Invacare Excelerator XLT User Manual Download Page 65 | Manualshive

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9 SERVICE PROCEDURES

Part No 1171891

65

Invacare® Top End® Recreation Handcycles

9.6

Tension Spring Installation

1.

Tighten eye bolts into fork assembly and front frame.

2.

Using a medium flat screwdriver, hook the tension spring to the fork assembly and front frame eye bolts.



This procedure applies to Excelerator and Lil’ Excelerator models only.
The tension spring is NOT intended to keep the handcycle straight when pedaling but to keep the handcycle from leaning excessively to
one side or another.
Tension is applied by loosening or tightening the eye bolts. This should be done before installation of the spring.

Eye Bolt

Eye Bolt

Tension Spring

Front Frame

Fork Assembly

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Summary of Contents for Excelerator XLT

Page 1: ...RE using this product read this manual and save for future reference For more information regarding Invacare products parts and services please visit www invacare com Invacare Top End Recreation Handc...

Page 2: ...from Invacare Trademarks are identified by and All trademarks are owned by or licensed to Invacare Corporation or its subsidiaries unless otherwise noted Shimano and Nexus are registered trademarks o...

Page 3: ...Product Parameters 11 Component Identification 16 Tire Pressure Conversion 18 3 SAFETY 19 General Guidelines 19 Proper Fit 20 Operating Information 21 Transferring Into Out of the Handcycle 25 4 SAFE...

Page 4: ...etermining Toe In Toe Out 51 Adjusting Toe In Toe Out 52 Replacing Camber Inserts 53 Replacing Tire Tube and Tuning Replacement of Spokes 53 9 SERVICE PROCEDURES 54 Installing Hand Crank Handles 54 In...

Page 5: ...st Strap 78 Replacing the Leg Guard 79 Replacing Seat 80 Replacing Seat Upholstery 81 Replacing Back Upholstery 82 Replacing the Seat Positioning Strap 83 10 OPTIONS 84 Installing Safety Lights 84 Ins...

Page 6: ...cian or a Shimano certified bicycle repair technician DANGER Danger indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING Warning indicates a...

Page 7: ...hom 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 this page Provide dealer s name...

Page 8: ...h caution P N 1154264 Rev A WARNING ALWAYS keep fingers and hands away from the chain while using the handcycle otherwise injury may occur P N 1154265 Rev A WARNING Backrest MUST be adjusted properly...

Page 9: ...caution P N 1154264 Rev A WARNING ALWAYS keep fingers and hands away from the chain while using the handcycle otherwise injury may occur P N 1154265 Rev A WARNING Backrest MUST be adjusted properly R...

Page 10: ...rator Backrest MUST be adjusted properly Refer to owner s manual Otherwise user s elbows may contact rear wheels during use Operate with caution P N 1154264 Rev A WARNING ALWAYS keep fingers and hands...

Page 11: ...rnal reversing drum brakes and parking brake Handles Ergonomic Crankset Alloy Crankset Hub FRONT Shimano Nexus 7 Speed Hub REAR Precision Black Anodized w inch Quick Release Stainless Axles Spokes 14...

Page 12: ...andles Ergonomic Vertical foam covered or Horizontal foam covered Crankset Alloy Crankset Hub FRONT Shimano Nexus 7 Speed Hub REAR Precision Black Anodized w inch Quick Release Stainless Axles Spokes...

Page 13: ...frame Handles Ergonomic Vertical Ovalized Aluminum mounted on Top End V crankset Crankset Top End V Crankset Hub FRONT Shimano Top End Components w 27 Speed External Cassette REAR Precision Black Anod...

Page 14: ...internal Parking Brake Handpedals Ergonomic Hub FRONT Shimano Nexus 7 Speed Hub with Internal Drum Brake REAR Precision Black Anodized w 1 2 inch Quick Release Stainless Axles Spokes 14 Gauge Stainle...

Page 15: ...cm Brakes Hand Crank internal Parking Brake Handpedals Horizontal Hub FRONT Shimano Nexus 7 Speed Hub with Internal Drum Brake REAR Precision Black Anodized w 1 2 inch Quick Release Stainless Axles S...

