Jewel (Tech) - RJ Mobility
Contents
1. 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 16 2 Parts List GZF No RJ 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 1 16 x 1 2 Split Pin F153 1 4 x 18G Plastic Plug M9 35 16 3 Inspection Check heel loop for security Nuts should be tightened to 10 Ibs ft 13 Nm Check pivot bolt for wear 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 br2. Battery charger controller and electrical system OK Charge battery if possible controller and electrical system OK Charge batteries AS SOON AS POSSIBLE controller and electrical system OK Indicates a fault in the controller or electrical system See table below for fault diagnosis Joystick displaced at turn on Fault Type The number of flashing bars indicate the possible area of fault Description GREEN High battery voltage GREEN Solenoid brake faulty GREEN Possible controller fault YELLOW Possible joystick fault YELLOW Charger connected YELLOW Right motor wiring fault YELLOW Right motor disconnected RED Left motor wiring fault RED Left motor disconnected RED Low battery voltage General Check that the insulation of the connecting cables is in good condition and that the connectors are fully mated Check to ensure the control system is securely mounted 34 SECTION 16 ELEVATING LEGREST 16 1 Diagram ELEVATING LEGREST 1 4 UNF X 1 7 8 HT BOLT ASSEMBLY SP333 ZINC PLATED F12 1 4 X 18G PLASTIC PLUG M9 1 4 UNF NYLOC NUT ZINC PLATED P90 LEGREST CARRIER BRACKET SF95 LEGREST STEM SF120 ELEVATING ROD SF123 LEGREST TRIGGER SPRING SF234 STEM SWIVEL TUBE SF88 LEGREST TRIGGER CALF PAD SF122 TSD10241 LEGREST TRIGGER 1 4 UNF NYLOC NUT BRACKET SF121 ZINC PLATED P90 CLAMP ASSEMBLY M102 1 16 x 1 2 SPLIT PIN F153 1 4 UNF X 1 1 4 HT BOLT ZINC PLATED F7
3. 11 4 Diagram CROSS BRACE ASSEMBLY SF 205 1 4 UNF NYLOC NUT ZINC PLATED P90 p d 5 8 UNF HEX HEAD BOLT ZINC PLATED F10 1 4 1 3 4 UNF HEX HEAD BOLT ZINC PLATED F11 1 4x1 5 8 UNF HEX HEAD BOLT g 6mm NYLON SPACER F65 1 4 BRASS WASHER F30 yom PLATED F10 1 4x1 UNF HEX HEAD BOLT ZINC PLATED F139 Q 1 4 BRASS WASHER F30 1 4x1 1 8 UNF HEX HEAD BOLT ZINC PLATED F4 1 4 UNF NYLOC NUT ZINC PLATED P90 1 4x1 UNF HEX HEAD BOLT ZINC PLATED F139 1 4x1 3 4 UNF HEX HEAD BOLT ZINC PLATED F11 1 4 BRASS WASHER F30 11 5 Parts List GZF No RJ No Cross Brace Assembly 17 Complete with Fasteners 006 SF205 Cross Brace Assembly 15 Complete with Fasteners 007 SF206 1 4 UNF Nyloc Nut P90 1 4 x 1 5 8 UNF Hex Head Bolt Zinc Plated F10 1 4 x 1 3 4 UNF Hex Head Bolt Zinc Plated F11 1 4 Brass Washer F30 1 4 x 1 UNF Hex Head Bolt Zinc Plated F139 1 4 x 1 1 8 UNF Hex Head Bolt Zinc Plated F4 1 4 Plastic Spacer F65 11 6 Inspection Check Cross Braces for bending and evidence of cracks around pivot holes Check each tab on the side frames for evidence of bending elongation or worn holes and cracks in brazing or tubing Check securing bolts for excessive wear 11 7 Cross Brace Assembly Removal Remove the two 1 4 UNF set screws securing the Cross Braces to each side frame 20 11 8 Cross Brace and Locking Link Assembly Fitting Fit the two 1 4 UNF set screws securing the Cross Braces to each side frame Tighten until t
4. A STARLOCK WASHER F37 RJ No Starlock Washer F37 5mm Plain Washer Q5 Lock Lever TSD1323 Plunger Spring TSD1229 Lock Pin TSD1306 12 SECTION 8 FOOTREST 8 1 Diagram HANGER ASSEMBLY SP231S QR 1 4 CLAMP BOLT ZINC PLATED F20 Cap 5 16 WASHER ZINC PLATED F22 a x 5 16 CLAMP BOLT 2 6 PLATED F21 CLAMP ASSEMBLY M102 HEEL LOOP ASSEMBLY TSD 11469 2 FOOTPLATE ASSEMBLY 1 4 x1 1 4 UNF SCREW ZINC PLATED F9 1 4 UNF PLAIN NUT ZINC PLATED F26 CX 7 5 FOOTPLATE M172L R P d 8 5 FOOTPLATE M173L R NOT SHOWN No 4x1 4 SELF TAPPING SCREW ZINC PLATED 0456A SPRING TSD 1349 8 2 Parts List GZF No RJ No Footrest Hanger with retaining Right 113 SP261S R clamp assembly M102 Left 114 SP261S L Retaining Clamp Assembly M102 5 16inch x 1 1 4inch Clamp Bolt zinc plated F20 5 16inch Clamp