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1. 2 Neel aa Ge ae id Date of test 13th May 2003 Chair serial No 22078 TRL Test Ref 02PM01 7176 19 r J ID 0 a f N a m Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 48 gt SECTION 19 Transportation 19 1 Diagram EYELET HOLES FOR KARABINERS LOCATION ON LOWER TUBE FOR FRONT TIE DOW All of the wheelchairs in our range are designed to be easily transported and most of them dismantle into manageable parts in seconds Consideration should be given to the type of vehicle in which the wheelchair may be carried A small car with a heavy power chair in the boot may be affected in the way in which it steers or brakes so care should be taken to distribute the load sensibly It should also be noted that even a lightweight manual wheelchair has considerable mass in the event of emergency braking and some form of restraint is essential when transporting any wheelchair in any vehicle It is strongly recommended that the user transfers to a vehicle seat and the wheelchair is transported separately However if this is not possible and the user intends to travel in a moving vehicle whilst seated in the wheelchair it is essential they follow clear safety guidelines and understand that this i2. 32 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 33 gt 15a 2 Parts List RJ Part No Controller Pilot 25A D49509 E 156 Controller Pilot 40A D49525 E 109 Controller Extension A03 134 Controller Mounting Plate G 278A M6x30 Hex HD Screw Zinc Plated F4125 M6 Nyloc Nut Zinc Plated P80 M5x8 Pozipan Screw Zinc Plated F18 Black Plastic Bung M8 15a 3 Inspection Check the M5 Pozipan screws are tight and hold the controller securely to the Controller Extension Check the condition of the Black Plastic Bungs 15a 4 Programmable Controller Removal Remove the two M5x8 Pozipan screws which secure the Controller to the Controller mounting plate o Release the two M6 Nyloc nuts from the underside of the Controller Extension and remove o the M6x30 Bolt holding the Controller Mounting Plate 15a 5 Programmable Controller Replacement Follow 15 4 in reverse 15a 6 Trouble shooting CONTROLLER LIGHTS DO NOT COME ON 1 Check the circuit breaker push buttons have not sprung out 2 Check the cable are connected correctly to the Controller Batteries Motors 3 Ensure the batteries are fully charged and that the charger is not still connected 33 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publicati
3. with DX connectors E 157 Intermediate loom E 158 Intec Battery Connector E146 Motor Assembly Left E 131L Motor Assembly Right E 131R 40 Amp Hr Battery E 128 29 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 30 gt 14 3 Electrical System Inspection A full function test of the powerchair should be carried out to determine any major faults which will be indicated by flashing lights on the controller By reference to Section 15 the fault may be diagnosed Check the condition of the main wiring loom for damage Check the beau plug connector P amp G controllers which should be tight fitting so that it is not easily dislodged in use Check the plugs connecting the main loom to the motor and battery looms should be examined to ensure that the wiring is secure with no evidence of chafing or damage The contacts inside the plugs should be inspected for prominence to ensure good contact is made A stall test should be performed to check that the circuit breakers function correctly Place the powerchair with the castor wheels against a solid object and ensuring the drive wheels do not spin push the joystick forward After a short period the power to the motors will be cut by the operation of the circuit breakers Reset the circuit breakers by pushing in the buttons which are found on the battery boxes 14
4. 4 Wiring Loom Removal and Replacement P amp G controllers Disconnect the beau plug from the rear of the controller Disconnect the motor and battery loom plugs from the main loom and withdraw the main loom To replace feed the main loom underneath the seat from the same side as the control ler Connect the motor and battery loom plugs to the main loom and re connect the beau plug to o the controller The application of petroleum grease to the contacts will assist in assembly and o offer protection against moisture 14 5 Wiring Loom Removal and Replacement Dynamic DL controllers The main loom is an integral part of the controller and is connected to the batteries and motors by means of a short intermediate loom terminating in DL type connectors To remove disconnect the main loom at the DL connectors positioned underneath the seat the loom is restrained to the frame by means of ty wrap s which will need to be replaced 14 6 Battery termination The loom terminates at the batteries by means of Intec connectors which are polarised to prevent incorrect assembly but note that it is NOT important which connector is connected to which battery 30 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 31 gt 14 6 Batteries and Battery Charging The batteries and battery charger require no mainten
5. HT BOLT ASSEMBLY SP333 ZINC PLATED F12 1 4 X 18G PLASTIC PLUG M9 1 4 UNF NYLOC NUT ZINC PLATED P90 LEGREST CARRIER fay BRACKET SF95 AG LEGREST STEM SF120 ELEVATING ROD SF123 LEGREST TRIGGER SPRING SF234 STEM SWIVEL TUBE SF88 LEGREST TRIGGER CALF PAD SF122 TSD10241 1 4 UNF NYLOC NUT rd a ZINC PLATED P90 CLAMP ASSEMBLY M102 5 1 16 x 1 2 SPLIT F153 zh Wy 1 4 UNF X 1 1 4 HT BOLT ZINC PLATED F7 NS BOTH ENDS ann 1 4 X 18G PLASTIC PLUG M9 1 4 UNF X 1 7 8 HT BOLT CALF PAD SWIVEL 1 4 UNF NYLOC NUT ZINC PLATED F12 BRACKET SF89 ZINC PLATED P90 gt 16 2 Parts List RJ Part No Legrest Assembly Complete Left SP333L Right SP333R Legrest Trigger Spring SP234 Elevating Rod SF123 Legrest Trigger SF122 Legrest Trigger Bracket SF121 Legrest Stem Left or Right SF120 Legrest Carrier Bracket Left or Right SF95 Calf Pad Swivel Bracket SF89 Stem Swivel Tube Left or Right SF88 Calf Pad MCP TSD10241 Clamp Assembly M102 1 4 UNF Nyloc Nut zinc plated P90 1 4 UNF x 1 7 8 HT Bolt zinc plated F12 1 4 UNF x 1 1 4 HT Bolt zinc plated F7 Type U rivet 2x1 4 F98 1 4 x 18G Plastic Plug M9 40 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 41 gt 16 3 Inspection Check heel loop for security Nuts should be tightened to 10 Ibs ft 13 Nm Check pivot bolt for wea