Page 16: ...Seat Positioning Strap Front Wheel with Internal Geared Hub Safety flag not shown Shifter not shown Chain Guard Safety Flag Holder Road Crown Compensator Hand Crank Assembly with Reversing Drum Brake...

Page 17: ...Chain Guard Seat Positioning Strap Upper Chain Ring Shifter Front Wheel with External Geared Hub Safety flag not shown Safety Flag Holder Road Crown Compensator Front Wheel with Internal Geared Hub B...

Page 18: ...95 kPa approx 7 kPa PSI KILOPASCALS PSI KILOPASCALS 50 345 90 621 55 379 95 655 60 414 100 690 65 448 105 724 70 483 110 758 75 517 115 793 80 552 120 827 85 586 Rear Wheel Back Hand Crank Assembly wi...

Page 19: ...re professional dealer or technical personnel before attempting to use this equipment otherwise injury or damage may occur A qualified technician MUST perform the initial set up of this wheelchair Als...

Page 20: ...front of the handcycle farthest from the rider s face The rider s knees MUST not obstruct hand crank operation XLT Series the rider MUST have a slight bend at the knee when feet are in the footrests...

Page 21: ...IONING STRAP SERIOUS INJURY CAN OCCUR IN THE EVENT OF A FALL FROM THE PRODUCT ALWAYS wear your seat positioning strap Invacare strongly recommends using the seat positioning strap as an additional saf...

Page 22: ...from the chain while using the handcycle The Backrest MUST be adjusted properly Otherwise user s elbows may contact rear wheels during use Operate with caution DO NOT let children play near the handc...

Page 23: ...ifting by means of any removable detachable parts of an handcycle may result in injury to the user or damage to the handcycle DO NOT stand on the seat or frame of the handcycle DO NOT carry any riders...

Page 24: ...arning assistance techniques for the handcycle have an experienced assistant help you before attempting it alone When you are assisting with a transfer to from the handcycle remember to use good body...

Page 25: ...e the procedure and use the backrest to push off WARNING RISK OF INJURY OR DAMAGE Before attempting to transfer in or out of the handcycle every precaution should be taken to reduce the gap distance P...

Page 26: ...and place LEFT leg across seat STEP C Place LEFT hand on the left side of handcycle seat frame NOT on crank STEP D Place RIGHT hand on the wheelchair frame STEP E Lift and shift weight down into handc...

Page 27: ...at spots wear and proper inflation Inspect chain chain guard for damage rust tension and stretch Adjust if necessary Lubricate each link 3 IN ONE oil or a quality bike lubricant Check for damage or lo...

Page 28: ...t detergent and water Inspect hand grips for looseness If loose replace Check that all labels are present and legible Replace if necessary 4 2 Troubleshooting Veers Right Veers Left Sluggish Turn or P...

Page 29: ...n oil quick release axles and or threaded once a week with a Teflon lubricant 5 Keep quick release axles free of dirt and lint to ensure positive locking and proper operation WARNING RISK OF INJURY OR...

Page 30: ...ed Cassette Chain on page 70 9 Regularly check for loose spokes in the front and rear wheels If loose have them aligned at your local bike shop 10 Check road crown compensator for proper operation Ref...

Page 31: ...make sure all attaching hardware is tightened securely Otherwise injury or damage may occur DO NOT operate the handcycle if the hand crank obstructs your view If the hand crank obstructs your view adj...

Page 32: ...ggested Maintenance Procedures on page 29 6 Perform one of the following All handcycles except for XLT PRO Pedal backwards to ensure reversing drum brake works properly XLT PRO Squeeze brake handle on...

Page 33: ...rdware is tightened securely Otherwise injury or damage may occur Before operating the handcycle review the General Guidelines in this manual Damaged brakes may not stop the handcycle Injury or damage...

Page 34: ...pedal the hand crank forward toward the front to propel the handcycle forward Rotate pedal the hand crank backward toward the rear to apply the brake and slow down or stop WARNING RISK OF INJURY OR D...

Page 35: ...71891 35 Invacare Top End Recreation Handcycles XLT and XLT Jr ONLY Front of Handcycle Hand Crank Seat Footrest Rear of Handcycle XLT Series Excelerator Series Front of Handcycle Rear of Handcycle Han...