Locking Nut zinc plated F21 5 16inch Washer zinc plated F22 Footplate Assembly 8 1 2inch complete Left 111 SP356 with Stem and Heel Loop Right 110 SP357 Footplate Assembly 7 1 2inch complete Left 111 SP358 with Stem and Heel Loop Right 110 SP359 Footplate Spring TSD1349 Heel Loop complete with nuts and washers 112 TSD11469 2 No 4 x 1 4 Pozipan Type Self Tapping Screw zinc plated 0456A 13 8 3 Inspection Check that footrest assembly locks into position Apply light grease to swivelling end Ensure that stem clamp holds footplate in position Ensure that footplate will remain in vertical position when required Ensu
5. Assembly Right 300 19 11R Brake Handle Left SF172LP Brake Handle Right SF172RP Black Ball Knob KB5 125 Brake Pivot SF173P Brake Lever Left SF171L Brake Lever Right SF171R Brake Shoe SF174A Return Spring Zinc Plated Left 258 SF233L Return Spring Zinc Plated Right 259 SF223R 1 16x1 2 Split Pin Zinc Plated F50 10 32x5 8 UNF Hex Head Screw Zinc Plated F13 15 9 2 Parts List Cont d GZF No RJ No 1 4 UNF Plain Nut Zinc Plated F26 2BA Wave Washer Copper F29 10 32 UNF Nyloc Nut Zinc Plated F24 Thread Protector 199462 9 3 Inspection Check ball knob for security Check levers for distortion Check brazed joints for cracks Check pivot shafts for distortion Replace pivot bolts if necessary due to excessive wear Ensure no oil grease on brake pad 9 4 Brake Assembly Removal Remove the two 1 16inch Split Pins from the Brake Pivot shaft and Brake Lever shaft Remove the 2BA Wavey Washers and slide the brake assembly from the frame 9 5 Brake Assembly Fitting Fit the Brake Pivot and Brake Lever shafts through the bushes on the frame Fit the 2BA Wavey Washers on each shaft and fit two new Split Pins Retain the Split Pins in the holes by bending the ends apart using small pliers Replace with a new Return Spring if necessary Ensure pivot bolts are not over tightened as this will lead to fracture of the brazed tabs on the brake handle Lubricate with light oil 9 6 Brake Adjustment The Brake Shoe position can be adjusted by
6. Battery Loom 201 18 Motor Assembly Left 624 E94LL Motor Assembly Right 623 E94R 30 Amp Hr Battery 620 E75 30amp hr Circuit Breaker 28 14 3 Electerical 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 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 Wiring Loom Removal and Replacement 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 sea
7. loosening the lock nut and repositioning the shoe The nuts should be adjusted to allow an operating force at the knob to be between 10lbf to 13lbf 44 to 58 N with the tyres inflated to the correct pressure 50psi 340 KiloPascals 16 SECTION 10 BACKRESTS 10 1 Diagram BACKREST ASSEMBLY LEFT G223 BACKREST ASSEMBLY RIGHT G224 BLACK PLASTIC BUNG M14 No 10 AVDEL NUTSERT 09657 01014 Lao G246 BLACK PLASTIC BUNG M14 3 16x1 SPRING PIN BLACK ZINC PLATED F43 1 4 BRASS WASHER F30 1 4 UNF TYPE P NYLOC NUT ras PLATED P90 SLIDING PEG HANDLE G244 1 4x1 3 4 UNF HEX HEAD BOLT ZINC PLATED F11 b ho ram SPRING PIN BLACK ZINC PLATED F43 17 10 2 Parts List Backrest Assembly Backrest Assembly Backrest Frame Backrest Frame Sliding Peg Sliding Peg Handle Black Plastic Bung Knurled Plastic Nut 3 16x1 Spring Pin Black Zinc Plated 1 4 Brass Washer 1 4 UNF Type P Nyloc Nut Zinc Plated Sliding Peg Spring Plunger stop GZF No Left Right Left 335 965 Right 336 966 1 4 x 1 3 4 UNF Hex Head Bolt Zinc Plated No 10 Avdel Nutsert 10 3 Inspection Check each backrest for evidence of bending Check each backrest for evidence of cracking through nutsert holes Check for free movement of the plunger Lubricate with light oil Check that the plunger locates in the hole on the side frame Ensure Nyloc nut still grips thread 10 4 Backrest Removal RJ No G223 G224 G246L G246R G2
