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Barrett crystal Technical Manual

The proven reliable indoor/outdoor powerchair
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TECHNICAL MANUAL
The Proven
Reliable
Indoor/Outdoor
Powerchair
Issue 06
May 2013
This Technical Manual will ensure that the wheelchair
is maintained to the required standard and is for use
Crystal
by trained personnel only
R.J.Mobility
100 Dewsbury Road, Elland. England. HX5 9BG
Tel.no. 01422 324830
Email - sales@rjmobility.com
Website - www.rjmobility.com
1
Fax.no. 01422 372503

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  • Page 1 Crystal TECHNICAL MANUAL The Proven Reliable Indoor/Outdoor Powerchair Issue 06 May 2013 This Technical Manual will ensure that the wheelchair is maintained to the required standard and is for use by trained personnel only R.J.Mobility 100 Dewsbury Road, Elland. England. HX5 9BG Tel.no.
  • Page 3 This Technical Manual contains important information regarding maintenance of the Crystal Powerchair thus ensuring its safe operation. Please make sure that you understand all instructions thoroughly. It is recommended that maintenance is undertaken at six monthly intervals for a wheelchair that is in constant daily use.

  • Page 4: 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 Programmable Controller (P&G Pilot) 15a Programmable Controller (Dynamic DL) 16 Elevating Legrest Armrest Outriggers Detachable Tray...

  • Page 5: 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 Crystal foldaway powerchair.

  • Page 6: Specifications

    SECTION 2: Specifications (Dimensions based on seat size 43cm x 43cm (17inch x 17inch) Overall length 100cm (39.5 inch) Overall width Nominal width+17.5cm (7 inch) Folded length 78cm (31 inch) Folded width 55cm (21.5 inch) Folded height 55cm (21.5 inch) Complete weight 70kg (154 lbs)
  • Page 7 SECTION 3: Wheelchair Diagram 3.1 Crystal Self-Propelling Powerchair 1-POWERCHAIR FOLDED 2-BATTERY WITH CIRCUIT BREAKER 2-BATTERY WITH CIRCUIT BREAKER 3-ARMREST 8-CONTROLLER 4-FOOTREST HANGER WITH FOOTPLATE 4-FOOTREST HANGER WITH FOOTPLATE 5-BATTERY TRAY 7-BATTERY TRAY 6-BATTERY STRAP RESTRAINT BAR...

  • Page 8: Maintenance Checks

    4.2.7 The battery charger is maintenance free, the only serviceable part is the fuse fitted to the mains plug. See Section 14.6 for comprehensive instruction. 4.2.8 Ensure the batteries are fully charged. 4.2.9 Drive the Crystal at maximum speed in forward, reverse, left and right directions checking that the joystick response is uniform.
  • Page 9 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 10: 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 1/4inch Whitworth Anti-tip Device See Section 11 1 5/16inch or 34mm AF Castors See Section 12 1 5/16inch or 34mm AF Power Drive System See Section 13 10mm Socket...

  • Page 11: Upholstery

    SECTION 6: Upholstery 6.1 Diagram 6.2 Parts List RJ Part No Seat Fabric Ninian 14 x 17 inch 35.5cm x 43cm SF61-14-17 Ninian 15 x 17 inch 38cm x 43cm SF61-15-17 Ninian 16 x 17 inch 40.5cm x 43cm SF63-16-17 Ninian 17 x 17 inch 43cm x 43cm SF63-17-17...
  • Page 12 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 13: Armrests

    SECTION 7: Armrests 7.1.1 Diagram (Non-Domestic) ARMREST ASSEMBLY SP*** L/H SP*** R/H ARMREST PAD M-170 PANEL SF-232L SF-232R BUNG M7/2440 No12x11/4” POZIpan AB SCREW ARMREST FRAME SF-604L SF-604R 7.1.2 Parts List (Non-Domestic) RJ Part No Armrest Assembly complete - Left XXSP2018L/9L-L - Right XXSP2018L/9L-R...
  • Page 14 7.3 Inspection Check armpad for excess wear or damage. Check armpad is secured to frame. Check side panel is not damaged. Ensure armrest locates in rear bracket on push handle when fitted to wheelchair. 7.4 Armrest Pad The armrest pad is secured to the armrest frame with three screws whilst the domestic armrest pad is secured to the armrest frame with two screws.

  • Page 15: Footrests

    SECTION 8: Footrest HANGER ASSEMBLY SP406 L/H 407 R/H 8.2 Parts List RJ Part No Footrest Hanger with retaining - Right SP406 clamp assembly M102 - Left SP407 Retaining Clamp Assembly M102 5/16 x 1 1/4 Inch Bolt, zinc plated 5/16 inch Locking Nut, zinc plated 5/16 inch Washer, zinc plated F22 Footplate...
  • Page 16 8.3 Inspection Check that footrest assembly locks into position. Apply light grease to swiveling end. Ensure that stem clamp holds footplate in position. Ensure that footplate will remain in vertical position when required. Ensure that there are no sharp edges/burrs which could injure user. 8.4 Footrest Removal Remove the footrest assembly from the powerchair by lifting and rotating the hanger section.

