R.J.Mobility GEM MK III Technical Manual

The proven reliable indoor/outdoor powerchair

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TECHNICAL MANUAL

The Proven

Reliable

Indoor/Outdoor

Powerchair

Issue 15

January 2013

This Technical Manual will ensure that the wheelchair

is maintained to the required standard and is for use

Gem

by trained personnel only

R.J.Mobility

100 Dewsbury Road, Elland. England. HX5 9BG

Tel.no. 01422 324803

Email - sales@rjmobility.com

Website - www.rjmobility.com

Page 1

Fax.no. 01422 372503

Table of Contents

Summary of Contents for R.J.Mobility GEM MK III

Page 1 January 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 Tel.no. 01422 324803 Fax.no. 01422 372503 Email - sales@rjmobility.com Website - www.rjmobility.com...
Page 2 This Technical Manual contains important information regarding maintenance of the Gem MKIII 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.
Page 3: Table Of Contents
Contents SECTION 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 Elevating Legrest Armrest Outriggers Detachable Tray Kerb Climber Page 3...
Page 4: User Categories
SECTION 1: User Categories Attendant Controlled. Degree of upper body control to maintain sitting position. 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.
Page 5: Specifications
SECTION 2: Specifications (Dimensions based on seat size 43cm x 43cm (17inch x 17inch) Overall length 100cm (39 inch) Overall width 63cm (25 inch) 3. Folded length 76cm (30 inch) 4. Folded width 36cm (14 inch) 5. Folded height 64cm (25 inch) Maximum weight 57kg...
Page 6 SECTION 3: Wheelchair Diagram 3.1 Gem Self-Propelling Powerchair Page 6...
Page 7: Maintenance Checks
See Section 14.7 for comprehensive instruction. 4.2.8 Ensure the batteries are fully charged. 4.2.9 Drive the Gem Mk III at maximum speed in forward, reverse, left and right directions checking that the joystick response is uniform. Page 7...
Page 8 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 5 gradient and attempt to accelerate. The powerchair will climb at normal speed.
Page 9: Tool Requirements
SECTION 5: Tool Requirements Spanners: 1/4“ BSW Legrest Clamp See Section 8 2-8mm A/F Spanners Parking Brake Section 10mm A/F Spanners Braces & Links See Section 20 1- 24mm AF Spanner Castors See Section 12 1-35mm AF Spanner Power Drive System See Section 20 2- 7/16inch A/F Spanners Backrest...
Page 10: Upholstery
SECTION 6: Upholstery 6.A Diagram BACKREST SCREW F-102 M5 SCREW CUP F-101 SEAT REINFORCING BAR SF-176 M5 AVDEL 09657-01014 6.1 Parts List RJ No Backrest Fabric Ninian SF-062-15-17 SF-064E-17-17 Seat Fabric Ninian G-83 SF-063E-17-17 Page 10...
Page 11 6.2 Inspection Fabric: Check for 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.
Page 12: Armrests
SECTION 7: Armrests 7.A Diagram ADJUSTABLE ARMREST ASSY LEFT GS-009 ADJUSTABLE ARMREST ASSY RIGHT GS-010 ARMREST PAD M-170 PLUG M7-2440 SELF TAPPER SCR F-111. ARMREST 7.1 Parts List RJ No Armrest Frame Left G-244L Armrest Frame Right G-244R 7.2 Inspection Check armpad for excess wear or damage.
Page 13 7.4 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.
Page 14: Footrests
SECTION 8: Footrest 8.A Diagram HANGER ASSY LH SP-406 HANGER ASSY RH SP-407 CLAMP BOLT F-20 CLAMP M-102 WASHER F-22 CLAMP NUT F-21 HEEL LOOP ASSY TSD-11469/2 SCREW F-9 NUT F-26 FOOTPLATE PLASTIC M-261 FOOTPLATE 71/2“ ALLOY M-172L/R FOOTPLATE 81/2“ ALLOY M-172L/R 8.1 Parts List RJ No Footrest Hanger with footplate assy complete Left...
Page 15 8.2 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. Ensure no sharp edges/burrs which could injure user. 8.3 Footrest Removal Remove the footrest assembly from the powerchair by lifting and rotating the hanger section.
Page 16: Brakes
SECTION 9: Brakes 9.A Diagram BRAKE ASSEMBLY GS-015/6 9.1 Parts List RJ No Brake Assembly Left GS-015 Brake Assembly Right GS-016 Brake Handle Left G-255L Brake Handle Right G-255R Black Ball Knob KB5-125 Brake Pivot SF-173 Brake Lever Left GS-001 Brake Lever Right GS-002 Brake Shoe SF-174A...
