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Contents
1. RR RR R NET www chasswheel com 10 5 PRESENTATION OF ELECTRICAL SYSTEM General description The nominal voltage of the electric system is 24 V for drive motors and actuator s the lightning system voltage is 12 V The power source of the system is two series connected gel batteries which are charged by a separate charger There are four drive motors and an actuator for balance adjustment There are four driving motors and one actuator for the sense of gravity Driving controller system The driving controller of the wheelchair is PG Drives Technology R Net system which consists of the following parts Power Module including power electronics and programmed values Joystick Module including the joystick controls and a socket for charger and programmer Actuator and lightning Module including connecting points for lights and actuator s Joystick Cable this is a cable between the Power Module and the Joystick Module The connection of the driving controller The wheelchair has four drive motors which are coupled crosswise The right channel of the controller is coupled to the motor circuit which consist of a parallel coupled front right and rear left drive motor Correspondingly the left channel of the controller is coupled to the motor circuit which consist of parallel coupled front left and rear right drive motor By that coupling arrangement the driving controller is made to suit the chassis s2. SERVICE MANUAL Read the manual carefully For more detailed information please contact us Chasswheel Ltd Myllyharjuntie 6 71800 SIILINJARVI Tel 358 0207 559 220 Fax 358 0207 559 221 CONTENTS ee eet 2 1 TECHNICAL INFORMATION CW3 FOUR xe da du duced ed 3 1 1Disclosure information eC m 4 1 2 The permanent labelling of the wheelchair 2 5 ZJDEELARATION OF CONFIRMATION EE 7 3 WARRANTY es aa nb na aca wa 8 4 ROUTINE MAINTENANCE enge ig 9 A LCS TOM 10 4 2 wrench settings and thread locking 10 5 PRESENTATION OF EE IER OR enee 11 5 1 agas EI ME asosini nett o pel 12 E EE EE EE 12 em eine psy ee e 12 550 SY ree 12 5 6Driving suas 2o m 12 6 WIRING DIAGRAM RUN NEN AR MANU RN OBI EEEE ES ENENG 13 E ie EE 13 BUS Ee 14 6 3Programming engineer evel sso naana s bed p Rp Rok Ra Eta ilt adc 15 Eelere eg 16 6 5The connecting Of the Joystick 17 elle Er Ke guai eo T 18 7 REMOVING AND INSTALLATION OF THE DRIVE MOTORG AA 20 8 CHANGING THE BALANCE ADJUSTING nitens ene inni ade 21 SUPPORTING RODS FIXING TO JOINT ARM 22 10 THE INSTALLATION
3. OF THE RUBBER BUSHINGS 23 11 REMOVING AND INSTALLATION OF THE GAS SPRING SUPPORT FRAME SEAT FRAME 24 IX STEERING CHE TRUE ee EE EE EE Ee 25 EH R NET www chasswheel com 2 1 TECHNICAL INFORMATION CW3 FOUR X DL Wheelchair classification Maximum recommended mass of the user Driving speed Driving distance depending on drive conditions Clearance Obstacle negotiation ability Maximum obstacle negotiation ability Slope climbing capacity Maximum safe slope Turning radius Turning space with one reverse Operating temperature Charger standard Maximum permitted charging current Weight including batteries Mass of the heaviest part of the chair Seat leg support and batteries detached Seat Recaro standard width seat depth back height seat surface height at the front edge seat plane angle Transport measurements C 125kg 10 km h approx 35km 100mm 100mm 115mm 209 109 1 15m 1 7m 25 C 40 C 90256 NB Popular 8 A 12A approx 130 kg 70kg 53 2 cm 46 51 cm 76 82 cm 57 cm 18 33 leg support and head rest detached back rest turned into the front position width length height varies depending on the seat Tyres Tyre pressure depending on the model Light equipment driving lights rear lights direction indicators Electric system Main fuse Driving controller Driving motors 4 x 250 W Brakes Sta
