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Decon wheel E-MOVE Service Manual

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  • Page 1 E-MOVE Service Manual...

  • Page 2: Table Of Contents

    Contents 1. Product Overview   ……………………………………………………………………… 1 1.1　Product Features  …………………………………………………………………… 1 1.2　Variations  …………………………………………………………………………… 2 2. Installation Requirements   ………………………………………………………… 3 2.1　Strength Requirements  ……………………………………………………………… 3 2.2　Structural Requirements  …………………………………………………………… 3 2.3　Functional Requirements  …………………………………………………………… 5 3. Unit Installation and Removal   …………………………………………………… 6 3.1　...

  • Page 3: Product Overview

    1. Product Overview 1.1　Product Features Sample E-Move Installa- ③ ④ ① ② ① Wheel drive unit assembly with AC servo flat motor ② Power switch ③ Dedicated battery with built-in microprocessor 　 Choice of nickel-metal hydride or lithium-ion battery ④ Mode switch (option)

  • Page 4: Variations

    1.2　Variations Model E-Move Product Tire size Note JWX2-B24E2 24 inch JWX2-C22E2 22 inch JWX2-C24E2 24 inch JWX2-D24E2 24 inch without mounting bracket JWX2-E24E2 24 inch without mounting bracket JWX2-F24E2 24 inch Selectable Part Hand rims: Stainless steel / Plastic coated...

  • Page 5: Installation Requirements

    ・Components with visible wear or corrosion. 2.2　Structural Requirements To install the E-Move, the wheelchair frame must meet the structural requirements listed below. Warning ・ Do not install the E-Move on a wheelchair frame that does not meet the structural requirements. Even where it can be successfully installed, problems may arise during use that could cause injury or ac- cident. 2.2.1　Wheelchair frame （1） The diameter of the axle hole is 18 mm or 20 mm. （2） The contact surfaces for the nuts around the axle hole must be flat and have ample surface area. （3） When the E-Move is installed, there must be no interference between the E-Move and the wheel- chair frame. Important ・ If you are using offset washers to avoid such interference, check the two items below and install up to three washers on each side. − The nut seats are completely secure. − The wheelchair brake seats are completely secure.
  • Page 6 2.2.2　Casters Seven-inch or larger casters are recommended for the front casters. With small-diameter casters, it is difficult to get over large bumps. The shock experienced going over bumps is also greater if the casters are small. Large diameter  Small diameter  (easy to get over bumps) (difficult to get over bumps)

  • Page 7: Functional Requirements

    2.3　Functional Requirements Warning ・ Do not install the E-Move on a wheelchair frame that does not meet the functional requirements. Even where it can be successfully installed, problems may arise during use that could cause injury or ac- cident. To install the E-Move, the wheelchair frame must meet the functional requirements listed below. （1） The frame must be constructed to allow 22- or 24-inch wheels to be attached. （2） The wheelchair is equipped with a parking brake that can be relocated and adjusted to the cor- rect position on the tires. When applied, the brake must be capable of stopping the wheelchair with the E-Move installed on a 7° forward or backward incline. （3） With the E-Move installed, it must be possible to tip the wheelchair forward and back by at least 20° and to the side by at least 15° . (A backward tipping angle of at least 25° is recommended.) Minimum Minimum 20° 20° Forward tipping angle Backward tipping angle Side tipping angle （4） Take care to ensure that the functioning of the wheelchair frame is not impaired by the instal- lation of the E-Move. Example: ・Movement of moveable arm supports, folding mechanism, parking brake effectiveness, etc.

  • Page 8: Unit Installation And Removal

    3. Unit Installation and Removal Warning ・ When cutting cable ties, do not cut on an angle. Always cut off the surplus as close as possible to the fastener. Cable ties cut to a point could cause injury to the customer. Note ・ In locations where the tightening torque is specified, always tighten to the specified torque. Insufficient tightening torque will cause looseness, while excessive torque could cause dam- age.

  • Page 9: Jwx-2 Components

    3.1　E-Move Components ③ ⑤ ⑥ ① ② OWNER’S MANUAL ⑤ ⑥ ④ ⑧⑨ ⑦⑨ ⑩ ⑬ ⑯ ⑲ ⑪ ⑭ ⑰ ⑫ ⑱ ⑮ Component Remarks ① Left wheel drive unit assembly For 22-inch or 24-inch (selectable) ② Right wheel drive unit assembly For 22-inch or 24-inch (selectable) Owner’s Manual, Warranty, Guidelines for Safe Use, ③ Manual set Installation Manual ④ Cable ties ⑤ Battery Nickel-metal hydride or lithium-ion (selectable) ⑥...