Page 17 9.2 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 there is no oil/grease on brake pad. 9.3 Brake Assembly Removal Remove the two 1/16inch Split Pins from the Brake Pivot shaft and Brake Lever shaft.
Page 18: Push Handles
SECTION 10: Push Handles 10.A Diagram BACKREST ASSEMBLY LEFT G-223 BACKREST ASSEMBLY RIGHT G-224 PLASTIC BUNG M-14 HAND GRIP M-57 M5 AVDEL 9657-1014 PUSH HANDLE L/R G-324L/R PLASTIC BUNG M-14 SCREW F-11 SPRING PIN F-43 WASHER F-30 NYLOC NUT P-90 HANDLE G-244 PLASTIC BUNG M-14 STOP SF-194...
Page 19 10.2 Inspection Check each backrest for evidence of bending. Check each backrest for evidence of cracking through nutsert holes. Check that push handle is secure to backrest. Check handgrip is secure. Check for free movement of the plunger. Lubricate with light oil. Check that the plunger locates in the hole on the side frame.
Page 20 SECTION 11: Frame, Locking Links And Cross Brace 11.A Diagram SIDE FRAME ASSEMBLY LEFT GS007 SIDE FRAME ASSEMBLY RIGHT GS008 M5 AVDEL 09657-01014 RH SIDEFRAME G-323 LH SIDEFRAME G-322 PLUG M-11 11.1 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.
Page 21 11.B Diagram CROSS BRACE ASSEMBLY 15“-SF 206 17“-SF 205 15“ CROSS BRACE LONG SF-203 17“ CROSS BRACE LONG SF-182 M6 NYLOC NUT M6x35 HEX SCR M6 NYLON WASHER M6x35 HEX SCR 15“ CROSS BRACE SHORT SF-203A 17“ CROSS BRACE SHORT SF-182A M6x25 HEX SCR 11.2 Parts List RJ No...
Page 22 11.4 Cross Brace and Locking Link Assembly Fitting Fit the two M5 hex screws securing the Cross Braces to each side frame. 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.
Page 23 SECTION 12: Castors 12.A Diagram 190mm Wide Profile M-171 12.1 Parts List RJ No 190mm wide profile MCP M-171 12.2 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.
Page 24: Power Drive System
SECTION 13: Power Drive System 13.A Diagram WAVE WASHER F-65 MOTOR E-131L/R WITH CARTRIDGE BRUSHES & NEUTRIC CONNECTOR. LARGE NYLON WASHER F-67 DRIVE COUPLING M-155 SPRING M-156 ANTI-TIP CASTOR ASSY GS-005 STUB AXLE D-01L HEX NUT D-09 KNOB M-074 MOTOR SPACER D-023 SPACER M-157 MOTOR PLATE LH GS-0003 SMALL NYLON WASHER F-66...
Page 25 13.B Motor Connectors ANDERSON CONNECTOR BLACK CLIFF CONNECTOR RED RING NEUTRIC CONNECTOR BLUE RING. 13.C Motor Brushes CARTRIDGE TYPE BRUSH 13.2 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.
Page 26 13.3 Motor Brush Removal & Replacement When ordering replacement motor brushes it is necessary to determine whether the motor has cartridge brushes or non-cartridge brushes as shown in fig 13.C For non cartridge brushes proceed as follows. 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.
Page 27 13.6 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 (M-158) away from the bolt head and using a 10mm spanner remove the drive securing bolt (F-95).
Page 28 13.9 Anti-Tip Roller Setting The function of anti-tip rollers on a power chair is to inhibit forward motion if an obstruction high- er than 100mm is encountered. Setting of the anti-tip rollers should be carried out as per the following instructions. 1-Place the wheelchair on a suitable hard flat floor.
Page 29 14.0 Batteries, Looms & Controls 14.A 14.1 Parts List RJ No Battery Box A12-10 Battery Box Lid (Front) G-352 Battery Box Lid (Rear) G-351 Battery Spacer A12-10 Motor Assembly * Left E-131L Motor Assembly * Right E-131R 30 Amp/Hr Battery E-133 40 Amp/Hr Battery E-128 Circuit Breaker (35A)
Page 30 14.2 Battery Looms Earlier Variants. LOOM WITH ANDERSON POWERPOLE CONNECTORS & SPADE BRAKE CONNECTORS 12V G-202. 14.B LOOM WITH ANDERSON POWERPOLE CONNECTORS & SPADE BRAKE CONNECTORS 24V G209. 14.C LOOM WITH ANDERSON POWERPOLE + SHROUD CONNECTORS A10-01. 14.D CLIFF CONNECTOR SOCKETS WIRING CONNECTIONS.
Page 31 14.4 Battery Looms Mk 111 Pilot Controller (Standard) E-109 FRONT LOOM G-350D CONTROL LOOM ( BEAU) G-349E LH MOTOR E-131L RH MOTOR E-131R NEUTRIC SOCKETS WIRING 14.5 Parts List RJ No Pilot Controller D49525 (40A) E-109 Controller Mtg Plate G-278A Controller Arm A03-134 Rear Battery Box Lid And Loom A10-16 Neutric...
Page 32 P&G Pilot 40A (D49525) Parameters Functions Notes Setting Set Acceleration Set Deceleration Set Turn Acceleration Set Turn Deceleration Set Forward Speed 100% Set Reverse Speed Set Turn Speed Set Sleep Timer 0 Sec Set Steer Correct Veer Compensation. Read Fault Log Display Fault Code History.