6. the cowl alongside the motor loom and refit the cowl Cut off the brake wires to the required length and fit new spade connectors Tape the brake wires to the outside of the motor loom to give complete protection Reconnect the motor to the main loom and test 13 8 Motor Brush Removal amp Replacement Disconnect the motor loom from the main loom release the two self tapping screws which hold the motor cowl and slide the motor cowl along the motor loom taking care not to apply any force to the wiring The brushes are located vertically either side of the brake assembly They are joined together by a wire and by gently pulling this will release the brushes To replace press gently into the slots and position wire so that it is not in contact with the brake assembly Refit the motor cowl taking care not to trap any wiring Re connect the motor loom and test On some later model powerchairs cartridge brushes are fitted which require no disman tling These are accessed from the outside of the motor and are removed by unscrewing the caps situated below the rim of the motor cowl 26 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 27 gt 13 9 Drive Coupling Removal and Replacement If it is only necessary to remove part of the drive assembly the following procedure applies Support the rear of the po
7. to seat 30 41cm 12 16 inch Leg rest angle 85 from horizontal Armrest to seat 23cm 9 inch Front armrest to backrest 42cm 17 inch Drive wheel diameter 315mm 12 5 inch Tyre size 12 5 x 2 25 Tyre pressures Rear 50psi 340 kilopascals KPA if pneumatic option fitted Maximum load capacity 114kg 18 stone 252 Ibs Turning Space a Spin turn 205cm 6ft 7 inch b 3 point turn 133cm 4ft 4 inch c 28inch doorway turn 100cm 3ft 3 inch Range 40 Amp hr Battery 17 8km 11 mile Static stability a Front 30 b Rear 30 c Side 20 Maximum forward speed 2 2 kph 1 4 mph 25A 5 5 kph 3 4 mph 40A Maximum stopping distance 1 5m 5ft Dynamic stability uphill 20 Note Please be aware other sizes may be available to special request Note The range test was conducted in accordance with ISO 7176 Pt 4 capacity is affected by ambient temperature user weight topography kerb climbing and battery maintenance Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 7 gt SECTION 3 Wheelchair Diagram 3 1 Crystal Self Propelling Powerchair 1 POWERCHAIR FOLDED 2 BATTERY WITH CIRCUIT BREAKER 2 BATTERY WITH CIRCUIT BREAKER 3 ARMREST 8 CONTROLLER 4 FOOTREST HANGER WITH FOOTPLATE 4 FOOTREST HANGER WITH FOOTPLATE 7 BATTERY TRAY J RESTRAINT BAR 6 BATTERY STRA
8. DRIVE COUPLING M 155 SPRING M 156 SPACER M 157 WHEEL TYRE ASSY G 29 SECTION 13 Power Drive System 13 1 Diagram STUB AXLE D 09L MOTOR E 131L R LOCKING BOLT SF 602 HEX NUT D 09 ANTI TIP CASTOR A14 18 KNOB F KN0065 BLK MOTOR SPACER D 023 SMALL NYLON WASHER F 66 DRIVE COLLAR M 159 TAB WASHER M 158 LOCK SCREW F 95 Motor amp Gearbox Wheel tyre Assembly Hex Nut Drive Coupling Spring Bronze Bush Drive Collar Spacer Nylon Washer Large Nylon Washer Small 1 4 x 1 1 4 UNF Hex Head Bolt Zinc Plated Tab Washer M6x10 Hex Head Screw Zinc Plated 10mm Spacer D 23 1 4 Spring Washer Wavey Washer Clamp Bolt Clamp Washer Clamp Nut Knob F 22 MOTOR PLATE BRK SF 605 PLUG CLAMP 13 2 Parts List RJ Part No Left E 131L Right E 131R G 297 ASS Stub Axle D 09L D 09 M 155 M 156 M 89 M 159 M 157 F 67 F 66 F 7 M 158 F 95 F 33 F 65 F 20 F 21 F KNO065 BLK 24 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 25 gt 13 3 Inspection The motor gearbox wheel assembly is mounted securely to the motor which should be securely attached to the side frame Check the tyre for excessive wear and the wheel for signs of damage Check for rim rock which will indicate worn bearings and or stub axle Maximum allowable is 5mm total Check for end float which
9. E 1 Check that the drive clutch dog s are engaged 2 If no click is audible from the motor when the joystick is moved then check the brakes 3 If clicks are audible then check the motor connections 2 POWERCHAIR DOES NOT DRIVE STRAIGHT Check motor connections Check brake connections Check for one brake dragging the casing will be warmer Check that both parking brakes are released PONS BATTERY CHARGER YELLOW MAINS LIGHT ON ONLY NO LIGHTS The mains supply is not reaching the charger Check that the mains is working and that the mains plug and fuse are in correct working order FLASHING LIGHTS This indicates that the battery voltage is low The charger has a safety feature which prevents it from commencing to charge if the battery voltage is lower than 8 volts for a 12 volt battery This low voltage battery condition is usually the result of a very deep discharge or totally worn out battery YELLOW MAINS LIGHT ON ONLY If one yellow light is on only and goes out when mains is disconnected the battery is not properly connected or may be flat Check the integrity of the battery connections Disconnect the mains supply sy 39 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 40 gt SECTION 16 Elevating Legrest 16 1 Diagram ELEVATING LEGREST 1 4 UNF X 1 7 8
10. General P amp G PP1b programmer amp diagnostics device See Section 15a Control Dynamics programmer amp diagnostics device See Section 15b Advised Watt Minute meter Current Draw Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 11 gt SECTION 6 Upholstery 6 1 Diagram BACKREST FABRIC SEAT FABRIC REINFORCING BARS SF176 MB X 20 LONG RAISED COUNTERSUNK SCREW F102 NO 8 FLANGED SCREW CUP F101 a an M5 AVDEL UNF NUTSERT RJ Part No Seat Fabric Ninian 14 x 17 inch 35 5cm x 43cm SF61 14 17 Ninian 15 x 17 inch 38cm x 43cm SF61 15 17 Ninian 16 x 17 inch 40 5cm x 43cm SF63 16 17 Ninian 17 x 17 inch 43cm x 43cm SF63 17 17 Ninian 18 x 17 inch 45 5cm x 43cm SF63 18 17 Backrest Fabric Ninian 14 x 17 inch 35 5cm x 43cm SF62 14 17 Ninian 15 x 17 inch 38cm x 43cm SF62 15 17 Ninian 16 x 17 inch 40 5cm x 43cm SF64 16 17 Ninian 17 x 17 inch 43cm x 43cm SF64 17 17 Ninian 18 x 17 inch 45 5cm x 43cm SF64 18 17 M5 x 20 long raised countersunk screw F102 No 8 flanged screw cup F101 M5 Avdel UNF Nutsert 09657 01014 Reinforcing Bars Seat and Backrest SF176 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 12 gt 6 3 Inspection Fabric Check f
11. ION 8 Footrest HANGER ASSEMBLY SP406 L H 407 R H 8 1 Diagram 5 16 INCH LOCKING NUT ZINC PLATED F21 5 16 INCH WASHER ZINC PLATED F22 5 16 X 1 1 4 INCH BOLT gt ZINC PLATED F20 CLAMP ASSEMBLY M102 HEEL LOOP ASSEMBLY TSD 114692 2 M6 X 35 HEX HD SCREW F126 M6 PLAIN NUT F222 NO 4 X 1 4 POZIPAN TYPE SELF TAPPING SCREW ZINC FOOTPLATE ASSEMBLY 306 L 307 R SPRING TSD 1349 PLATED 0456A NOT SHOWN NOT SHOWN 8 2 Parts List RJ Part No Footrest Hanger with retaining Right SP406 clamp gt assembly M102 Left SP407 gt Retaining Clamp Assembly M102 5 16 x 1 1 4 Inch Bolt zinc plated F20 5 16 inch Locking Nut zinc plated F21 5 16 inch Washer zinc plated F22 Footplate Assembly 8 1 2 inch complete with Stem and Heel Loop Left SP306L Right SP306R Footplate Assembly 7 1 2 inch complete with Stem and Heel Loop Left SP211L Right SP211R Footplate Spring TSD1349 Heel Loop complete with nuts and washers TSD 114 69 2 No 4 x 1 4 Pozipan Type Self Tapping Screw zinc plated 0456A M6 x 30 Hex Hd Screw F125 M6 Plain Nut F222 15 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 16 gt 8 3 Inspection Check that footrest assembly locks into position Apply light grease to swiveling end Ensure that stem clamp holds footplate in position Ensure tha