Page 36: ...6 OPERATION Invacare Top End Recreation Handcycles 36 Part No 1171891 Front of Handcycle Rapid Fire Shifter Brake System Seat Footrest Rear of Handcycle XLT PRO Hand Crank...

Page 37: ...to a complete stop Apply by pedaling in reverse XLT PRO Model Only Hand Brakes Hands On Brakes 1 Squeeze brake handle s as needed to slow or come to a complete stop 2 Release when desired speed is ach...

Page 38: ...chet lever and lift until the handle locks in place To Disengage the Parking Brake squeeze and release the ratchet button Excelerator Series To Engage the Parking Brake squeeze the handle and push the...

Page 39: ...ired gear is achieved Mountain Drive To switch mountain drive ON push the gear shift button IN from the right side while the option is UNDER NO LOAD To switch mountain drive option OFF push the gear s...

Page 40: ...tact your local bike shop Refer to this chart and information that follows for an explanation of the upper derailleur chain rings in combination with the lower derailleur gears If your pedaling cadenc...

Page 41: ...ieved Shifting from Easier Gears to Harder Gears Upshift Rapid Fire Shifter Pull shift lever located towards the outside using thumb or index finger and release Repeat until the desired gear is achiev...

Page 42: ...on a rear wheel or ground and the other hand on one of the handpedals and start to back up keeping control of the handcycle at all times 6 5 Maneuvering in Tight Areas XLT PRO If you cannot make a fu...

Page 43: ...stments repair or service and before use make sure all attaching hardware is tightened securely Otherwise injury or damage may occur WARNING RISK OF INJURY OR DAMAGE Footrest straps MUST be inspected...

Page 44: ...move the button screws and locknuts that secure the footplates to the half clamps 2 Adjust the footplates to one of five depths 3 Line up the mounting holes in the footplates with the mounting holes i...

Page 45: ...e chain if necessary Refer to Installing Adjusting Seven Speed Hub Chain on page 67 or Refer to Installing Adjusting Twenty Seven Speed Cassette Chain on page 70 WARNING RISK OF INJURY OR DAMAGE DO NO...

Page 46: ...move the two socket screws securing the front of the seat frame and align the seat height adjustment clamp with the desired height adjustment hole in the seat height adjustment bracket Install the two...

Page 47: ...by jiggling the seat making sure that the seat engages into the locking notch and adjustment lever returns to its original forward facing position Excelerator Series To ensure proper fit adjust the h...

Page 48: ...hile lifting up on the back support tubes pull the seat upward to the desired position Decreasing Back Angle While pushing down on the back support tubes push the seat down to the desired position 5 T...

Page 49: ...ube in and adjust the back height to one of three heights depending on original back height 3 Install the back upholstery onto the handcycle Refer to Replacing Back Upholstery on page 82 This procedur...

Page 50: ...ive drag 7 Repeat STEPS 1 6 for the opposite wheel WARNING After any adjustments repair or service and before use make sure all attaching hardware is tightened securely Otherwise injury or damage may...

Page 51: ...terline measurement of the rear wheels is smaller than the front centerline measurement of the rear wheels a toe out condition exists If the back centerline measurement of the rear wheels is LARGER th...

Page 52: ...proximately in a straight line 3 Securely tighten the socket screws and clamps that secure the camber inserts to the camber bar 4 Measure the distance between the center lines at the rear and front of...

Page 53: ...ber bar 2 Remove the existing camber insert from the camber bar 3 Install the new camber insert into the camber bar 4 Adjust the toe in toe out of the handcycle Refer to Adjusting Toe In Toe Out on pa...

Page 54: ...andles and Posts 1 Loosen socket screws to adjust handle position Detail B 2 Tighten socket screws to secure handles in desired position WARNING After any adjustments repair or service and before use...

Page 55: ...r service and before use make sure all attaching hardware is tightened securely Otherwise injury or damage may occur Failure to install handle assembly properly could result in injury It is recommende...

Page 56: ...d Crown Compensator on page 63 9 Loosen but do not remove the socket screw that secures the shifting lever to the seat frame 10 Remove the hex bolt and locknut that secure the brake arm to the brake a...

Page 57: ...rk 29 Torque the two cap nuts 260 390 in lbs 29 4 44 0 n m 30 Install the brake arm clamp onto the new fork 31 Secure the brake arm to the brake arm clamp with the hex bolt and locknut Torque to 22 26...