4. 76 7 22 Front location of 180 mm 500 mm sideways armrest structure 7176 4 energy 35 km handrim consumption diameter 7176 2 dynamic stability 10 Horizontal uphill location of axle 7176 10 Obstacle 115 mm 7176 5 Minimum 1150 mm climbing turning radius 7176 6 maximum speed 10 km h forward 7176 6 minimum 1000 mm ee www chasswheel com R NET braking distance from max speed 1 2 The permanent labelling of the wheelchair Identification plates situated on the left side of the frame ELECTRICALLY POWERED WHEELCHAIR Class C Manufacturer Type CW 3 FOUR X DL Weight 130 kg CHASSWHEEL OY Max mass of the user 125 kg Myllyharjuntie 6 71800 SIILINJARVI A Zeie Frame no Year Month ELECTRIC WHEELCHAIR Wheelchair classification For outdoor use Maximum safe slope 10 CLASS C USED ON STEEPER SLOPES THAN Obstacle negotiation ability 100mm 10 M OR GREATER LEVEL General driving restriction DIFFERENCES THAN 100 mm CAN CAUSE SAFETY RISKS Situated on the battery casing rear case Battery Battery Battery connecting diagram Blue Red i inci j S 42V G 2 Situated inside the battery casing cover CAUTION OWNER S MANUAL FOR Driving INFORMATION Direction Main fuse value information Situated on the main fuse box Using the other than gel batteries is forbidden warning Situated on the top of the battery casing rear case USING THE OTHER THAN GEL BATTERIES IS FORBID
5. DEN R NET www chasswheel com 5 Freewheeling sign D breaks locked the wheelchair can be driven N breaks released the wheelchair can be towed Situated in every fender Attention read the user manual Situated on the supporting frame both sides from the seat Do not push the wheelchair from the back rest Situated on the battery casing cover A risk of the finger trap These labels are situated in the points where the danger exists Tyre pressure range Situated in every tyre R NET www chasswheel com 6 2 DECLARATION OF CONFIRMATION CE The Manufacturer Chasswheel Ltd Myllyharjuntie 6 71800 SIILINJARVI FINLAND declares that the CHASSWHEEL CW3 FOUR X DL electrically powered wheelchair conforms to the following standard requirements EN 12184 2006 EN 1041 1998 EN ISO 14971 2007 ISO 9999 1997 prEN 12182 1999 ISO 6440 1985 ISO 7176 1 1999 2 2001 3 2003 4 1997 5 1986 6 2001 7 1998 8 1998 9 2001 10 1988 11 1992 14 1997 15 1996 Siilinj rvi 15 3 2008 Risto Heikkinen Managing Director R NET www chasswheel com 7 3 WARRANTY Chasswheel Oy grants a two 2 year warranty for the CHASSWHEEL CW3 FOUR X DL electric wheelchair s frame and chassis the driving control system driving motors and the seat Batteries and charging appliances are not included in the warranty On every wheelchair there is a model plate which shows a unique serial number This warranty covers faul
6. USTMENT ACTUATOR 3 SEAT ACTUATOR 4 BACK REST MK 72 Ah MK 72 Ah ACTUATOR 5 FOLDABLE BACK REST ACTUATOR 6 FREE INHIBIT 2 SPEED LIMITATION INHIBIT 4 SEAT FUNCTION LIMITATION INHIBIT 5 SEAT ANGLE LIMITATION FUSE BLACK RED 24 V R NET www chasswheel com 13 6 2 Axle cable series R NET www chasswheel com 14 6 3 Programming engineer level Profile 1 Profile 2 Profile name Inside Outside Speeds Maximum forward speed 50 100 Minimum forward speed 15 15 Maximum reverse speed 30 40 Minimum reverse speed 10 10 Maximum turning speed 12 12 Minimum turning speed 10 10 Maximum forward acceleration 20 40 Minimum forward acceleration 10 20 Maximum forward deceleration 85 85 Minimum forward deceleration 85 85 Maximum reverse acceleration 20 40 Minimum reverse acceleration 10 20 Maximum reverse deceleration 45 45 Minimum reverse deceleration 25 25 Maximum turn acceleration 20 30 Minimum turn acceleration 10 15 Maximum turn deceleration 30 30 Minimum turn deceleration 15 15 Power 80 100 Torque 90 90 Fast brake rate 80 80 EH R NET www chasswheel com 15 6 4 ISM device wiring Actuator Channels leftlights 1 3 5 Right lights 2 4 Actuator Channels 1 3 amp 5 Assumes no Joystick Orientation programming has beeen undertaken INHIBITS 4 amp 5 Into the ReBus channels of the ISM device are connected joystick Module and Power Module through