  • Page 10: Installing The Jwx-2

    3.2　Installing the E-Move With the exception of the cabling, the procedure for installing the E-Move in a modular-type wheel- chair is the same for both left and right sides. Accordingly, the model description given below is for installation on the left side. Use the same procedure to install on the right. 　Required tools: 4 mm and 5 mm hexagonal wrenches (Allen keys), 24 mm socket, socket wrench, torque wrench, 22 mm and 24 mm spanners Remove the axle sleeve (a) installed on the wheelchair. Remove the existing wheel and axle sleeve (a) from the side bracket (b) on the wheelchair. （a） （b） Install the axle sleeve (c). （f） （d） （1） Install the stopper arm (d) and boss (e) on the wheelchair side bracket (b) and tem- porarily tighten the bolt (f). （e） （b）...
  • Page 11 （2） Fit the axle sleeve (c) into the stopper arm (d) and side bracket (b). （i） Important （b） ・ Insert the axle sleeve (c) from the stopper arm side. ・ The outer diameter of the threaded section of the （f） axle sleeve (c) is 18 mm. If the diameter of the axle （h） hole in the wheelchair side bracket (b) is 20 mm, insert the bush (g) between the axle hole and axle （g） sleeve (c). （3） Fit the 3.2 mm thick washer (h) onto the （c） （d） axle sleeve and temporarily tighten the nut (i). （4） Fully tighten the nut (i) and bolt (f) in the sequence below. 1. Nut (i) Tightening torque 40 – 50 N･m 2. Bolt (f) Tightening torque 8.5 – 12 N･m Note ・ If the wheelchair frame interferes with the stopper arm (d). insert a 3.2 mm thick offset washer between the stopper arm (d) and the wheelchair side bracket (b). For details, see...
  • Page 12 Install the wheel drive unit assem- bly (k). （1） Lift up the handle plate (m). （m） （2） Align the holes in the axle (n) and plate （n） lock (j) with the axle hole in the axle （c） sleeve (c) and the pin on the stopper arm (d) and then fit them together. Note ・ If there is interference between the wheel- c h ai r f r a m e a n d c o m p o n e nts s u c h a s th e p ower s witch, inser t 3.2 m m thick offset washers between the axle sleeve (c) and the （d）...
  • Page 13 Connect the cable. （p） （1） Open the cap (p) on the coupler box case (q). （q） （2） Connect the cable so that the coupler （r） triangular mark (r) (yellow mark) is aligned with the triangular mark (s) on the coupler box. （s） （3） Rotate the ring (t) on the coupler (u) on the end of the cable to lock it into place. Check that the coupler (u) is firmly se- （u） cured. （t）...

  • Page 14: Installing And Removing The Wheel Drive Unit Assembly

    3.3　Installing and Removing the Wheel Drive Unit Assembly Important ・ The same procedure is used for installing and removing both the left and right wheel drive unit assemblies. Accordingly, the model description below is for the right side. Use the same procedure for the left side. 　Required tools: 17 mm deep socket, socket wrench, torque wrench 3.3.1　Removal Method for Releasable Wheels Remove the battery (a). （a） The figure shows the procedure  for a nickel-metal hydride battery. Disconnect the cable (b). （c） （b） 1. Turn the ring (d) on the coupler (c) on the （d） end of the cable (b) to loosen it, and then pull it upwards to disconnect the cable. 2. Fit the cap (f) onto the coupler (e) for the （f） left wheel. （e）...
  • Page 15 Re m ove the wheel d rive u nit asse m - bly (h). （h） Raise the handle plate (g). Then, while sup- porting the battery housing so that the wheel drive unit assembly (h) does not rotate, pull the handle plate (g) to remove the wheel drive unit assembly (h), taking care not to damage the cable. Note ・ Su p p or t th e b atter y h o u sin g s o th at th e wheel drive unit assembly (h) does not rotate （g）...

  • Page 16: Component Adjustment

    4. Component Adjustment 4.1　Adjusting the Battery Seat Angle When adjusting the battery seat angle because interference with the seat back makes battery removal dif- ficult, adjust the angle so that the battery is roughly parallel with the wheelchair back pipe. 　Required tools: Philips-head screwdriver, 12 mm socket, socket wrench, torque wrench Dismount the right-hand wheel drive...
  • Page 17 Adjust the angle of the battery seat (d). Remove the 3 bolts (e) and adjust the angle of the battery seat (d). Important ・ The battery seat (d) can be adjusted through 4 （e） steps. ・ The seat angle shifts through roughly 15° for each step.