8. of the DL Controller acts as both a fuel gauge and a warning gauge When all lights are on the batteries are fully charged As the power is used the green lights and then amber lights will go out When only the red lights are left on the batteries will require recharging If a fault is detected the illuminated display will flash To determine the fault count the number of flashes and refer to the following table 1 Limp Mode Turn the controller off amp then on again 2 Accessory Fault Possible remote joystick fault 3 Left Motor There may be a fault or a loose connection 4 Right Motor There may be a fault or a loose connection 5 Left Park Brake There may be a fault or a loose connection 6 Right Park Brake There may be a fault or a loose connection 7 Low Battery You may need to charge your batteries 8 Over Voltage Check the battery circuit for loose connection 9 10 Limp Mode Turn the controller off amp then on again 11 Motor stalled or joystick Switch the controller off then back on again out of neutral time out 12 Module Mismatch Check the compatibility of modules 33 Pilot Controller The battery gauge is a 10 segment illuminated display which indicates if the controller is turned on and also gives the status of the battery the controller and the powerchair electrical system Red Yellow and Green bars lit Red and Yellow bars lit Red bars only lit Rapid flashing of bars Ripple up and down of bars
9. 8 G244 M14 F47 F43 F30 P90 F71 SF194 F11 09657 01014 Unscrew 5 off No 10 UNF countersunk screws holding the backrest fabric to the backrest assembly Unscrew the 1 4 UNF nut and withdraw the bolt 10 5 Push Handle Fitting Insert the 1 4 UNF bolt through the backrest and hinge plates Replace the washer and tighten the Nyloc nut until the backrest pivots freely without excessive free play Fit the 5 off No 10 UNF countersunk screws to hold the backrest fabric to the backrest assembly 18 SECTION 11 FRAME LOCKING LINKS AND CROSSBRACES 11 1 Diagram SIDE FRAME ASSEMBLY LEFT 300 19L SIDE FRAME ASSEMBLY RIGHT 300 19R No 10 AVDEL NUTSERT 09657 01014 a d lt SIDE FRAME RIGHT 300 l p Os CHI E S RN ARMREST LOCK go Z ASSEMBLY pP P go a C M P d La i ze p i al d G E 3 4 SQUARE BLACK BUNG M11 3 4 SQUARE BLACK BUNG M11 1 3 8x5 8 BLACK Hee eL IDE FRAME LEFT 300 19L BUNG M195 a 11 2 Parts List RJ No Side Frame Assembly Left G1 Side Frame Assembly Right G2 3 4 Square Black Plastic Bung M11 1 3 8x5 8 Black Plastic Bung M195 No 10 Avdel Nutsert 09657 01014 11 3 Inspection Check Armrest Locking assembly operates effectively Check each tab on the sideframes for evidence of bending elongation or worn holes and cracks in brazing or tubing Check tube inserts are fitted correctly Examine frame for damage 19
10. ASHER DRIVE COLLAR M159 SPRING M156 SPACER M157 WHEEL ASSEMBLY 13 2 Parts List GZF No RJ No Motor amp Gearbox Left 624 E95L Motor amp Gearbox Right 623 E95R Motor Brush Replacement Not Shown Wheel Assembly G297 ASS Stub Axle D9L Hex Nut 314 D9 Drive Coupling 958 M155 Spring 959 M156 Bronze Bush 320 M89 Drive Collar 962 M159 Spacer 960 M157 Nylon Washer Large F67 Nylon Washer Small F66 1 4 x 1 1 4 UNF Hex Head Bolt Zinc Plated F7 M74 24 Tab Washer M158 M6x10 Hex Head Screw Zinc Plated F95 10mm Spacer D23 1 4 Spring Washer F33 Wavey Washer F65 Clamp Bolt F20 Clamp Washer F22 Clamp Nut F21 Knob 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 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
11. MBER 2 JEWELTECHA SECTION 1 USER CATEGORIES A2 Attendant Controlled Degree of upper body control to maintain sitting position A4 A5 Occupant capable of using one hand to control the powerchair having spatial awareness co ordinated motor skills and sufficient manual dexterity to operate the controller 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 Jewel foldaway powerchair PO O I Es 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 SECTION 2 SPECIFICATIONS Dimensions based on seat size 43cm x 43cm 17inch x 17inch Overall length Overall width Folded length Folded width Folded height Maximum weight Heaviest Component Seat plane angle Seat depths available Seat widths available Seat height at front Backrest angle Backrest height Footrest to seat Leg to seat angle Armrest to seat Front armrest to backrest Drive wheel diameter Tyre Pressures Maximum load capacity Turning Space a Spin turn b Between walls Range 30 Amp hr Battery Static Stability a Front b Rear c Side Maximum forward speed Maximum stopping di