  • Page 17: Brakes

    SECTION 9: Brakes 9.2 Parts List RJ Part No Brake LH M-256L Brake RH M-256R 9.3 Inspection Check levers for distortion. Check pivot shafts for distortion. 9.6 Brake Adjustment The Brake Bar position can be adjusted by loosening the two socket set screws and repositioning the bar.

  • Page 18: Push Handles

    SECTION 10: PUSH HANDLES 10.1 Diagram PUSH HANDLE ASSEMBLY SP-404 L/H & SP-405 R/H (BARRETT STYLE) SP-404-8L/9L L/H & SP-405-8L/9L R/H (90° 8L/9L STYLE) 10.2 Parts List RJ Part No Push Handle Assy complete (Barrett style) SP-404 SP-405 Push Handle Assy complete (8L/9L style)
  • Page 19 10.3 Inspection Check each push handle for evidence of bending. Check each push handle for evidence of cracking through nutsert holes. Check handgrip is secure. Check for free movement of plunger. Lubricate with light oil. Check that plunger locates in the hole at rear of the side frame. Ensure nyloc nut still grips thread.
  • Page 20 SECTION 11: CROSSBRACE ASSEMBLY 11.1 Diagram CROSS BRACE ASSEMBLY SP205 There are two Cross Brace Assemblies in this wheelchair which have identical parts. 11.2 Parts List RJ Part No Cross Brace Assembly 14" complete with fasteners SP-206-14 Cross Brace Assembly 15" complete with fasteners SP-206-15 Cross Brace Assembly 16"...
  • Page 21 11.3 Inspection Check Cross Braces for bending and evidence of cracks around pivot holes. Check each tab on the sideframes for evidence of bending, elongation or worn holes, and cracks in brazing or tubing. 11.4 Cross Brace Assembly Removal Remove the two 1/4 UNF set screws securing the Cross Brace Assembly to each sideframe. 11.5 Cross Brace and Locking Link Assembly Fitting Fit two 1/4 UNF set screws to secure the Cross Brace Assembly to each sideframe.
  • Page 22 11.7 Parts List RJ Part No Locking Link Assembly 14" complete with fasteners SP208-14 Locking Link Assembly 15" complete with fasteners SP208-15 Locking Link Assembly 16" complete with fasteners SP207-16 Locking Link Assembly 17" complete with fasteners SP207-17 Locking Link Assembly 18" complete with fasteners SP207-18 M6 X 25 hex head set screw, zinc plated F124...
  • Page 23 SECTION 12: Castors 12.1 Diagram 190mm Wide Profile M-20 12.2 Parts List RJ Part No 190mm wide profile MCP M-20 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.

  • Page 24: Power Drive System

    SECTION 13: Power Drive System 13.1 Diagram WAVE WASHER F-65 STUB AXLE D-09L MOTOR E-131L/R LARGE NYLON WASHER F-67 LOCKING BOLT SF-602 DRIVE COUPLING M-155 ANTI-TIP CASTOR A14-18 HEX NUT D-09 SPRING M-156 WHEEL/TYRE ASSY G-297 KNOB F-KN0065-BLK SPACER M-157 MOTOR SPACER D-023 SMALL NYLON WASHER F-66 MOTOR PLATE BRK SF-605...
  • Page 25 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.
  • Page 26 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.
  • Page 27 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).
  • Page 28 SECTION 14a: Electrical System P&G Pilot 13.1 Diagram 14.2 Parts List RJ Part No P&G Pilot controller (25A) E-156 P&g Pilot controller (40A) E-109 Main Wiring Loom A10-017B Intec Battery Connector E146 Motor Assembly Left E-131L Motor Assembly Right E-131R 40 Amp/Hr Battery E-128...
  • Page 29 SECTION 14b: Electrical System Dynamic DL 13.1 Diagram 14.b Parts List RJ Part No Dynamic DL controller (25A) with DX connectors E-157 Intermediate loom E-158 Intec Battery Connector E146 Motor Assembly Left E-131L Motor Assembly Right E-131R 40 Amp/Hr Battery E-128...

  • Page 30: Electrical System

    14.3 Electrical System Inspection A full function test of the powerchair should be carried out to determine any major faults which will be indicated by flashing lights on the controller. By reference to Section 15 the fault may be diagnosed. Check the condition of the main wiring loom for damage.
  • Page 31 14.6 Batteries and Battery Charging The batteries and battery charger require no maintenance but a check for function should be carried out. 14.6.1 Battery Inspection Remove the batteries from the powerchair. Examine the batteries for any damage. Beware: acid-gel may leak from a damaged battery which is highly corrosive. Any contamination should be washed off immediately with copious amounts of clean water.