7. attery cable is disconnected The axle of the motor that is under removing is supported underside Release the tyre from the motor 5 x hexagonal bolt 6 mm wrench Release the fender 3 x hexagonal head bolt 10 mm wrench Release the fender holder 2 x flange bolt 10 mm wrench Release the protective casing from the frame 4 x cross mouthed srew Release the seat if necessary Release the connector coming from the motor remove the cable ties Release the remaining motor s fastening srews 9 Motor is pulled off from the axle Gi N Motor installation 1 Check that the breaks are released and locked while turning the break lever 2 Set the motor on the axle 3 Fasten motor s underside screws use middle hard thread locking do not over stretch 4 Install the fender holder and fasten the last motor connector srew 5 Connect the motor connector 6 Install the protective caising 7 Fasten the motor s electric cable on the supporting shaft with cable ties 8 Install the fender 9 Install hte tyre 10 Remove the supporting 11 Connect the battery and check the function 12 After changing the motor there could appear uneven streering while driving the wheelchair This could be fixed by changing STEER CORRECT settings For changing the setting is needed different programming device EE ESS SS SS R NET www chasswheel com 20 8 CHANGING THE BALANCE ADJUSTING ACTUATOR Removing of the actuat
8. ck Module Maximum charging current is 12 A 5 5 Lightning system The wheelchair has a lighting system 12 V which includes following 2 white driving lights in front 2 red rear lights LED EE Ajowalo Les 2 orange direction indicators LED Kaz Bulbs renewal NEN Driving lights 12 V 3W E 10 Direction indicator maintenance free Rear lights maintenance free Vi AT 5 6 Driving light lamp replacement Picture 1 Picture 1 1 The small screw behind the lamp is loosened 2 The driving light is turned counter clockwise when the lantern is got off from its base 3 The lamp is removed and replaced with new lamp 4 The reassembly is done in the opposite order Other lighting devices are maintenance free LED lights B RHrRoo P e G n R NET www chasswheel com 12 6 WIRING DIAGRAM 6 1 Main cable series FRONT LIGHT WHITE LEFT R9 z z z z uz gt gt g 2p 29 39 93 65 om a a ca on a j e tel WHITE 5 SE Ei gt e E E 9 RED 3 S S E INDICATOR 3 LEFT i m e g JSM ACTUATOR 2 E a E 2 gt 2 2 2 REAR LIGHT S327 225 23 LEFT SS FRONT LIGHT ORANGE Zz INDICATOR 59 RIGHT a BLUE REAR LIGHT lt RIGHT 29 BLACK ACTUATOR 1 FOOT REST ACTUATOR 2 GRAVITY ADJ
9. djusting nut is turned until the right position is found After that the locking nuts are tightened and the bump travel is checked The adjustment of the bumb travel When the wheelchair is at flat plane the clearance is adjusted with suitable gauge 3 mm R NET www chasswheel com 22 10 THE INSTALLATION OF THE RUBBER BUSHINGS The installation of the rubber bushing of the supporting rod The bushings are pressed to the supporting rods by using a suitable tool Do not use grease or oil to ease the installation Some non disturbing liquid e g soap can be used The joint arm thread is cleaned for thread locking liquid Tightening torque 60 Nm Steering rods installation to axle tube The rubber bushing is pressed to the end of the steering rod by using a suitable tool Silicon crease must be used This lubricates the joint and eases the installation Do not use other grease or oil Assembly is shown in the picture below The upper washer is necessary to install cii Li 1 Tightening torque 60Nm zx cA Upper washer Streering rod end R NET www chasswheel com 23 11 REMOVING AND INSTALLATION OF THE GAS SPRING SUPPORT FRAME SEAT FRAME Removing 1 The actuator is driven to middle or front position so the gas spring has lowest tension 2 The front fixing screw of the gas spring is loosened so the tension disappears 3 The rear fixing screw is loosened Installation 1 The rear end of t
10. he gas spring is fitted to seat frame This is a joint so the screw is not fully tightened fig 3 2 The front mounting bracket is fitted to supporting frame fig 1 3 The screw is fitted to the bracket with front end of the gas spring 4 The bracket Is turned to horizontal position with 10 mm spanner fig 2 5 The screw is tightened 6 The actuator is driven and the function is tested Supporting frame Fig 1 E Bracket The front end of the gas spring Screw DIN 912M6 x 25 DIN 985 M6 Set frame bracket DIN 127 M6 DIN 912 M6 x 16 Se The rear end of the gas spring R NET www chasswheel com 24 12 STEERING ADJUSTMENT E Locking nut VW e Length adjusting screw Streering rod rods 1 The slide is centralized and locked by centralizing pin 2 The locking nuts of the steering rods uw are loosened 3 The rods are turned until their angle to frame is 90 4 The locking nuts are tightened Centralizing VYA ch 6 X The adjustment of the turning radius 1 The locking nut is loosened CN Adjusting Screw 2 The adjusting screw of turning radius is c of turning radius turned until the turning radius is suitable NN the axle is not touching the leg support with turnings 3 The locking nut is tightened 4 The other side is adjusted in same way Locking nut R NET www chasswheel com 25