12. OCKET FRONT REAR SOCKET CONTROLLER MOUNTING CONTROLLER MOUNTING PLATE G66A CONTROLLER EXTENSION G67A PILOT CONTROLLER E109 di CONTROLLER MOUNTING PLATE G278A 1 4x1 1 8 UNF HEX HEAD SCREW ZINC PLATED F4 CONTROLLER EXTENSION M5x8 POZI PAN SCREW ZINC PLATED F18 BLACK PLASTIC BUNG M8 A03 134 CONTROL DYNAMICS DL T CONTROLLER E123 M5x8 POZI PAN screw 77 7 8 ZINC PLATED F18 BLACK PLASTIC BUNG M8 1 4 UNF NYLOC NUT ZINC PLATED P90 E um 15 2 Parts List GZF No RJ No Penny amp Giles Pilot Controller Controller Extension A03 134 Controller Mounting Plate G278A P amp G Pilot Controller 621 E108 1X1 1 8 UNF Hex HD Screw Zinc Plated F4 1 4 UNF Nyloc Nut Zinc Plated P90 M5x8 Pozipan Screw Zinc Plated F18 Black Plastic Bung M8 Control Dynamics DL Controller Controller Extension G67A Controller Mounting Plate G66A Control Dynamics DL Controller E123 M5x8 Pozipan Screw Zinc Plated F18 Black Plastic Bung M8 15 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 15 4 Programmable Controller Removal Penny amp Giles Pilot Controller Remove the two M5x8 Pozipan screws which secure the Controller to the Controller mounting plate Release the two 1 4 UNF Nyloc nuts from the underside of the Controller Extension and remove the 1 4 x 1 1 8 UNF Bolt holding the Controller Mounting Plate Control Dy
13. RJ MOBILITY LTD JEWEL INDOOR POWERCHAIR TECHNICAL MANUAL THE PROVEN RELIABLE INDOOR POWERCHAIR This Technical Manual will ensure that the wheelchair is maintained to the required standard and is for use by trained personnel only This Technical Manual contains important information regarding maintenance of the Jewel 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 should 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 maintenance and operating instructions please contact RJ MOBILITY LTD Boy Lane Wheatley Halifax HX3 5AF England Tel 44 0 1422 358888 Fax 44 0 1422 355924 Section O OI CONTENTS USER CATEGORIES SPECIFICATIONS POWERCHAIR DIAGRAM MAINTENANCE CHECKS TOOL REQUIREMENTS UPHOLSTERY ARMRESTS FOOTRESTS BRAKES BACKRESTS FRAME LOCKING LINKS AND CROSSBRACES CASTORS POWER DRIVE SYSTEM ELECTRICAL SYSTEM PROGRAMMABLE CONTROLLER ELEVATING LEGREST ARMREST OUTRIGGERS DETACHABLE TRAY KERB CLI
14. acket 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 36 SECTION 17 ARMREST OUTRIGGERS 17 1 Diagram 1 4x7 8 HEAD BOLT ZINC PLATED F3 ARMREST OUTRIGGER G273 BLACK PLASTIC BUNG s OUTRIGGER SPACER G274 1 4 UNF NYLOC P90 ARMREST OUTRIGGER BACKREST LOCATION G275 1 4x1 1 8 HEX HEAD BOLT ZINC PLATED F4 TE Ax7 8 HEX HEAD BOLT ZINC PLATED F3 17 2 Parts List GZF No RJ No Armrest Outrigger Socket Assembly Left G273 ASS L Armrest Outrigger Socket Assembly Right G273 ASS R Armrest Outrigger Rear Location Assembly G275 ASS Armrest Outrigger Socket G273 Armrest Outrigger Backrest location G275 Outrigger Spacer G274 1 4 x 7 8 UNF Hex Head Bolt Zinc Plated F3 1 4 x 1 1 8 UNF Hex Head Bolt Zinc Plated F4 1 4 UNF Nyloc Nut Zinc Plated P90 7 8 Black Plastic Bung M17 lt 37 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 armrest tube at insertion point 17 4 Dismantli