  • Page 32: Programmable Controller (Dynamic Dl)

    SECTION 15 a: Programmable Controller P&G Pilot (25A & 40A) 15a.1 Diagram...
  • Page 33 15a.2 Parts List RJ Part No Controller Pilot 25A (D49509) E-156 Controller Pilot 40A (D49525) E-109 Controller Extension A03-134 Controller Mounting Plate G-278A M6x30 Hex. HD Screw Zinc Plated F4125 M6 Nyloc Nut Zinc Plated P80 M5x8 Pozipan Screw Zinc Plated F18 Black Plastic Bung 15a.3 Inspection...
  • Page 34 CONTROLLER LIGHTS FLASH The Penny & Giles Pilot controller has a built-in diagnostics system, which shows the re- lated fault by the number of lights flashing. A diagram below shows the related faults to the number of lights flashing (see FIG 1). CONTROLLER LIGHTS ON BUT POWERCHAIR WILL NOT DRIVE Check that the drive lock devices are engaged.
  • Page 35 P&G Pilot 25A (D49509) Parameters Functions Notes Setting Set Acceleration Set Deceleration Set Turn Acceleration Set Turn Deceleration Set Forward Speed Set Reverse Speed Set Turn Speed Set Sleep Timer 0 Sec Set Steer Correct Veer Compensation. Read Fault Log Display Fault Code History.
  • Page 36 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 37 SECTION 15 b: Programmable Controller Dynamic DL (40A) 15b.1 Diagram...
  • Page 38 15a.2 Parts List RJ Part No Controller Extension G-067A Controller Mounting Plate G-066A Control Dynamics DL Controller (D40UDH1) E-157 M5x8 Pozipan Screw Zinc Plated F-18 Black Plastic Bung 15b.3 Settings The controller is set to Program 2 (default settings). 15b.3 Inspection Check the M5 Pozipan screws are tight and hold the controller securely to the Controller Extension.
  • Page 39 15b.6 Inspection (cont) Low Battery Voltage. High Battery Voltage. Left Motor Fault. Right Motor Fault. Left/Right Park Brake Fault. Controller Fault. Motor Stalled or Joystick out of neutral. CONTROLLER LIGHTS ON BUT POWERCHAIR WILL NOT DRIVE. Check that the drive clutch dog’s are engaged. If no “click“...

  • Page 40: Elevating Legrest

    SECTION 16: Elevating Legrest 16.1 Diagram ELEVATING LEGREST ASSEMBLY SP333 16.2 Parts List RJ Part No Legrest Assembly Complete Left SP333L Right SP333R Legrest Trigger Spring SP234 Elevating Rod SF123 Legrest Trigger SF122 Legrest Trigger Bracket SF121 Legrest Stem, Left or Right SF120 Legrest Carrier Bracket, Left or Right SF95...
  • Page 41 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 42: Armrest Outriggers

    SECTION 17: ARMREST OUTRIGGERS 16.1 Diagram ARMREST ASSEMBLY SP201-8L/9L ARMREST ASSEMBLY SP364 (DOMESTIC) 16.2 Parts List RJ Part No Armrest Socket Extension Assembly SF-307 Armrest Outrigger Tab SF-305 1/4”UNFx21/2” bolt zinc plated F-80 1/4” UNF Nut zinc plated P-90 2BA x 3/8 Pozi Pan Machine Screw zinc plated F-145 16.3 Inspection Check for damage to sockets.
  • Page 43 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 44: Detachable Tray

    SECTION 18: DETACHABLE TRAY 18.1 Diagram 18.2 Parts List RJ Part No Tray Bracket - left SF316L - right SF316R Tray GWD 837 Tray Bracket GWD 838 18.3 Inspection Check for damage to the tray, particularly for wooden splinters. Check security of attachment screw ‘B’ and check tray attachment screws for security. Check all adjustment knobs are present, undamaged and hold tray at the required position.
  • Page 45 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 re-tighten. Insert the tubular mounting stems complete with stem brackets supplied with the tray, into the armrest stem assembly with the horizontal extensions of the mounting stems projecting forward.
  • Page 46 SECTION 17: RECLINING BACKREST 17.1 Diagram RECLINING BACKREST ASSEMBLY G104. 17.2 Parts List RJ Part No Backrest Tube Assembly complete G104 Handle G142 Ratchet pull rod - Left G144L - Right G144R Spring G141ND Ratchet Plate G140 Wing Nut 6mm chrome No.
  • Page 47 CERTIFICATE This is to certify that the Barrett Crystal wheelchair has been crash tested in accordance with ISO 7176-19 by TRL and fully complies. Date of test 13th May 2003. Chair serial No-22078. TRL Test Ref- 02PM01-7176-19.

  • Page 48: Transportation

    SECTION 19: Transportation 19.1 Diagram EYELET HOLES FOR KARABINERS. LOCATION ON LOWER TUBE FOR FRONT TIE DOWN. All of the wheelchairs in our range are designed to be easily transported and most of them dismantle into manageable parts in seconds. Consideration should be given to the type of vehicle in which the wheelchair may be carried.
  • Page 49 The wheelchair should be secured to the vehicle floor in-line with the direction of travel. The occupant should be separately restrained to the vehicle and to the wheelchair. Installers and operators of restraint systems should be trained in their correct use by the restraint manufacturer, or approved specialist.
  • 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...

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