Page 58: ...PROCEDURES Invacare Top End Recreation Handcycles 58 Part No 1171891 STEPS 1 2 3 35 36 37 STEPS 8 33 STEPS 6 7 34 Socket Screws Fork Crank Assembly Brake Assembly Socket Nut Hardware Fork Road Crown C...

Page 59: ...5 17 18 19 20 21 22 35 STEPS 12 13 26 27 28 29 STEPS 15 16 23 24 Brake Arm Clamp Hex Bolt Brake Arm Locknut Bottom Bearing Fork Crank Assembly Frame O Ring Bearing Top Nuts Fork Footrest Hex Bolts Lo...

Page 60: ...the fork assembly and front frame 7 Using a medium flat screwdriver hook the tension spring to the fork assembly and front frame eye bolts The tension spring is NOT intended to keep the handcycle stra...

Page 61: ...sk to the tabs of the existing crank arm 2 Remove the two socket screws from the existing crank arm clamp 3 Use socket screw from crank arm in the center hole to open binder of crank arm 4 Remove sock...

Page 62: ...tion Handcycles 62 Part No 1171891 Right Crank Arm Tabs Spindle Socket Screw and Cap Chain Ring Disk Socket Screws Crank Arm Clamp Left Crank Arm Mounting Bolts Crank Arm Clamp and Socket Screws Spind...

Page 63: ...end of the road crown compensator from the fork bolt 3 Remove the bolt and spacer securing the frame end of the road crown compensator to the frame Adjusting Road Crown Compensator 1 Rotate the fork e...

Page 64: ...d Recreation Handcycles 64 Part No 1171891 Adjustment Fork End Road Crown Compensator Installed Fork Road Crown Compensator Frame Removed Fork Bolt Road Crown Compensator Frame End Fork End Bolt Lockn...

Page 65: ...k assembly and front frame eye bolts This procedure applies to Excelerator and Lil Excelerator models only The tension spring is NOT intended to keep the handcycle straight when pedaling but to keep t...

Page 66: ...XLT and XLT Jr 1 Run the cable from the right side of the fork assembly to mounting position on the left side just below the left side of the seat 2 Attach the seven speed shifter to the seat rail 3 S...

Page 67: ...tion chain over the hand crank sprocket assembly 3 Run the chain over the top chain tensioner 4 Position the chain around the wheel sprocket and back up towards the bottom chain tensioner 5 Place chai...

Page 68: ...9 SERVICE PROCEDURES Invacare Top End Recreation Handcycles 68 Part No 1171891 STEP 2 Sprocket Assembly STEP 4 Chain Tensioners Hand Crank Bottom Chain Top Chain Wheel Sprocket STEPS 1 5 STEP 3...

Page 69: ...n the hex screw to secure the adjustable chain tensioner in place WARNING Idler MUST be adjusted to ensure proper chain tension If proper tension is not present chain may disengage from the chainring...

Page 70: ...on the chain derailleur and thread the chain under the derailleur 4 Thread the chain around the wheel sprocket 5 Run the chain around the bottom of the wheel sprocket and back up towards the hand cra...

Page 71: ...d cover to the fork mounting bracket using the existing screw 6 Secure the top of the new chain guard cover to the chain guard mounting bracket using the two screws This procedure applies Excelerator...

Page 72: ...ssembly using the two socket screws XLT XLT Jr Excelerator and Li l Excelerator with Mountain Bike Option 1 Remove the two screws nuts and washers securing the existing sprocket guard to the hand cran...

Page 73: ...rt up and or down until the proper tension on the chain is achieved 3 Tighten the clamp that secures the crank handles to the fork securely The proper chain tension will be approximately 1 2 inch of c...

Page 74: ...chain over the front wheel sprocket 2 Position the front wheel axle into the fork slots 3 Tighten the knob on the opposite side of the quick release lever and secure the wheel to the fork with the qu...

Page 75: ...nt wheel hub Installing 1 Loop the chain not shown over the front wheel hub Detail B 2 Position the front wheel axle into the fork slots 3 Line up the projecting ends of the non turn washer with the s...

