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RJ Mobility jewel Technical Manual

Indoor powerchair
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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.

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  • Page 1 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.
  • Page 2 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.

  • Page 3: Table Of Contents

    CONTENTS Section 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 CLIMBER JEWELTECHA.

  • Page 4: User Categories

    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.

  • Page 5: Specifications

    SECTION 2. SPECIFICATIONS (Dimensions based on seat size 43cm x 43cm (17inch x 17inch) Overall length 89cm (35inch) Overall width 54cm (21inch) Folded length 64cm (25inch) Folded width 38cm (15inch) Folded height 55cm inch) Maximum weight 50kg (110 lbs) Heaviest Component 21kg (47 lbs) Seat plane angle...

  • Page 6: Powerchair Diagram

    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...

  • Page 7: Maintenance Checks

    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. 4.2.8 Ensure the batteries are fully charged. 4.2.9 Drive the Jewel at maximum speed in forward, reverse, left and right directions checking that the joystick response is uniform.
  • 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 6 gradient and attempt to accelerate. The powerchair will climb at normal speed.

  • Page 9: Tool Requirements

    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 7mm Socket and Drive Rear Lock Link See Section 11 1/4inch Whitworth Anti-tip Device See Section 11 1 5/16inch or 34mm AF Castors...

  • Page 10: Upholstery

    SECTION 6: UPHOLSTERY 6.1 Diagram BACKREST FABRIC G295/SIZE No. 10 UNF x 5/8 LONG REINFORCING BARS SF176 COUNTERSUNK SCREW BLACK ZINC PLATED F138 No. 10 FLANGED SCREW CUP F38 CANVAS LOCATION SPIGOT G27 SEAT FABRIC SF453/SIZE No. 10 UNF x 3/4 LONG COUNTERSUNK SCREW BLACK ZINC PLATED F15 No.
  • Page 11 6.3 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 7.1 Diagram ARMREST PAD M170 ARMREST ASSEMBLY LEFT G244-ASSL ARMREST ASSEMBLY RIGHT G244-ASSR 5/8x20G ROUND INSERT M5 12x1.1/4 POZI PAN SELF TAPPING SCREW ZINC PLATED F111 5/8x20G ROUND INSERT M5 ARMREST FRAME G244L 7.2 Parts Lists GZF No RJ No Armrest Frame Left...
  • Page 13 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.

  • Page 14: Footrests

    SECTION 8: FOOTREST 8.1 Diagram HANGER ASSEMBLY SP231S 5/16x1 1/4 CLAMP BOLT ZINC PLATED F20 5/16 WASHER ZINC PLATED F22 5/16 CLAMP BOLT ZINC 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"...
  • Page 15 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. Ensure 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.

  • Page 16: Brakes

    SECTION 9: BRAKES 9.1 Diagram BRAKE ASSEMBLY 300-19-11 RETURN SPRING ZINC PLATED SF233L 233R BLACK KNOB BRAKE HANDLE SF172 LP SF172 RP 1/16" x 1/2" SPLIT PIN ZINC PLATED F50 10/32 UNF NYLOC NUT ZINC PLATED F24 BRAKE PIVOT SF 173P 2BA WAVEY WASHER COPPER F29 1/16"...
  • Page 17 9.2 Parts List Cont'd GZF No RJ No 1/4 UNF Plain Nut Zinc Plated 2BA Wave Washer Copper 10/32 UNF Nyloc Nut Zinc Plated 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.

  • Page 18: Backrests

    SECTION 10: BACKRESTS 10.1 Diagram BACKREST ASSEMBLY LEFT G223 BACKREST ASSEMBLY RIGHT G224 BLACK PLASTIC BUNG M14 No. 10 AVDEL NUTSERT 09657/01014 BACKREST G246 1/4x1.3/4 UNF HEX HEAD BOLT ZINC PLATED F11 BLACK PLASTIC BUNG M14 3/16x1 SPRING PIN BLACK ZINC PLATED F43 1/4 BRASS WASHER F30 1/4 UNF TYPE P NYLOC NUT ZINC PLATED P90...
  • Page 19 10.2 Parts List GZF No RJ No Backrest Assembly Left G223 Backrest Assembly Right G224 Backrest Frame Left 335/965 G246L Backrest Frame Right 336/966 G246R Sliding Peg Sliding Peg Handle G244 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...

  • Page 20: Frame, Locking Links And Crossbraces

    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 SIDE FRAME RIGHT 300-19R ARMREST LOCK ASSEMBLY 3/4 SQUARE BLACK BUNG M11 3/4 SQUARE BLACK BUNG M11 1 3/8x5/8 BLACK SIDE FRAME LEFT 300-19L BUNG M195...
  • Page 21 11.4 Diagram CROSS BRACE ASSEMBLY SF 205 1/4 UNF NYLOC NUT ZINC PLATED P90 1/4x1 5/8 UNF HEX HEAD BOLT ZINC PLATED F10 1/4x1 3/4 UNF HEX HEAD BOLT ZINC PLATED F11 6mm NYLON SPACER F65 1/4x1 UNF HEX HEAD BOLT ZINC PLATED F139 1/4x1 1/8 UNF HEX HEAD BOLT ZINC PLATED F4 1/4 BRASS WASHER F30 1/4x1 5/8 UNF HEX HEAD BOLT...
  • Page 22 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 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 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.