12. P Ko in Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Publication name Crystal Tech Rev 05 PDF Page 8 Printed on 22 04 2013 09 19 15 SECTION 4 Maintenance Checks Open the powerchair all movements should be free throughout the folding range Examine the seat and backrest fabrics for wear damage or staining Examine retaining screws for tightness and general condition See Section 6 Examine armrest pads for wear or damage and tightness of attachment screws See Section 7 Examine armrest locking assembly for wear and tear and that each armrest is securely retained See Section 7 Examine footrest hanger for effective locking when fully forward and back Examine clamp assembly for secure location of footplate assembly stem tube Check that footplates remain vertical when raised Examine heel loops for damage or excessive wear and security of attachment See Section 8 Examine the parking brake assemblies for wear damage or misalignment See Section 9 Check operation of folding push handle assembly and that it is free to move and locks into place positively See Section 10 Check that the hand grips are not damaged and are securely fitted to the push handle Ensure that tube plugs and ends are fitted to Front of seat tubes Front of bottom frame tubes Armrests front and rear Top of backrest tubes Lift the front of the powerchair and rest t
13. Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 1 Barrett TECHNICAL MANUAL The Proven Reliable Indoor Outdoor Powerchair Issue 06 May 2013 This Technical Manual will ensure that the wheelchair is maintained to the required standard and is for use by trained personnel only R J Mobility 100 Dewsbury Road Elland England HX5 9BG J V4 Tel no 01422 324830 Fax no 01422 372503 Email sales rjmobility com Website www rjmobility com 1 Ko in Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 2 gt Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 3 gt This Technical Manual contains important information regarding maintenance of the Crystal Powerchair thus ensuring its safe operation Please make sure that you understand all instructions thoroughly It is recommended that maintenance is undertaken at six monthly intervals for a wheelchair that is in constant daily use The safety of the wheelchair user is paramount If there is any doubt as to the suitability of re using existing parts they shoul
14. Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 22 gt 11 7 Parts List RJ Part No Locking Link Assembly 14 complete with fasteners SP208 14 Locking Link Assembly 15 complete with fasteners SP208 15 Locking Link Assembly 16 complete with fasteners SP207 16 Locking Link Assembly 17 complete with fasteners SP207 17 Locking Link Assembly 18 complete with fasteners SP207 18 M6 X 25 hex head set screw zinc plated F124 M6 self locking nut zinc plated P80 1 4 Diameter Nylon plain washer F86 11 8 Inspection Check Locking Link for security of thumb catch and correct operation The Locking Link should open close easily and the thumb catch must hold securely in the open position so that the wheelchair will not fold under load Check each tab on the side frames for evidence of bending elongation or worn holes and cracks in brazing or tubing 11 9 Locking Link Assembly Removal gt Remove the M6 x 25 Screw securing the Locking Link Assembly to each sideframe gt 11 10 Locking Link Assembly Fitting Fit two 1 4 UNF High Tensile Cap Screws to secure the Locking Link Assembly to each sideframe Tighten until the Locking Link is just securely held then loosen the nut half a turn The Locking Link Assembly must be free to move without binding but show no signs of excessive free play Lubricate with ligh
15. ST SOCKET EXTENSION SOCKET SF307 Z BORE SPACER M6 NUT ZINC PLATED P80 16 2 Parts List gt RJ Part No gt Armrest Socket Extension Assembly SF 307 Armrest Outrigger Tab SF 305 1 4 UNFx21 2 bolt zinc plated F 80 1 4 UNF Nut zinc plated P 90 2BA x 3 8 Pozi Pan Machine Screw zinc plated F 145 16 3 Inspection Check for damage to sockets Ensure spacers are fitted Check screw threads are not stripped particularly on push handle bracket Ensure armrests locate in push handle bracket when fitted to wheelchair Check for bending of armrest tube at insertion point 16 4 Dismantling Release nuts securing sockets to side frame and remove Slide sockets away from frame and remove spacers Release extension bracket from push handle 16 5 Fitting Replace spacers in side frame sockets Slide outrigger sockets into position and insert bolts Tighten nuts to 10 Ibs ft 13 Nm Hook rear bracket over push handle loop and tighten screw to 3 Ibs ft 4 Nm 42 Ko NE san Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 43 gt 17 3 Inspection Check for damage to sockets Ensure spacers are fitted Check screw threads are not stripped particularly on backrest bracket Ensure armrests locate in backrest bracket when fitted to powerchair Check for bending of armre
16. ack Plastic Bungs 15b 4 Programmable Controller Removal Remove the four M5x8 Pozipan Screws which secure the Controller to the Controller Extension Release the four M5x8 Pozipan Screws which secure the Controller to the Controller Mounting Plate K 15b 5 Programmable Controller Replacement Follow 15b 4 in reverse 15b 6 Trouble shooting CONTROLLER LIGHTS DO NOT COME ON Check the circuit breaker push buttons have not sprung out 2 Check the cables are connected correctly to the Controller Batteries Motors 3 Ensure the batteries are fully charged and that the charger is not still connected CONTROLLER LIGHTS FLASH The Control Dynamics DL controllers have a built in diagnostics system which shows the related fault by the number of times the lights flash In order to identify the fault count the number of times the lights flash and refer to the tables below The diagrams below show the light displays see FIG 1 38 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 39 gt 15b 6 Inspection cont Oo00o0000 1 Low Battery Voltage n 2 High Battery Voltage Pl 3 Left Motor Fault 4 Right Motor Fault 5 Left Right Park Brake Fault 6 Controller Fault Figure 1 7 Motor Stalled or Joystick out of neutral 1 CONTROLLER LIGHTS ON BUT POWERCHAIR WILL NOT DRIV