  • Page 18: Adjusting The Power Switch Location And Angle

    4.2 　 Adjustin g the Po wer Sw itch L o c atio n a n d A n gle, Fitting and Adjusting the Mode Switch, Changing the Switch Location (Left/Rig ht) a nd Con necting the Wiring 　Required tools: Philips-head screwdriver, nippers, 4 mm hexagonal wrench (Allen key), 10 mm socket, socket wrench, torque wrench, 26 mm spanner 4.2.1　Adjusting the Power Switch Position...
  • Page 19 Free the cables (d). （e） （f） （1） Remove the 4 bolts (e) and remove the battery seat (f). （2） Cut the cable ties (g). Note ・ When cutting the cable ties (g), take care not to cut the cables (d). （g）...
  • Page 20 Secure the cable (d). （d） （l） （a） （1） Starting from the power switch (i), fit the cable (d) into the channel in the unit back plate (a) and secure it with the cable tie (l). Note （i） ・ Avoid excessive looseness or tautness in the （l）...
  • Page 21 4.2.2　Installing the Mode Switch Install the optional mode switch using the procedure below. Dis m ou nt the left-ha nd w heel d rive （b） unit assembly (a). If the left -hand wheel drive unit assembly (a) is installed in the wheelchair frame, dismount （c）...
  • Page 22 Remove the grommet (h). （h） Remove the grommet (h) from the coupler box holder (i). （i） Connect the mode switch cable (j) Run the mode switch cable (j) through the （k） （i） grommet (h), fit it into the holder (i) and con- nect the coupler (k).
  • Page 23 Secure the cable (j) （l） （m） （j） Secure the mode switch (j) cable in the chan- nel in the unit back plate (l) and fasten the cable in place using the cable tie (m). （l） （m） Bundle up the cable (j) Bundle up the surplus cable (j) with the cable tie (n) and secure it in the hollow (o) in the unit back plate.
  • Page 24 4.2.3　Adjusting the Switch Angle The description of the method for adjusting the power switch angle also serves as a model for mode switch angle adjustment. Use the same procedure for the mode switch. Dismount the right-hand wheel drive （b） unit assembly (a). If the right-hand wheel drive unit assembly (a) is installed in the wheelchair frame, dismount （c）...
  • Page 25 4.2.4　Adjusting the Switch Length The description of the method for adjusting the power switch length also serves as a model for mode switch length adjustment. Use the same procedure for the mode switch. Dismount the right-hand wheel d rive （c） unit assembly (a).
  • Page 26 Free the cables (d). （e） （f） （1） Remove the 4 bolts (e) and remove the battery seat (f). （2） Cut the cable ties (g). Note ・ When cutting the cable ties (g), take care not to cut the cables (d). （g）...
  • Page 27 Secure the cable (d). （d） （l） （1） Starting from the power switch (i), fit the cable (d) into the channel in the unit back plate (a) and secure it with the cable tie (l). Note （i） ・ Avoid excessive looseness or tautness in the （l）...
  • Page 28 4.2.5　Relocating the Switch (Left/Right) This section describes how to swap the switch positions between left and right when the power switch and mode switch are installed. If no mode switch is installed, use this procedure only for the power switch. D is m o u nt t h e left o r r ig ht w h e el （c）...
  • Page 29 Remove the power switch (h). （h） （1） Remove the bolt (i) and remove the power （i） switch (h). （2） Cut the cable tie (j). （d） Note （j） ・ When cutting the cable tie (j), take care not to cut the cable (d). （3）...
  • Page 30 Remove the mode switch (q). （m） （s） （r） （q） （1） Remove the bolt (r) and remove the mode switch (q). （2） Cut the cable tie (s). Note ・ When cutting the cable tie (s), take care not to cut the cable (m). Remove the coupler box case (t).
  • Page 31 Switch arou nd the power switch (h) and mode switch (q). （1） Disconnect the coupler (z) on the end of the cable (m) for the mode switch (q). （2） Switch around the power switch (h) and （m） mode switch (q). （z）...

  • Page 32: Adjusting The Position Of The Coupler Box (Coupler For The Left-Hand Wheel Drive Unit Assembly)

    4.3　Adjusting the Position of the Coupler Box (Coupler for the Left-hand Wheel Drive Unit Assembly) 　Required tools: 10 mm socket, socket wrench, torque wrench, nippers Dis m ou nt the left-ha nd w heel d rive unit assembly (a). If the left-hand wheel drive unit assembly (a) is installed in the wheelchair frame, dismount it.