15. d 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 Check Velcro on frame is present and secure 6 4 Fabric Removal If the Nutserts need replacement use Avdel recommended tooling 6 5 Fabric Fitting No 10 UNF x 3 4 LONG COUNTERSUNK SCREW BLACK ZINC PLATED F15 REINFORCING BAR SF176 No 10 UNF AVDEL NUTSERT 09657 01014 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 10 SECTION 7 ARMRESTS 7 1 Diagram ARMREST ASSEMBLY LEFT G244 ASSL pc dd PAD ARMREST ASSEMBLY RIGHT G244 ASSR m us ROUND INSERT M5 12x1 1 4 POZI PAN SELF TAPPING SCREW ZINC PLATED F111 5 8x20G ROUND INSERT M5 gt 7 2 Parts Lists GZF No RJ No Armrest Frame Left 632 G244L Armrest Frame Right 631 G244R Armrest Pad 119 M170 No 12 x 1 1 4 Pozi Pan Self Tapper Screw Zinc Plated F111 5 8 x 20G Black Round Insert M5 7 3 Inspection Check armpad for excess wear or damage Check armpad is secured to frame Ensure armrest ocates in srear bracket on push handle when fitted to powerchair Check armr
16. e 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 backrest assembly and that it is free to move and locks into place positively See Section 10 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 the backrests 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
17. e 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 asembly can now be removed 13 7 Motor Brake Removal 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 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
18. eral 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 General P amp G PP1b programmer amp diagnostics device Control Dynamics programmer amp diagnostics device Advised Watt Minute meter Current Draw See Section 8 See Section 8 See Section 9 See Section 11 See Section 11 See Section 12 See Section 13 See Section 13 See Section 20 See Section 11 See Section 11 See Section 20 See Section 20 See Section 6 See Section 6 See Section 12 13 See Section 13 See Section 15 See Section 15 SECTION 6 UPHOLSTERY 6 1 Diagram BACKREST FABRIC G295 SIZE No 10 UNF x 5 8 LONG COUNTERSUNK SCREW BLACK ZINC PLATED F138 REINFORCING BARS SF176 No 10 FLANGED i SCREW CUP F38 CANVAS LOCATION SPIGOT G27 d No 10 UNF x 3 4 LONG COUNTERSUNK SCREW BLACK ZINC PLATED F15 No 10 FLANGED SCREW CUP F38 No 10 AVDEL UNF NUTSERT 09657 01014 6 2 Parts Lists RJ No Backrest Fabric Ninian G295 Size Seat Fabric Ninian SF453 Size Reinforcing Bar SF176 No 10 x 3 4 UNF Csk Screw Black Zinc Plated F15 No 10 Flanged Screw Cup F38 No 10 UNF Avdel Nutsert 09657 01014 No 10 x 5 8 UNF Csk Screw Black Zinc Plated F138 Canvas Location Spigot G27 6 3 Inspection Fabric Check for staining wear tear and stitching Check nut inserts in frame for security and strippe
19. est lock latch assembly retains armrest to frame assembly 7 4 Armrest Pad The armrest pad is secured to the armrest frame with three screws Removal of the screws releases the pad Secure the pad with the attachment screws to refit 11 7 5 Armrest Lock Assembly To dismantle the assembly place a screwdriver or similar tool between the starlock washer F37 and the lock lever TSD 1323 and prise apart Remove the starlock washer plain washer Q5 and the lock lever Withdraw the lock pin TSD 1306 and plunger spring TSD 1229 from the pin housing in the armrest location tube To assemble place the plunger spring TSD 1229 over the lock pin TSD 1306 and locate in the pin housing inside the armest location tube Pull the lock pin TSD 1306 through the pin housing using a small pair of pliers and place a length of tube in the armest location tube or reverse the armrest in the location tube This will retain the lock pin inside the pin housing Fit the lock lever TSD 1323 and plain washer Q5 over the lock pin and press a new starlock washer F37 onto the end of the lock pin Thumb pressure should be sufficient to fit the starlock washer or alternatively tap with a light hammer a 2 a A x gt d j He B on p d LOCK PIN TSD1306 Cum P di A b Fy ES SY Cu e b SPRING TSD1229 LOCK LEVER TSD 1323 SN P d 2 27 a 5 PLAIN WASHER Q5 mm Q ok j M p Pee de MEE Xy uo Cy