17. ance but a check for function should be carried out 14 6 1 Battery Inspection Remove the batteries from the powerchair Examine the batteries for any damage Beware acid gel may leak from a damaged battery which is highly corrosive Any contamination should be washed off immediately with copious amounts of clean water Seek medical advice if any irritation persists The battery condition should be checked Ideally this should be done using specialised equipment such as a discharge tester However this may take several hours as the battery will be left in a discharged state and will require re charging At the least a drop test should be performed using a simple car battery load tester This measures internal resistance and it is known that the internal resistance of a battery increases as the battery ages and performance decreases This type of test does not provide an assurance that the battery is fully capable of delivering its rated active energy and is dependent on the experience of the test engineer All testing should be performed on fully charged batteries and the test engineer should satisfy himself that this is so 14 6 2 Battery Replacement If the batteries are deemed fit for further use they may be re fitted to the powerchair Replace and smear the terminals with petroleum grease Ensure the connections are tight and the battery wiring looms are undamaged Refit to the powerchair a 14 6 3 Battery Charger Inspection gt The c
18. d be discarded and replaced with manufacturer approved parts User Manuals should be stamped at correct intervals following completion of maintenance work If you fail to understand anything or have any questions concerning mainte nance and operating instructions please contact RJ MOBILITY 100 Dewsbury Road Elland HX5 9BG England Tel 44 0 1422 324830 Fax 44 0 1422 372503 Trading division of Boxford Limited Registered No 01699383 England and Wales Registered office as above Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 4 gt Contents SECTION 1 User Categories Specifications Powerchair Diagram Maintenance Checks Tool Requirements Upholstery Armrests Footrests Brakes Push Handles Frame Locking Links And Cross Braces 12 Castors Power Drive System Electrical System Programmable Controller P amp G Pilot 15a Programmable Controller Dynamic DL 16 Elevating Legrest Armrest Outriggers Detachable Tray Transportation 2 3 4 5 6 T 8 9 1 1 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Publication name Crystal Tech Rev 05 PDF Page 5 Printed on 22 04 2013 09 19 15 A2 A4 AS SECTION 1 User Categories Attendant Controlled Degree of upper body control to maintain sitting pos
19. dition of all cables 4 3 2 Check that the controller is securely mounted IMPORTANT o This chair must only be used with the push handles upright and o locked in position Both armrests must be be securely located at the sides of the seat and be engaged with the push handles Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 10 gt SECTION 5 Tool Requirements Spanners 1 4inch Whitworth Legrest Clamp See Section 8 10mm AF Heel Loops See Section 8 8mm AF Parking Brake See Section 9 1 4inch Whitworth Anti tip Device See Section 11 1 5 16inch or 34mm AF Castors See Section 12 1 5 16inch or 34mm AF Power Drive System See Section 13 10mm Socket and Driver Power Drive System See Section 13 7 16inch AF General Allen Keys 4mm Locking Link See Section 11 Pozidrive Screwdriver Upholstery See Section 6 Avdel Nutsert Rivet Tool Upholstery See Section 6 Loctite Thread Locking Castors amp Wheels See Section 12 13 Compound Grade 241 Terminal Crimp Tool Power Drive System See Section 13 to suit 0 5mm to 6 0mm crimps Torque Wrench gt Minimum Operating Range gt 8 Ibs ft 11 Nm General Small Pliers General Light Soft Head Hammer General Light Oil e g 3 in 1 General Wire cutter General Power Drill and 6mm Bit General 1 4inch Receptacle wire crimp tool General Snap Rivet tool
20. e bolt threads and tighten 10 Ibs ft 13 5Nm torque Finally bend the tabs up ensuring that they are in contact with the bolt head IMPORTANT Motor and gearbox maintenance is limited to complete assembly replacement except replacing motor brakes and brushes 27 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 28 gt SECTION 14a Electrical System P amp G Pilot 13 1 Diagram r I RED BLACK BLACK YELLOW f YELLOW I BROWN I BLUE I GREY ORANGE L YELLOW _ L YELLOW i ee i e a 12v 40Ah 12v 40Ah on dl OR en nl FRONT BATTERY REAR BATTERY 14 2 Parts List RJ Part No P amp G Pilot controller 25A E 156 P amp g Pilot controller 40A E 109 Main Wiring Loom A10 017B Intec Battery Connector E146 Motor Assembly Left E 131L Motor Assembly Right E 131R 40 Amp Hr Battery E 128 28 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 29 gt SECTION 14b Electrical System Dynamic DL 13 1 Diagram ee meen o pieoonenesnenere enten Ha f re alii Frontene REAR BATTERY 14 b Parts List RJ Part No Dynamic DL controller 25A
21. eerGonpensaion fo Read Fault Log Display Fault Code History i Prose Conta System Resor Fado Dous n SSS p gt Diegnosios messene lengneenngmem p gt Set Soft Reverse Prevent Reversing Digging In Set Current Limit Max amp Min Current Limits 25A Max 25A Min Set Foldback Temp Reduce Current At This Temp Set Timed Foldback Reduce Current After This Stall Time 25 60sec Set Compensation Match Motor Impedance 130 m ohm Set Battery Menu Match Controller to Loom Resistance 64 m ohm Set Park Brake Trip No C f Sminpeeen fe fSetmintumac fam Serintumbecerm fe kaserne 1 Preset Eng Vawes Seto Fasor Deas 35 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 36 gt P amp G Pilot 40A D49525 Parameters Set Turn Deceleration 50 100 30 40 0 Sec Set Forward Speed Set Reverse Speed Set Turn Speed Set Sleep Timer Set Steer Correct Read Fault Log Veer Compensation Display Fault Code History Preset Control Sys tem Help Mode Diagnostics Restore Factory Defaults Read Fault code Engineering Menu K Set Soft Reverse Prevent Reversing Digging In 70 Max amp Min Current Limits 40A Max 40A Min 55 C Set Current Limit Set Foldback Temp Reduce Current At This Temp Set Timed Foldback Reduce Cur
22. ent Replacement is a straightforward reversal of the above procedure The attachment nuts and bolts should be renewed and tightened to a torque of 35 Ibs ft 47Nm 25 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 26 gt 13 6 Motor Brake Removal IMPORTANT Investigate warranty status before proceeding Failure to do so may invalidate your warranty Motor and gearbox maintenance is limited to complete assembly replacement except replacing motor brakes and brushes Check Brake and Motor functions operate correctly after any maintenance when completed Remove the motor cowl by releasing the two self tapping screws and lifting off the motor cowl being careful to feed the loom through the grommet so that no force is applied to the wiring Disconnect the motor plug and brake wires and cut off the crimped spade connectors From inside the cowl pull the two brake wires through from the motor loom sheath Using Allen key remove the two securing bolts on the top of the brake assembly The brake assembly can now be removed a 13 7 Motor Brake Removal gt The brake is not serviceable so a new one must be fitted Place on top of the motor and secure with Allen bolts after applying small quantity of thread locking compound Torque to 10lbs ft 13 5Nm Feed the two brake wires through the grommet in