Page 33 14.6 Battery Looms Pilot Plus JOYSTICK MODULE TYPE JSM (D49671) E-139 COMPLETE WITH BUS CABLE. POWER MODULE 50A (D49975) E-138 CONTROL LOOM A10-05B. FRONT LOOM G-350D REAR BATTERY BOX LOOM A10-04B. RH MOTOR LH MOTOR RH MOTOR E-131R LH MOTOR E-131L P&G MOTOR PLUGS WIRING 14.7 Parts List RJ No...
Page 34 P&G Pilot Plus 50A (D49671) Parameters Functions Notes Setting Set Acceleration Set Deceleration Set Turn Acceleration Set Turn Deceleration Set Forward Speed 100% Set Reverse Speed Set Turn Speed Set Sleep Timer 0 Sec Set Steer Correct Veer Compensation. Read Fault Log Display Fault Code History.
Page 35 14.8 Battey Looms Dynamic DL DYNAMIC DL CONTROLLER WITH DX CONNECTORS (DL40UDH1) E-116 CONTROL LOOM A10-15 FRONT LOOM G-350D REAR BATTERY BOX LOOM A10-04. NEUTRIC SOCKETS WIRING LH MOTOR E-131L RH MOTOR E-131R 14.9 Parts List RJ No Rear Battery Box Lid And Loom A10-16 Neutric Socket (NL4MP) E-149 Neutric Plug...
Page 36 Dynamic DL 40A (DL40UDH1) Parameters Page 36...
Page 37: Electrical System
14.10 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.
Page 38 14.13 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 nut on the outside and release.
Page 39 PILOT & PILOT PLUS 14.18 Trouble shooting CONTROLLER LIGHTS DO NOT COME ON Check the circuit breaker push buttons have not sprung out. Check the cable are connected correctly to the: Controller Batteries Motors Ensure the batteries are fully charged (and that the charger is not still connected). CONTROLLER LIGHTS FLASH The Penny &...
Page 40 DYNAMIC DL CONTROLLER 14.19 Trouble Shooting CONTROLLER LIGHTS DO NOT COME ON Check the circuit breaker push buttons have not sprung out. Check the cables are connected correctly to the: Controller Batteries Motors Ensure the batteries are fully charged (and that the charger is not still connected).
Page 41: Elevating Legrest
SECTION 15: Elevating Legrest 15.1 Diagram ELEVATING LEGREST ASSEMBLY SP333L/R 15.2 Parts List 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...
Page 42 15.3 Inspection Check heel loop for security. Nuts should be tightened to 10 lbs/ft (13 Nm). Check pivot bolt for wear. Check calf pad for wear/damage. Check adjustment rod for bending. Check footplate maintains set position. 15.4 Elevating Legrest Removal Remove the footrest assembly from the powerchair by lifting and rotating the hanger section.
Page 43: Armrest Outriggers
SECTION 16: ARMREST OUTRIGGERS 16.1 Diagram 16.2 Parts List 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 1/4 x 1 1/8 UNF Hex Head Bolt Zinc Plated...
Page 44 16.3 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. 16.4 Dismantling Release nuts securing sockets to side frame and remove.
Page 45: Detachable Tray
SECTION 17: Detachable Tray 17.1 Diagram 17.2 Parts List RJ No Tray Bracket - Left 296/32/L - Right SF316R Tray Tray Bracket 17.3 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.
Page 46 17.4 Assembly 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 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.
Page 47: Kerb Climber
SECTION 18: Kerb Climber 18.1 Diagram 18.2 Parts List RJ No Kerb Climber Assembly G220 Actuator G215 Cross Tube G220/3 Sleeve G220/6 Cross Bar Spring Plate G220/4 M6x40 Socket Countersunk Screw Black Zinc Plated M6x35 Skt Hd Screw Zinc Plated M6 Nyloc Nut Zinc Plated P80 M6x20 Plain Washer Zinc Plated...
Page 48 18.3 Kerb Climber Inspection With the kerb climber attached to the powerchair grasp the actuator and move backwards and forwards through an arc. Feel for any jerkiness which will indicate that the return spring is ruptured. This can be corroborated by measuring the height to the front edge of the actuator which should be between 115-125mm.
Page 49 Technical Manual Amendment Record ISSUE SECTION DATE COMMENTS AMENDED 26-10-04 Complete re-write 22-01-08 Pilot & pilot plus parameters revised Page 49...
Page 50 Maxi Independent Maxi Meteor Barrett Jewel Meteor Independent Barrett 10 Original Meteor Barrett 7 Mini Meteor Barrett Gem Baby Barrett Barrett 101 Tilt & Space Portering Page 50...