSTALLING ADJUSTMENT BRACKET XTERRA GT 54 Part No 1110516 BASE FRAME PROCEDURE 7 REMOVING INSTALLING THE FRONT AND REAR SHROUDS FIGURE 3 REMOVING Remove the two 2 mounting screws and washers that secure the front or rear shroud to the base frame 2 Remove shroud INSTALLING Position shroud in place and secure with t
105. wheel hub to the motor Keystock gearbox assembly with locknut washer and keystock as shown in FIGURE 2 FIGURE 2 REMOVING INSTALLING Torque locknut to 45 ft Ibs DRIVE WHEEL HUB XTERRA GT 90 Part No 1110516 MOTORS WHEELS SECTION 10 REMOVING INSTALLING MOTOR FIGURE 3 REMOVING 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 Remove the batteries Refer to REMOVING INSTALLING BATTERIES in SECTION 8 of this manual 3 Remove the front shroud Refer to REMOVING INSTALLING FRONT AND REAR SHROUDS in SECTION 7 of this manual NOTE The number of cable ties and their locations outlined below is one example of how to properly tie wrap the cables for the LEFT motor The number and locations of tie wraps may vary from the LEFT to RIGHT motor assembly as well as from model to model When removing tie wraps their location MUST be noted for proper reinstallation of new tie wraps 4 Cut the tie wraps that secure the motor cable to the motor 5 Cut the tie wrap that secures the motor cable and sensor cable to the motor mount 6 Cut the tie wrap that secures the wire harness wrap to the battery tray 7 Cut the tie wrap that secureS the motor cable and sensor cable together 8 Cut the two 2 tie wraps that secure the wire harness wrap around the motor s
106. wo 2 mounting screws and washers Torque mounting screws to 40 in Ibs BASE FRAME Mounting Rear Screws Shroud Washer Front Shroud Washer ind Mounting Screws FIGURE 3 REMOVING INSTALLING THE FRONT AND REAR SHROUDS Part No 1110516 55 XTERRA GT BASE FRAME SECTION 7 BASE FRAME REMOVING INSTALLING TORSION BAR FIGURE 4 Definition The torsion bar serves two purposes it keeps the right and left suspension arms in alignment and 2 provides a more defined driving performance REMOVING DETAIL Because of the tight tolerance removing the hitch pin clip from both ends of the torsion bar must be performed by the following A With a pair of pliers grab the bottom of the pin and push up B With an elongated screw driver pop the hitch pin out by catching the top loop and prying upward 2 Pull torsion bar forward to remove INSTALLING Position torsion bar in base frame as shown in FIGURE 4 2 Secure torsion bar in place with two 2 hitch pin clips Torsion Bar located See DETAIL B in this area NOTE Detail is provided to show general lo cation of torsion bar eese Hitch Pin Clip Hitch Pin Cli V Torsion Bar FIGURE 4 REMOVING INSTALLING TORSION BAR XTERRA GT 56 Part No 1110516 BASE FRAME SECTION 7 REMOVING INSTALLING PORT BRACKET FIGURE 5 REMOVING 1 Remove the batteries Refer to REMOVING INSTALLING BATTERIES

Invacare® Xterra™GT™ Wheelchair

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Invacare&reg; Xterra&trade;GT&trade; Wheelchair

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Invacare® Xterra™GT™ Wheelchair