11. ndard battery MK Gel Battery 73 A h Spindle motor balance adjustment Frame Shock absorption 69cm 100cm 82 89 cm 3 00 8 1 3 3 5 bar 130 kPa 350 kPa 12V 2x3W 24 V 12V 24V 80A R Net system 1000W 4 pcs 2 pcs Linak 28 S steel stove enamelled powder paint 2 shock absorbers I steering attenuator R NET www chasswheel com 1 1 Disclosure information Manufacturer Chasswheel Oy Address Model Annex A normative Information disclosure in manufacturer s specification sheets Myllyharjuntie 6 FIN 71800 SIILINJARVI CW 3 FOUR X DL Maximum occupant mass 125 kg Standard Min Max Standard Min Max reference reference 7176 5 Overall lenght 1270 mm 1370 7176 7 1 Seat plane angle 10 21 with legrest 7176 5 Overall width 692 mm 692 mm 7176 7 2 Effective seat 390 mm 510 mm depth 7176 5 folded length 1000 mm 1000 7176 7 4 Effective seat 520 mm 600 mm width 7176 5 folded width 692 mm 692 mm 7176 7 5 Seat surface 570 mm 740 mm height at front end 7176 5 folded height 820 mm 820 mm 7176 7 6 backrest angle 50 Total mass 130 kg 7176 7 7 backrest height 500 mm 600 mm mass of the 80 kg 7176 7 11 footrest to seat 400 mm 500 mm heaviest part distance 7176 1 static stability 25 7176 7 15 leg to seat 90 160 downhill surface angle 7176 1 static stability 25 7176 7 16 armrest to seat 150 mm 310 mm uphill distance 7176 1 static stability 15 71
12. or 1 Remove the seat by opening 4 screws that holds the seat on the seat frame If the actuator is working it is driven to middle position when the gas spring tension is lowest One battery terminal is detached Disconnect the actuator cable from the cable series connector 2 Remove the retaining cable tie from the back tube of the seat frame Open actuators fastening screws Release the actuator from the holder Oy Om ipee Installation of the actuator 1 Install rear part of the actuator in to the holder and stretch the screw and the nut 2 Screw the actuators axle so that the axle s hole and supporting frames retaining hole are concentric 3 The axel s slot is pushed in to the mounting point and holes are aimed at concentric by using for exemple a mandrel with help Tight the front end screw and the nut Attach the actuator s cable with cable tie into the hole in the seat frame Connect the actuator s cable in the cable series connector 2 Connect the battery and check the function Connect the battery and check the function Check that the cables and pipes moves properly during motion 10 Install the seat back poc quocum um J eM ui R NET www chasswheel com 21 9 SUPPORTING RODS FIXING TO JOINT ARM 10 The side way adjustment of the seat frame If the seat position is not correct the a
13. ould be done during the maintenance to observe the condition of the drive motors veering reduced efficiency noise etc R NET www chasswheel com 9 4 1 Lubrication Lubrication object Interval Lubricant Upper joints bearing of the axle At least once a year lubricating oil graphite Vaseline Slide rail of the supporting and or frame in connection with assembly lubricating oil Steering rod end rubber In connection with service of the bushing releaser silicon based crease or oil 4 2 Torque wrench settings and thread locking Moment Attachment Nm Thread locking The spring attachment in the frame 35 Hard Lower bearing attachment in the axle 35 Nylock Lower bearing attachment in the holder 35 Nylock Holder attachment in the spring 35 Nylock Supporting rods attachment to joint arm 50 Medium Hard Medium Hard Medium Hard Supporting rods attachment to axles 35 Steering joint bearings attachment to axles 35 8 Medium Hard Attachment of drive motors Joint arm attachment to frame 50 Medium Hard Attachment of the steering damper 35 Medium Hard Attachment of the slide bracket to the slide 8 Medium Hard Attachment of the slide bracket to the Medium Hard frame 12 Attachment of the bearing bracket to the Medium Hard seat frame 12 Attachment of the seat M6 10 Medium Hard some seat screws may have self locking Medium Hard type thread M8 35