  • Page 24: Castors

    SECTION 12: CASTORS 12.1 Diagram 190mm WIDE PROFILE M51 M14 x 22 LONG 140 SWIVEL RADIUS 23.95mm A/F HEXAGON 12.2 Parts List GZF No RJ No 190mm wide profile MCP 12.3 Inspection Check for excessive wear in crown bearings and wheel spindle. Replace castor if necessary.

  • Page 25: Power Drive System

    SECTION 13: POWER DRIVE SYSTEM 13.1 Diagram STUB AXLE D9L SPRING WASHER F33 HEX BOLT F7 M6x10 HEX SCREW F95 WAVE WASHER F65 HEX NUT D9 BRONZE BUSH M89 TAB WASHER M158 DRIVE COUPLING M155 SPACER D23 LARGE NYLON WASHER F67 SMALL NYLON WASHER F66 DRIVE COLLAR M159...
  • Page 26 Tab Washer M158 M6x10 Hex Head Screw Zinc Plated 10mm Spacer 1/4 Spring Washer Wavey Washer Clamp Bolt Clamp Washer Clamp Nut 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.
  • Page 27 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 lbs/ft (47Nm). 13.6 Motor Brake Removal IMPORTANT Investigate warranty status before proceeding. Failure to do so may invalidate your warranty.
  • Page 28 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.

  • Page 29: Electrical System

    SECTION 14: ELECTRICAL SYSTEM 14.1 Diagram YELLOW 9 BRAKE G91 YELLOW YELLOW G91 RED BROWN 1 RH MOTOR – BLUE 2 RH MOTOR + G91 BLACK GREY 3 LH MOTOR – ORANGE 4 LH MOTOR 5 BATTERY 6 BATTERY G202-11 RED BLACK 7 BATTERY –...
  • Page 30 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.
  • Page 31 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 nut on the outside and release.

  • Page 32: Programmable Controller

    SECTION 15: PROGRAMMABLE CONTROLLER 15.1 Diagram CONTROL DYNAMICS CONTROL DYNAMICS PENNY & GILES DX SYSTEM DL CONTROLLER PILOT CONTROLLER JOYSTICK SPEED LIMITER ON/OFF SWITCH JOYSTICK BATTERY GAUGE BATTERY GAUGE JOYSTICK ON/OFF SWITCH ON/OFF SWITCH BATTERY GAUGE REMOTE SOCKET CHARGING SOCKET SPEED LIMITER SPEED LIMITER...
  • Page 33 15.2 Parts List GZF No RJ No Penny & Giles Pilot Controller Controller Extension A03/134 Controller Mounting Plate G278A P&G Pilot Controller E108 1X1 1/8 UNF Hex. HD Screw Zinc Plated 1/4 UNF Nyloc Nut Zinc Plated M5x8 Pozipan Screw Zinc Plated Black Plastic Bung Control Dynamics DL Controller Controller Extension...
  • Page 34 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.
  • Page 35 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 Battery charger;...

  • Page 36: Elevating Legrest

    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 LEGREST CARRIER ZINC PLATED P90 BRACKET SF95 LEGREST STEM SF120 ELEVATING ROD SF123 LEGREST TRIGGER...
  • Page 37 16.3 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. 16.4 Elevating Legrest Removal Remove the footrest assembly from the powerchair by lifting and rotating the hanger section.

  • Page 38: Armrest Outriggers

    SECTION 17: ARMREST OUTRIGGERS 17.1 Diagram 1/4x7/8 HEX HEAD BOLT ZINC PLATED F3 BLACK PLASTIC BUNG M17 ARMREST OUTRIGGER G273 OUTRIGGER SPACER G274 1/4 UNF NYLOC NUT P90 ARMREST OUTRIGGER BACKREST LOCATION G275 1/4x1 1/8 HEX HEAD BOLT ZINC PLATED F4 1/4x7/8 HEX HEAD BOLT ZINC PLATED F3 17.2 Parts List...
  • Page 39 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 Dismantling Release nuts securing sockets to side frame and remove.

  • Page 40: Detachable Tray

    SECTION 18: DETACHABLE TRAY 18.1 Diagram TRAY ASSEMBLY GWD 837 ARMREST PAD M170 12x1.1/4 SELF TAPPING SCREW ZINC PLATED F111 TUBE PLUG ARMREST G244L/R KNOB M74KK TRAY BRACKET 296/32 18.2 Parts List GZF No RJ No Tray Bracket - Left 296/32/L - Right SF316R...
  • Page 41 18.4 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 42 TECHNICAL MANUAL AMENDMENT RECORD ISSUE SECTION DATE COMMENTS AMENDED -43-...

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