Page 76: ...the brake pad assembly so that when the parking brake is engaged the brake pads rest solely on the rim of the wheel Replacing Brake Pads 1 Remove the mounting nuts and brake pads 2 Secure the replace...

Page 77: ...STEPS 1 5 for the opposite footrest if necessary Excelerator Series 1 Remove the button screws and locknuts that secure the footrests to the footplate clamps 2 Align a new footplate on the footplate...

Page 78: ...d the outer footrest tube and under the inner footrest tube and firmly connect the hook and loop portions of the footrest strap Details A and B 4 Ensure the footrest strap is firmly attached to the lo...

Page 79: ...g leg guard from clamps 3 Insert new leg guard into clamps 4 Position each mounting clamp onto the fork under the brake cable 5 Adjust the leg guard to the desired position 6 Tighten both allen screws...

Page 80: ...ve the locknuts from the threaded studs from seat rails on both sides of seat 4 Remove the seat from the seat rails 5 Reverse STEPS 3 4 to install a new seat onto the seat rails 6 Reverse STEPS 1 2 to...

Page 81: ...another are to the rear of the seat frame 5 Secure the four fastening flaps together 6 Reinstall seat cushion and back upholstery if applicable onto chair WARNING After any adjustments repair or servi...

Page 82: ...the existing back upholstery and remove from the handcycle 4 Install the new back upholstery onto the handcycle 5 Securely latch the fastening flaps on the bottom of the new back upholstery to the bac...

Page 83: ...e Seat Positioning Strap On Wide Backs 1 Release the fastening strips securing the existing seat positioning strap to the back frame 2 Secure the new seat positioning strap to the back frame using the...

Page 84: ...to the clamp and tighten securely B Front safety light Position the clamp onto the side frame Install the set screw into the clamp and tighten securely Operating the Safety Light 1 Press GREY button t...

Page 85: ...provided 2 Attach the water bottle mounting bracket to the mounting tube using the hardware provided 3 Push water bottle into mounting bracket until secure 10 3 Using Safety Helmet 1 Secure helmet usi...

Page 86: ...o the handcycle with the mounting brackets and set screws 5 Secure the wheelchair to the tow bar with the fastening strips provided WARNING DO NOT use if draft bumper extends past rear wheels If draft...

Page 87: ...om wheel rim 2 Align metal plug with fork assembly 3 Secure sensor to fork using hardware provided 4 Remove one of the chain guard screws and attach the computer mounting bracket 5 Snap computer into...

Page 88: ...ing bolts and locknuts secure the receiver bracket to the wheel tray 7 Remove the two mounting bolts and locknuts from the rear wheel bar and set aside 8 Using two mounting bolts and locknuts secure t...

Page 89: ...cket to the rear wheel bar with the two screws 4 Repeat steps 1 3 for the opposite side if necessary Rear Wheel Bar 1 Remove the two mounting bolts and locknuts securing the rear wheel bar to the whee...

Page 90: ...sen the alignment screw on each side 5 Position the alignment gauge between the rear of the rear tires 6 Adjust the alignment inserts so the alignment gauge fits snugly between the rear of the rear ti...

Page 91: ...tal handle using top slot only and secure to glove 2 Run glove loop through bottom slot on palm and over back of hand until tight Secure glove loop to back of glove 3 Reattach glove strips to back of...

Page 92: ...n between the backrest and cushion 3 Replace cushion Attach small straps around the drafting bumper D Tool and tire repair kit Attaches with buckles around the back bar of the handcycle frame E Cable...

Page 93: ...d Attachment 1 Loosen the two allen screws on each mounting clamp 2 Adjust the leg guard to the desired position 3 Tighten both allen screws on each mounting clamp securely I Crutch Holder Attach the...

Page 94: ...echnical Writing Department Invacare Corporation One Invacare Way Elyria OH 44035 TechnicalWriting invacare com FAX 440 329 6975 Product User Owner Product Service Technician User Assistant Health Car...

Page 95: ...Part No 1171891 95 Invacare Top End Recreation Handcycles Notes...

Page 96: ...w topendchair com USA One Invacare Way Elyria Ohio USA 44036 2125 800 333 6900 Manufactured by Top End Sports and Recreation Products 4501 63rd Circle North Pinellas Park Florida 33781 5914 727 522 86...

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