20. 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 gel filled and require no maintenance except to check for damage and security of connections See Section 14 7 for comprehensive instruction The battery charger is maintenance free the only serviceable part is the fuse fitted to the mains plug See Section 14 7 for comprehensive instruction Ensure the batteries are fully charged Drive the Jewel at maximum speed in forward reverse left and right directions checking that the joystick response is uniform 4 2 10 4 2 11 4 2 12 4 2 13 4 2 14 4 2 15 4 2 16 4 3 4 3 1 4 3 2 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 Slowly drive the powerchair up a maximum 1 in 6 gradient and attempt to accelerate The powerchair will cli
21. he 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 Overtightening of Cross Brace Assembly will prevent the pivoting action and will lead to fracture of the tab on the side frame 11 9 Diagram 1 4 BRASS WASHER F30 Z 1 4 UNF NYLOC NUT ZINC PLATED P90 NJ 1 4x1 UNF SOCKET CAP SCREW ZINC PLATED F137 1 4 BRASS WASHER F30 11 9 Parts List GZF No RJ No Front Locking Link Assembly 17 109 SF 207F Front Locking Link Assembly 15 005 SF 208F 1 4 x 1 UNF Socket Cap Screw Zinc Plated F137 1 4 UNF Nyloc Nut Zinc Plated P90 1 4 Brass Washer F30 6mm Nylon Washer F86 11 10 Inspection Check Locking Links 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 powerchair will not fold under load Check each tab on the side frame for evidence of bending elongation or worn holes and cracks in the brazing or tubing 21 11 12 Locking Link Assembly Removal Remove the 1 4 UNF Socket Cap Screw securing the Locking Link to each side frame 11 13 Locking Link Assembly Fitting Fit the two 1 4 UNF Socket Cap Screws to secure the Locking Link assembly to each side frame Tighten until the Locking Link is just securely held then loosen the nut half a turn The Locking Lin
22. k Assembly must be free to move without binding but no signs of excessive free play Lubricate with light oil eg 3 in 1 Overtightening of Cross Brace Assembly will prevent the pivoting action and will lead to fracture of the tab on the side frame 22 SECTION 12 CASTORS 12 1 Diagram 190mm WIDE PROFILE M51 140 SWIVEL RADIUS M14 x 22 LONG B 23 95mm A F HEXAGON mm 12 2 Parts List GZF No RJ No 190mm wide profile MCP 557 M51 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 SECTION 13 POWER DRIVE SYSTEM 13 1 Diagram STUB AXLE D9L hx1 HEX BOLT F7 SPRING WASHER F33 M6x10 HEX SCREW F95 WAVE WASHER F65 HEX NUT D9 BRONZE BUSH M89 TAB WASHER M158 DRIVE COUPLING M155 SPACER D23 o0 LARGE NYLON OS WASHER F67 numo L L SMALL NYLON i W
23. mb at normal speed Reverse down a 1 in 6 slope and check that the powerchair will come to a halt if the joystick is released 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 Check that all cables are connected to the controller batteries motors and brakes Check that the circuit breaker push buttons on the battery boxes have not sprung out Check that the free wheel devices are releasing and engaging correctly Check that controller rubber gaiter and switch cover are in good condition Check the insulation condition of all cables Check that the controller is securely mounted SECTION 5 TOOL REQUIREMENTS Spanners 1 4inch Whitworth Legrest Clamp 10mm AF Heel Loops 8mm AF Parking Brake 7mm Socket and Drive Rear Lock Link 1 4inch Whitworth Anti tip Device 1 5 16inch or 34mm AF Castors 1 5 16inch or 34mm AF Power Drive System 10mm Socket and Driver Power Drive System 10mm Socket and Driver Kerb Climber 7 16inch AF General Allen Keys 3 16inch AF Locking Link 2 5mm Locking Link 5mm Kerb Climber 5 32inch Kerb Climber Pozidrive Screwdriver Upholstery Avdel Nutsert Rivet Tool Upholstery Loctite Thread Locking Castors amp Wheels Compound Grade 241 Terminal Crimp Tool Power Drive System to suit 0 5mm to 6 0mm crimps Torque Wrench Minimum Operating Range 8 Ibs ft 11 Nm General Small Pliers Gen