23. harger is maintenance free but a check for function should be made Check for damage to the charger and to the mains and charging cables Ensure the ventilation slots are clear Connect the charger to the powerchair and then to the mains Switch on the mains and the yellow light should light up immediately followed shortly afterwards by the orange charging indicator The yellow bulk charge complete light will illuminate between 4 and 11 hours after commencement of charging depending on the state of discharge of the batteries The green charging complete will illuminate between 8 and 14 hours after commencement of charging depending on the state of discharge of the batteries Full operating and use instructions are given in the battery charger s User Manual sup plied with the powerchair 31 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 32 gt SECTION 15 a Programmable Controller P amp G Pilot 25A amp 40A 15a 1 Diagram SPEED LIMITER CHARGING SOCKET PROGRAMMER POWER SOCKET REAR SOCKET ar CONTROLLER CONTROLLER MOUNTING PLATE G278A 1 4x1 1 8 UNF HEX HEAD SCREW ZINC PLATED F4 M5x8 POZI PAN SCREW ZINC PLATED F18 VG conTROLLER EXTENSION A03 134 ZINC PLATED F18 M5x8 POZI PAN screw F di BLACK PLASTIC BUNG M8 f 1 4 UNF NYLOC NUT ZINC PLATED P90
24. he push handles on the floor Examine the structure of the frame for damage Check the pivot points for undue slackness caused by loose nuts and bolts or worn parts Check that front and rear locking links fully lock See Section 11 Check castors for free rotation of the wheel and the complete assembly Examine castors for wear in the bearings Examine locating spindle for signs of bending at the point where it is attached to the frame See Section 12 Examine tyres for uneven wear Check wheels for free rotation excessive end float and rim rock Check controller is secure to mounting bracket and that this can be secured to powerchair by knurled knob handle on armrest Examine controller for damage particularly any which may allow ingress of fluid Check joystick knob is secure to controller speed control knob and charging socket cover are in place Move joystick around quadrant checking for any roughness or stickiness on release the joystick must self centre immediately otherwise braking of the powerchair will be compromised Ensure that all LED s are functional so that it can be determined when controller is switched on off and that any diagnostic information is accurate Check that beau plug on wiring loom fits securely The batteries fitted are leak proof and require no maintenance except to check for damage and security of connections See Section 14 6 for comprehensive instruction The battery charger is maintenance free the only ser
25. hts Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 18 gt SECTION 10 PUSH HANDLES 10 1 Diagram PUSH HANDLE ASSEMBLY SP 404 L H amp SP 405 R H BARRETT STYLE SP 404 8L 9L L H amp SP 405 8L 9L R H 90 8L 9L STYLE HAND GRIP M57 M5 X 45 HEX HEAD BOLT ZINC PLATED F11 M6 SELF LOCKING THIN NUT ZINC PLATED P80 10 2 Parts List RJ Part No Push Handle Assy complete Barrett style L H SP 404 R H SP 405 Push Handle Assy complete 8L 9L style L H SP 404 8L 9L R H SP 405 8L 9L Push Handle LH Barrett style SF 160L Push Handle RH Barrett style SF 160R Push Handle LH 90 8L 9L style Push Handle RH 90 8L 9L style head bolt zinc plated hex head bolt zinc plated 1 4 UNF self locking thin nut zinc plated Hand grip SF 577L SF 577R 1 4 UNFx3 4 hex F10 F P90 M57 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 19 gt 10 3 Inspection Check each push handle for evidence of bending Check each push handle for evidence of cracking through nutsert holes Check handgrip is secure Check for free movement of plunger Lubricate with light oil Check that plunger locates in the hole at rear of the side frame Ensure nyloc nut still grips thread 10 4 Push Handle Removal Unscrew 4 off M5x20 countersunk screws holdi
26. ition Occupant capable of using one hand to control the powerchair having spatial awareness co ordinated motor skills and sufficient manual dexterity to operate the control ler The occupant should also have enough upper body control to maintain a sitting position Chin Controlled Degree of upper body control to maintain sitting position Capable of using chin movements to control powerchair Co ordinated motor skills IMPORTANT The above identifies the minimum user characteristics suitable for the Crystal foldaway powerchair Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 6 O eo hule a 20 21 22 23 24 k k 25 26 Kol SECTION 2 Specifications Dimensions based on seat size 43cm x 43cm 17inch x 17inch Overall length 100cm 39 5 inch Overall width Nominal width 17 5cm 7 inch Folded length 78cm 31 inch Folded width 55cm 21 5 inch Folded height 55cm 21 5 inch Complete weight 70kg 154 Ibs Heaviest Component 36kg 79 lbs Seat plane angle 55 to ground Seat depths available 43cm 17 inch Seat widths available 35 5cm 14 inch 38cm 15 inch 40 5cm 16 inch 43cm 17 inch 45 5cm 18 inch Seat height at front 49cm 191 2 inch Backrest angle 90 Std 100 Optional Backrest height above seat 44cm 17 5 inch Footrest
27. m the wheelchair rear wheel to avoid danger of accidental unlatching This product has been used to transport users in motor vehicles over many years without serious incident and it must be decided by the user carer whether to do so at their own risk It is not as safe as traveling in a vehicle seat and there are risks involved These are minimised with the use of effective recommended equipment restraints and our company believes in freedom of choice for informed individuals so please be aware of the risks and make your own informed choice Amendment Record SECTION DATE COMMENTS AMENDED gt 12 02 06 WARNINGS HIGHLIGHTED 24 10 06 GRAMMAR CORRECTIONS 49 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 50 gt Maxi Meteor Maxi Independent Barrett Jewel Meteor Independent Barrett 10 Original Meteor Barrett 7 Mini Meteor Barrett Gem Baby Barrett Barrett 101 Tilt amp Space Portering 50