14. the communication cable Cables must be situated so that they cannot be flattened and not be aimed at pull while using the wheelchair E CM e R NET www chasswheel com 16 6 5 The connecting of the Joystick Module Joystick Charger Socket Communication Cable Joystick Module is connected into ISM device through the communication cable The cable must be situated so that it cannot be flattened and not be aimed at pull while using the wheelchair SSS R NET www chasswheel com 17 6 6 Micro switch connection Inhibit 2 located in the frame on the right side of the control rod s guide limits speed in half 5km h if the cable drops off only limited speed is in use a Micro switch Inhibit 2 R NET www chasswheel com 18 Gretrichtung beide Motorec ROT ml auf 6 7 Drive motor DREHZAH n1 3300 min ISC KLASSE F SCHUTZART IP 43 GETRIESE 18 71 ORERZAHL n2 175 BREMSE SPANNUNG 24VEC Position ME fir Scniebepetried a Gieses Dokument 51 urheberrechttech geschstzt 5 da nue t cen inlernen Gebrauch verwende werden Dee Weitergabe an Drille auch weise in jg licher Ferm bedar der ausa iri er i durch die Micre Molor Eriersiraste 52 6106 it Technische Anderungen vorbenalten E Ce Ise Poto komplett SEL SC AUFSZE IC HNUNG 19 www chasswheel com R NET 7 REMOVING AND INSTALLATION OF THE DRIVE MOTORS Removing The b
15. tructure based on the turning of the axles The driving technique of the wheelchair differs from the driving technique of a two wheel drive wheelchair There are many programming possibilities in the driving controller of which some has to be installed at the factory and the rest can be altered when the wheelchair has to be adjusted to suit the user Programming is made by a separate programmer PP 1 K X Na 9 i R NET www chasswheel com 11 5 1 Drive motors The wheelchair has four permanent magnetized 24 V motors similar to each other with gear and parking brake 5 2 Balance adjustment The balance adjustment is made by an actuator which moves the supporting frame in relation to the main frame When the supporting frame is moved backwards the seat starts to lean back at a certain stake The actuator is controlled by the joystick when the actuator adjusting mode is selected 5 3 Free wheeling If the wheelchair must be pushed the parking brakes are released by turning the lever in the middle of both axles about 90 counter clockwise from ON to OFF position A micro switch in connection with the releasing device breaks the parking brake circuit and prevents the driving of the wheelchair in brake less state 5 4 Battery charging The batteries are charged by a separate charger which is connected to the XLR connector in the front of the Joysti
16. ts that occur in normal operation of the wheelchair The warranty does not cover faults caused by normal wear and improper or lack of maintenance as indicated in the owner s manual and the service instructions Furthermore the warranty does not cover faults originating from overloading or incorrect programming Normal wear occurs in parts such as tyres rubber mountings leaf springs joints and slide surfaces Increased noise of the driving motors is also caused by normal wear Indirect expenses incurred in dealing with faults are not included in the warranty EH R NET www chasswheel com 8 4 ROUTINE MAINTENANCE The maintenance period is dependent on the usin circumtances The period should not be more than one year However it is necessary to observe the condition of the wheelchair all the time During the routine maintenance the following objects must be checked the condition of tyres and their fixing the function of the parking brakes and the releasers the tightness of the screws see page 13 for more information the weariness of the joints the condition of the electrical cabling is checked visually all functions of the driving controller the condition of the charging socket the condition of the joystick rubber gaiter the condition of the batteriesthe greasing of the joints testing the condition of the motors virrankulutus moottoria kohti 1 h ajan tyre pressure max tyre pressure given on tyres label A test drive sh
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