24. mm AF 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 the 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 SECTION 14 ELECTRICAL SYSTEM 14 1 Diagram YELLOW F 9 BRAKE YELLOW _ _ 091 YELLOW G91 RED BROWN BLUE k 1 MOTOR 2 RHMOTOR GREY ORANGE LH MOTOR LH MOTOR RED BATTERY BATTERY BATTERY BATTERY G202 11 RED BLACK TIT G91 YELLOW G202 10 YELLOW RH MOTOR CONTROL BOX CONNECTOR G91 BLACK CIRCUIT BREAKER lt BATTERY 1 BATTERY 2 NOTE R amp B REFER TO CONNECTOR COLOURS RED amp BLACK LH MOTOR 14 2 Parts List GZF No No Main Wiring Loom G202
25. namic DL Controller 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 15 5 Programmable Controller Replacement Follow 15 3 in reverse 32 15 6 Inspection Each controller acts as a diagnostic system and if a fault is detected the battery gauge will flash to a pre determined sequence Control Dynamic DL Controller The three colour illuminated display onthe top surface of the DL Controller acts as both a fuel gauge and a warning gauge When all lights are on the batteries are fully charged As the power is used the green lights and then amber lights will go out When only the red lights are left on the batteries will require recharging If a fault is detected the illuminated display will flash To determine the fault count the number of flashes and refer to the following table 1 Low battery You may need to charge your batteries 2 High battery Possible charger fault 3 Left Motor There may be a fault or a loose connection 4 Right Motor There may be a fault or a loose connection 5 Left or Right Park Brake There may be a fault or a loose connection 6 Controller fault Please contact Customer Services 7 Motor stalled or joystick Switch the controller off then back on again out of neutral time out Control Dynamic DX System The three colour illuminated display on the top surface
26. ng 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 Sn SECTION 18 DETACHABLE TRAY 18 1 Diagram TRAY ASSEMBLY GWD 837 ARMREST PAD M170 THu 1211 4 SELF TAPPING SCREW ZINC PLATED F111 P cad uet PLUG PEN M5 O ae M74KK TRAY BRACKET 296 32 ARMREST G244L R 18 2 Parts List GZF No No Tray Bracket Left 296 32 L Right SF316R Tray 837 Tray Bracket 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 39 18 4 Assembly Remove plastic bung Remove screw 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 retighten 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 bracke
27. re 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 14 SECTION 9 BRAKES 9 1 Diagram BRAKE ASSEMBLY 300 19 11 RETURN SPRING ZINC PLATED SF233L BLACK KNOB BRAKE HANDLE SF172 LP SF172 RP 1 16 x 1 2 SPLIT PIN ZINC PLATED F50 10 32 UNF NYLOC NUT hace ZINC PLATED F24 x N 2BA WAVEY WASHER COPPER m BRAKE PIVOT SF 173P gt 1 16 x 1 2 SPLIT PIN ZINC PLATED F50 BRAKE LEVER SF171R SF171L 10 32x5 8 UNF HEX HEAD SCREW ZINC PLATED F13 1 4 UNF PLAIN NUT ZINC PLATED F26 amp maen PROTECTOR 199462 2BA WAVEY WASHER COPPER F29 10 32x5 8 UNF HEX HEAD SCREW ZINC PLATED F13 2BA WAVEY WASHER COPPER F29 10 32 UNF NYLOC ZINC PLATED F24 Z di 2BA WAVEY WASHER COPPER F29 1 4 UNF PLAIN NUT ZINC PLATED F26 BRAKE SHOE SF1 9 9 2 Parts List GZF No RJ No Brake Assembly Left 300 19 11L Brake
28. se they may be re fitted to the powerchair Replace in their containers and smear the terminals with petroleum grease Ensure the connections are tight and the battery wiring looms are undamaged Refit to the powerchair 14 7 3 Battery Charger Inspection The charger 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 disdcharge of the batteries Full operating and use instructions are given in the battery charger s User Manual supplied with the powerchair E SECTION 15 PROGRAMMABLE CONTROLLER 15 1 Diagram CONTROL DYNAMICS CONTROL DYNAMICS PENNY amp GILES DX SYSTEM DL CONTROLLER PILOT CONTROLLER ON OFF SWITCH SPEED LIMITER JOYSTICK _ SWITCH BATTERY GAUGE SPEED CHARGING Cup SOCKET CHARGING SOCKET PROGRAMMER SOCKET PROGRAMMER POWER p X S