28. ng the seatback upholstery to the Push Handle Assembly Unscrew 1 4 UNF nut and withdraw the bolt 10 5 Push Handle Fitting Insert 1 4 UNF bolt through Push Handle and hinge bush Tighten the nyloc nut until Push Handle pivots freely without excessive free play Fit 4 off M5x20 countersunk screws to hold the seat back upholstery to the Push Handle Assembly Wrap the 50mm wide Velcro strap around the lower end of the Push Handle and secure to the rear Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 20 gt SECTION 11 CROSSBRACE ASSEMBLY 11 1 Diagram CROSS BRACE ASSEMBLY SP205 M6 LOCKNUT P80 1 4 NYLON WASHER F86 gt a V M6 x 25 HEX HEAD SET SCREW ZINC PLATED F124 M6 LOCKNUT P80 M6 x 35 HEX HEAD BOLT ZINC PLATED F126 1 4 NYLON WASHER F86 14 NYLON F86 M6 x 40 HEX HEAD SET SCREW ZINC PLATED F207 1 4 NYLON M6 LOCKNUT P80 Xy WASHER F86 M6 x 25 HEX HEAD SET SCREW ZINC PLATED F124 There are two Cross Brace Assemblies in this wheelchair which have identical parts 11 2 Parts List RJ Part No Cross Brace Assembly 14 complete with fasteners SP 206 14 Cross Brace Assembly 15 complete with fasteners SP 206 15 Cross Brace Assembly 16 complete with fasteners SP 205 16 Cross Brace Assembly 17 complete with fasteners SP 205 17 Cross Brace As
29. on name Crystal Tech Rev 05 PDF Page 34 gt CONTROLLER LIGHTS FLASH The Penny amp Giles Pilot controller has a built in diagnostics system which shows the re lated fault by the number of lights flashing A diagram below shows the related faults to the number of lights flashing see FIG 1 KA HIGH BATTERY VOLTAGE Zz LU m SOLENOID BRAKE FAULT oO ee POSSIBLE CONTROLLER FAULT VIS POSSIBLE JOYSTICK FAULT A DUHH HA CHARGER CONNECTED ma Tu VA RIGHT MOTOR WIRING FAULT MED RIGHT MOTOR DISCONNECTED OP OJ LEFT MOTOR WIRING FAULT a UJg LEFT MOTOR DISCONNECTED WY Wf ON BATTERY VOLTAGE An 1 K CONTROLLER LIGHTS ON BUT POWERCHAIR WILL NOT DRIVE 1 Check that the drive lock devices are engaged 2 If no click audible from the motor when joystick is first moved check the brake connections 3 If clicks are heard check motor connections A P amp G PROGRAMMER REF PP1 MAY BE USED TO PROGRAM PARAMETERS AS LIST ED IN THE FOLLOWING TABLES Parameters should only be modified by a qualified person 34 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 35 gt P amp G Pilot 25A D49509 Parameters Set Acceleration Set Deceleration Set Turn Acceleration SerTumbeeeeen fee Setroardspeca fm SetReverso Speed fm arms ae Sersep mer fose Set Seer Corect v
30. or staining wear tear and stitching Check nut inserts in frame for security and stripped threads Check securing screws for bending and stripped threads and burrs Cushions if fitted Check cushions for staining wear tear and stitching Check Velcro attachment tabs are present and secure 6 4 Fabric Removal If the Nutserts need replacement use Avdel recommended tooling 6 5 Fabric Fitting M5 X 20 INCH COUNTERSUNK SCREW REINFORCING BAR M5 UNF AVDEL NUTSERT Slide reinforcing bar into stitched section on each side of the seat fabric only Fit countersunk screws through flanged cups and fit through holes in fabric and reinforcing bars Place fabric on seat and backrest tubes and tighten screws taking care not to exert excessive force to flatten the flange cup or cut into the fabric Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 13 gt SECTION 7 Armrests 7 1 1 Diagram Non Domestic ARMREST ASSEMBLY SP L H SP R H ARMREST PAD M 170 PANEL SF 232L SF 232R 1 Na M7 2440 No12x11 4 POZIpan AB S N I ARMREST FRAME SF 604L gt SF 604R gt 7 1 2 Parts List Non Domestic RJ Part No Armrest Assembly complete Left XXSP2018L 9L L Right XXSP2018L 9L R Armrest Pad Black M170 No 12 x 1 1 4 Pozipan AB self tapping screw zinc
31. plated F111 Armrest Panel Left SF232L Right SF232R AVEX 1 8 pop rivet not shown F46 Armrest frame Left SF 604L Right SF 604R Tube plug M7 2440 in E Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 14 gt 7 3 Inspection Check armpad for excess wear or damage Check armpad is secured to frame Check side panel is not damaged Ensure armrest locates in rear bracket on push handle when fitted to wheelchair 7 4 Armrest Pad The armrest pad is secured to the armrest frame with three screws whilst the domestic armrest pad is secured to the armrest frame with two screws Removal of the screws releases the pad Secure the pad with the attachment screws to refit 7 5 Armrest Panel The plastic panel is removed by carefully drilling off the heads of the two pop rivets using a 1 4 or equivalent drill bit Slide the panel forwards on the armrest frame until the moulded hooks release from the tube The plastic panel is fitted by placing the moulded hooks against the armrest frame tubes and pushing the panel backwards on the frame Fit 2 new pop rivets using the correct tool 14 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 15 gt SECT
32. r Check calf pad for wear damage Check adjustment rod for bending Check footplate maintains set position 16 4 Elevating Legrest Removal Remove the footrest assembly from the powerchair by lifting and rotating the hanger section Release stem clamp and withdraw footplate and stem Release nuts securing calf pad and remove Release pivot bolt and separate elevating section from swivelling section Remove rubber end cap from adjustment rod and holding trigger withdraw rod 16 5 Elevating Legrest Fitting Assemble elevating section to swivelling section Use new pivot bolt if necessary Slide adjustment rod through bracket and trigger ensuring spring is positioned to force trigger forward Replace rubber end cap Assemble calf pad to bracket Tighten nuts to 10 Ibs ft 13 Nm Insert footplate stem into tube and tighten clamp to 35 Ibs ft 47 Nm Apply light grease to swivelling end and insert into castor tube Ensure no grease oil on adjustment rod or it will cause slippage 41 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 42 gt SECTION 17 ARMREST OUTRIGGERS 16 1 Diagram ARMREST ASSEMBLY SP201 8L 9L ARMREST ASSEMBLY SP364 DOMESTIC 2BA X 3 8 POZI PAN MACHINE SCREW ZINC PLATED F145 Z gt OUTRIGGER M6 X 65 BOLT X 2 1 2 TAB SF305 ZINC PLATED F266 ARMRE
33. rent After This Stall Time 25 60sec Set Compensation Match Motor Impedance 130 m ohm Set Battery Menu Match Controller to Loom Resistance sawan f Sammon fm SetwinTurnacen fm SetwinTurDeosin fom eera Preset Eng values Set To Facio Dous 36 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 37 gt SECTION 15 b Programmable Controller Dynamic DL 40A 15b 1 Diagram JOYSTICK gt BATTERY GAUGE ON OFF SWITCH SPEED LIMITER CHARGING SOCKET PROGRAMMER gt SOCKET CONTROLLER MOUNTING PLATE G66A CONTROLLER EXTENSION G67A M5x8 POZI PAN SCREW ZINC PLATED F18 BLACK PLASTIC BUNG M8 CONTROL DYNAMICS DL CONTROLLER E123 37 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 38 gt 15a 2 Parts List RJ Part No Controller Extension G 067A Controller Mounting Plate G 066A Control Dynamics DL Controller D40UDH1 E 157 M5x8 Pozipan Screw Zinc Plated F 18 Black Plastic Bung M 8 15b 3 Settings The controller is set to Program 2 default settings 15b 3 Inspection Check the M5 Pozipan screws are tight and hold the controller securely to the Controller Extension Check the condition of the Bl
34. s not as safe as using the vehicle seat and is at their own risk It is the responsibility of the transport operator and the wheelchair user to ensure that safety measures taken are suitable for both the wheelchair user and other passengers All passengers in motor vehicles accept that there is risk involved in travel but this is compounded by wheelchair use The wheelchair brakes are not designed to withstand forces such as cornering acceleration and braking within a motor vehicle therefore additional special restraints must be provided 48 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 49 gt The wheelchair should be secured to the vehicle floor in line with the direction of travel The occupant should be separately restrained to the vehicle and NOT to the wheelchair Installers and operators of restraint systems should be trained in their correct use by the restraint manufacturer or approved specialist Additional fittings such as trays should be removed and stowed separately Itis recommended that wheelchairs with a full height backrest or head rest are used to prevent excessive movement of the head both during normal travel and in the event of an impact R J Mobility recommend the Unwin 4 Point Tie Down system However it is important to ensure that the user restraint buckle is facing away fro
35. sembly 18 complete with fasteners SP 205 18 M6 x 35 long HT hexagon head bolt zinc plated F126 M6 self locking nut zinc plated P80 1 4 Diameter Nylon plain washer F86 M6 x 25 HT hexagon head set screw zinc plated F124 Nylon spacer F65 20 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 21 gt 11 3 Inspection Check Cross Braces for bending and evidence of cracks around pivot holes Check each tab on the sideframes for evidence of bending elongation or worn holes and cracks in brazing or tubing 11 4 Cross Brace Assembly Removal Remove the two 1 4 UNF set screws securing the Cross Brace Assembly to each sideframe 11 5 Cross Brace and Locking Link Assembly Fitting Fit two 1 4 UNF set screws to secure the Cross Brace Assembly to each sideframe Tighten until the Cross Brace is just securely held then loosen the nut half a turn The Cross Brace Assembly must be free to move without binding but show no signs of excessive free play Lubricate with light oil eg 3 in 1 Over tightening of Cross Brace Assembly screws will prevent pivoting action and will lead to fracture of tab to side frame 11 6 Diagram LOCKING LINK ASSEMBLY SP 207 M6 ee F130 o 1 4 NYLON WASHER F86 Yy og M6 x 25 HEX HD SCREW ZINC PLATED F124 M6 x 25 HEX HD SCREW SCREW ZINC PLATED F124 21
36. st tube at insertion point 17 4 Dismantling Release nuts securing sockets to side frame and remove Slide sockets away from frame and remove spacers Release extension bracket from backrest 17 5 Fitting Replace spacers in side frame sockets Slide outrigger sockets into position and insert bolts Tighten nuts to 10 Ibs ft 13 Nm Hook rear bracket over backrest loop and tighten screw to 3 Ibs ft 4 Nm 43 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 44 gt SECTION 18 DETACHABLE TRAY 18 1 Diagram TRAY BRACKET GWD 838 E TRAY 4 aN GWD 837 b 1 C TRAY BRACKET SF316 18 2 Parts List RJ Part No Tray Bracket left SF316L gt right SF316R gt Tray GWD 837 Tray Bracket GWD 838 18 3 Inspection Check for damage to the tray particularly for wooden splinters Check security of attachment screw B and check tray attachment screws for security Check all adjustment knobs are present undamaged and hold tray at the required position 18 4 Assembly Remove plastic bung A Remove screw B Insert 3 4 dia tube item C over end of armrest tube Line up holes in item C with screw hole in armrest tube Insert screw B and re tighten Insert the tubular mounting stems complete with stem brackets supplied with the tray into the armrest
37. stem assembly with the horizontal extensions of the mounting stems projecting forward Place the tray symmetrically on the stem brackets ensuring that the flat plates are located between two guide strips on the under side of the tray Mark through the screw holes in the stem brackets Remove the tray and brackets from the wheelchair and secure brackets to tray with screws supplied Refit tray assembly to wheelchair Screw the two loose knurled knobs supplied with tray assem bly into nuts welded to armrest stem assembly item C Adjust tray position and tighten the four knobs 44 Ko NE same Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 45 gt 18 4 Assembl Remove plastic bung A Remove screw B Insert 3 4 inch diameter tube item C over end of armrest tube Line up holes in item C with screw hole in armrest tube Insert screw B and re tighten Insert the tubular mounting stems complete with stem brackets supplied with the tray into the armrest stem assembly with the horizontal extensions of the mounting stems projecting forward Place the tray symmetrically on the stem brackets ensuring that the flat plates are located between the two guide strips on the under side of the tray Mark through the screw holes in the stem brackets Remove the tray and brackets from the po
38. t footplate will remain in vertical position when required Ensure that there are no sharp edges burrs which could injure user 8 4 Footrest Removal Remove the footrest assembly from the powerchair by lifting and rotating the hanger section Loosen the clamp with a 1 4inch Whitworth spanner and slide the stem assembly out 8 5 Footrest Fitting Re assemble heel loop to footplate and tighten nuts to 10 Ibs ft 13 5Nm Insert footplate stem into hanger tube and tighten clamp to 35 Ibs ft 47Nm The footplate should remain in the vertical position when required This is maintained by semi elliptic spring acting between the footplate and the pivot tube This does not normally require maintenance 16 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 17 gt SECTION 9 Brakes 9 2 Parts List RJ Part No Brake LH M 256L Brake RH M 256R 9 3 Inspection Check levers for distortion Check pivot shafts for distortion 9 6 Brake Adjustment The Brake Bar position can be adjusted by loosening the two socket set screws and repositioning the bar Adjust to allow an operating force at the handle to be between 10Ibf to 13lbf 44 to 58 N with the tyres inflated to the correct pressure 50psi 340 KiloPascals Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rig