29. stance Dynamic stability uphill 89cm 35inch 54cm 21inch 64cm 25inch 38cm 15inch 55cm 21 zinch 50kg 110 Ibs 21kg 47 lbs 8 5 To Ground 43cm 17inch 40cm 16inch 43cm 17inch 40cm 16inch 38cm 15inch 36cm 14inch 49cm 19inch 11 5 To seat perpendicular 43cm 17inch above seat 36 46cm 14 18inch 85 From Horizontal 26 35cm 9 14inch 42cm 17inch 170mm 6 2 inch N A Solid Tyres 114kg 18 stone 252 Ibs 185cm 6ft 133cm 3ft 9inch 8 8km 5 5mile 21 24 18 2 2kph 1 4mph 1 5m 5ft 18 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 SECTION 3 POWERCHAIR DIAGRAM 3 1 JEWEL SELF PROPELLING POWERCHAIR 1 POWERCHAIR FOLDED 3 BATTERY BOXES 2 CIRCUIT BREAKER 4 ARMREST t CONTROLLER 5 FOOTREST HANGER WITH PLATE 6 BATTERY TRAY 4 2 4 2 1 4 2 2 4 2 3 4 2 4 4 2 5 4 2 6 4 2 7 4 2 8 4 2 9 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 Examin
30. t from the same side as the controller Connect the motor and battery loom plugs to the main loom and re connect the beau plug to the controller The application of petroleum grease to the contacts will assist in assembly and offer protection against moisture 14 5 Battery Loom Removal and Replacement There are two distinct looms fitted depending on which battery box is being worked upon When viewed from the rear of the powerchair the front battery box has a loom with one grey plug the rear battery box has a loom with two plugs one grey and one black Remove the rear battery box from the powerchair and remove the lid The connections to the battery terminals should be removed and then pull off the connections to the circuit breaker Re fitment is a reversal of the above Note that the grey plug is positioned to the front and the black plug exits from the rear Remove the front battery box from the powerchair and remove the lid The connections to the battery terminals should be removed and then pull off the connections to the circuit breaker Re fitment is a reversal of the above Note that the grey plug exits from the rear of the lid 29 14 6 Circuit Breaker Removal and Refitment Follow the above procedure for removal of the battery wiring looms When the wiring loom has been pulled off the circuit breaker it can be removed from the battery box lid Grasp the circuit breaker with one hand and with a pair of pliers grip the serrated nu
31. t on the outside and release Re fitment is a reversal of the above 14 7 Batteries and Battery Charging The batteries and battery charger require no maintenance but a check for function should be carried out 14 7 1 Battery Inspection Remove the batteries from the powerchair and from their containers It should be noted if the battery connections are tight 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 doeso 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 7 2 Battery Replacement If the batteries are deemed fit for further u
32. the brake assembly Refit the motor cowl taking care not to trap any wiring Re connect the motor loom and test 26 On some later model powerchairs cartridge brushes are fitted which require no dismantling These are accessed from the outside of the motor and are removed by unscrewing the caps situated below the rim of the motor cowl 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 powerchair 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 34mm AF and 35
33. 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 Raise the rear of the powerchair and support on suitable stands Engage the drive 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 7 16 AF spanners release the four nuts bolts which attach the mounting plate to the side frame Withdraw the bolts and remove the assembly 25 13 5 Power System Replacement Replacement is a straightforward reversal of the above procedure The attachment nuts and bnolts should be renewed and tightened to a torque of 35 Ibs ft 47Nm 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 th
34. ts 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 powerchair 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 40 TECHNICAL MANUAL AMENDMENT RECORD SECTION DATE COMMENTS AMENDED 43
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