39. t oil eg 3 in 1 Over tightening of Locking Link screws will prevent pivoting action and will lead to fracture of tab to side frame 22 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 23 gt SECTION 12 Castors 12 1 Diagram 190mm Wide Profile M 20 140 SWIVEL RADIUS M14 x 22 LONG EE EE 23 95mm A F H y HEXAGON 12 2 Parts List RJ Part No gt 190mm wide profile MCP M 20 gt 12 3 Inspection Check for excessive wear in crown bearings and wheel spindle Replace castor if necessary Check for condition of stud which screws into frame View frame and check both castor mounting tubes are at the same angle checking for frame distortion due to impact damage replace if necessary Check tyre security to rim and for splits cracking or damage Check security of castor 12 4 Castor Removal Unscrew the hexagon at the top of the castor swivel using a 24mm 15 16inch AF spanner until the castor is removed 12 5 Castor Fitting Apply Loctite thread locking compound Grade 241 or equivalent to the thread and tighten to 30 35 Ibs ft 40 47 Nm 23 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 24 WAVE WASHER F 65 LARGE NYLON WASHER F 67
40. viceable part is the fuse fitted to the mains plug See Section 14 6 for comprehensive instruction Ensure the batteries are fully charged Drive the Crystal at maximum speed in forward reverse left and right directions checking that the joystick response is uniform Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 9 gt 4 2 10 Switch off the controller hold the joystick forward and switch the controller on the powerchair must not drive Release the joystick for two seconds and then the powerchair will drive normally 4 2 11 Slowly drive the powerchair up a maximum 1 in 6 gradient and attempt to accelerate The powerchair will climb at normal speed 4 2 12 Reverse down a 1 in 6 slope and check that the powerchair will come to a halt if the joystick is released 4 2 13 Whilst driving slowly up the gradient release the joystick and check that the powerchair does not roll back excessively before the automatic parking brakes come on 4 2 14 Check that all cables are connected to the controller batteries motors and brakes 4 2 15 Check that the circuit breaker push buttons on the battery boxes have not sprung out 4 2 16 Check that the free wheel devices are releasing and engaging correctly 4 3 Check that controller rubber gaiter and switch cover are in good condition 4 3 1 Check the insulation con
41. werchair and secure brackets to tray with screws supplied Refit tray assembly to the powerchair Screw the two loose knurled knobs supplied with the tray assembly into nuts welded to the armrest stem assembly item C Adjust tray position and tighten the four knobs 45 Printed from Serif PagePlus 13 0 8 31 Copyright 1994 2008 Serif Europe Ltd All Rights Reserved Printed on 22 04 2013 09 19 15 Publication name Crystal Tech Rev 05 PDF Page 46 Kol SECTION 17 RECLINING BACKREST RECLINING BACKREST ASSEMBLY G104 BACKREST TUBE G104 M6 X 40 HEX HD BOLT ZINC PLATED F207 M6 NYLOC NUT ZINC PLATED P80 M6 X 45 HEX HD BOLT ZINC PLATED F11 M6 NYLOC NUT ZINC PLATED P80 Backrest Tube Assembly complete Ratchet pull rod Plate No 10 UNF Nyloc Nut zinc plated M6 x 40 hex head bolt zinc plated M6 Nyloc Nut zinc plated M6 x 45 hex head bolt zinc plated PE 17 1 Diagram RATCHET PULL ROD G144 LEFT OR RIGHT STATE BACKREST HEIGHT 10 UNF NYLOC NUT ZINC PLATED F24 6MM WING NUT CHROME F58 BK RATCHET PLATE G140 RJ Part No G104 Handle G142 Left G144L Right G144R Spring G141ND Ratchet G140 Wing Nut 6mm chrome F58 F24 F207 P80 F11 46 OD JO Ve p r 2 y ee Ul This is to certify that the Barrett Crystal wheelchair A has been crash tested in accordance with ISO 7176 19 by TRL and fully complies OOO
42. werchair on suitable stands and disconnect the motor wiring loom from the main loom Bend the tab washer M158 away from the bolt head and using a 10mm spanner remove the drive securing bolt F95 This is made easier if the drive is engaged The drive components can now be withdrawn from the motor drive shaft and care should be taken not to lose any parts Examine the components for damage or wear as indicated from the previous checks If the wheel bushes need replacing these can be removed by the use of a soft drift and hammer Replacement of wheel bushes requires the use of a press to prevent burring the edges of the bushes If it is necessary to replace the stub axle D9L the motor will require removal from the mounting plate Using a 7 16 AF spanner release the three retaining bolts and withdraw being careful not to lose the spacers The motor can now be removed by sliding the drive shaft out of the stub axle Using spanners 13 8 A F remove the stub axle Replace the stub axle D9L apply thread locking compound and tighten to 35 Ibs ft 47Nm torque Refit the motor to the mounting plate insert spacers and tighten bolts to 10 Ibs ft 13 5Nm torque Re assemble the thrust washers metal wavy F65 first plain nylon second Fit the wheel and small plain nylon washer Fit the drive collar M159 cup washer M157 spring M156 and drive dog M155 Use a new tab washer M158 and bolt F95 Apply threadloc compound Grade 66 to th
43. will indicate worn thrust washers Maximum allowable is 3mm Check that the free wheel mechanism engages and dis engages freely and that the drive dogs do not have rounded corners Check the drive securing bolt in the end of the drive shaft is tight and the tab washer is bent up for security Check the motor loom for damage and that the plug wiring is secure Check for unusual noises such as whining or rubbing which might indicate that the solenoid brake is touching the cowl Move the joystick around the quadrant and check that when released it self centres and the brakes operate An audible click will be heard from each motor when the brakes are applied and released Kol Raise the rear of the powerchair and support on suitable stands Engage the drive Kol mechanism and move the joystick around the quadrant to simulate forward reverse and turning Observe the wheel rotation to ensure it mirrors joystick movement and check for any wheel tyre distortion 13 4 Power System Removal If it is required to remove the complete drive assembly as one unit the following procedure applies Support the rear of the powerchair on suitable stands and disconnect the motor wiring loom from the main loom Using 19mm spanners release the M12 nut SF 602 which attach the mounting plate to the side frame Remove M6 hex nut and bolt immediately underneath the bottom of the push handle and withdraw the wheel motor assembly 13 5 Power System Replacem
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