  • Page 33: Adjusting The Warning Lamp (Led) Direction

    Note （e） ・ T h e s u r plu s s w it c h c a ble (e) s h o u ld b e （i） bundled together with the cable tie (g) and stowed in the hollow (h) in the left-hand wheel drive unit assembly, as shown in the figure.

  • Page 34: Using Offset Washers

    4.5　Using Offset Washers 　Required tools: 4 mm and 5 mm hexagonal wrenches (Allen keys), 24 mm socket, socket wrench, torque wrench, 22 mm and 24 mm spanners In most cases where the wheel drive unit assembly or stopper arm (a) interferes with the wheelchair frame, the （b）...

  • Page 35: Component Installation, Removal, Disassembly, Assembly And Adjustment

    5. Component Installation, Removal, Disas- sembly, Assembly and Adjustment 5.1　Removing and Re-installing the Handrim Important ・ The same procedure is used for removing and re-installing both the left and right handrims. Accordingly, the model description given below is for the right side. Use the same procedure for the left side. 　Required tools: 4 mm and 1.5 mm hexagonal wrenches (Allen keys), flat-head screwdriver 5.1.1　Removing the Handrim...
  • Page 36 Remove the handle plate (b). Turn the handle plate (b) counterclockwise to remove it. Important ・ Fit a flat-head screwdriver into the groove (d) in the end of the wheel axle on the inside of the chair to hold the axle so that it does not turn at the same （d）...
  • Page 37 Remove the handrim (g). Remove the 3 bolts (h) and then remove the （g） handrim (g). （h） （h） 5.1.2　Re-installing the Handrim The re-installation procedure is simply the removal procedure in reverse. Bolts (h) Tightening torque 9.0 – 12.0 N･m Lock screw (c) Tightening torque 0.8 –...

  • Page 38: Removing And Re-Installing The Wheel Assembly

    5.2　Removing and Re-installing the Wheel Assembly Important ・ The same procedure is used for removing and re-installing both the left and right wheel assemblies. Accord- ingly, the model description below is for the right side. Use the same procedure for the left side. In case a new wheel assembly was installed, the hand rim sensor has to be calibrated.
  • Page 39 Pull out the Wheel Assembly Remove the washer (d) and wheel assembly (e), taking care not to damage the cables. （d） （e） 5.2.2　Re-installing the Wheel Assembly The re-installation procedure is simply the removal procedure in reverse. Self-locking nut (b) Tightening torque 25.0 –...

  • Page 40: Removing And Re-Installing The Circuit Board

    5.3　Removing and Re-installing the Circuit Board Note ・ The circuit board is a precision electronic component. Do not expose it to static electricity or moisture. Doing so could cause a fault. Important ・ The method for removing and re-installing the circuit board on the left is given here as a model. Use the same procedure for the circuit board on the right.
  • Page 41 Remove the transparent cover (d). （c） （d） Remove the 3 screws (b) and the clip spring (c). （b） Then remove the transparent cover (d). （b） Discon nect the coupler (e) and the （j） （j） cables (f, g, h, i). 1. Disconnect the 5 couplers (e) (6 couplers （e）...
  • Page 42 5.3.2　Re-installing the Circuit Board Re-install the removed components. （m） The re-installation procedure is simply the re- moval procedure in reverse, but care should be taken with the items below. Note ・ Before re-installing the circuit board (k), （k） check that the heat dissipation sheet (m) is neatly affixed.

  • Page 43: Removing And Re-Installing The Coupler Box

    5.4　Removing and Re-installing the Coupler Box 　Required tools: Nippers, Philips-head screwdriver, 10 mm socket, socket wrench, 2.5 mm hexagonal wrench (Allen key), 26 mm spanner, torque wrench 5.4.1　Removing the Coupler Box Remove the battery (a). Warning （a） ・ Always remove the battery. Failure to do so could result in an electric shock during the procedure.
  • Page 44 Cut the cable tie (b). Note ・ When cutting the cable tie (b), take care not to cut the cable (c). （c） （b） （f） Cut the cable tie (d). （g） Turn the wheel assembly (e) over and cut the cable tie (d) used to secure the cables (c, f) to the coupler box holder (g).
  • Page 45 D is c o n n e ct t h e m o d e s w it c h c a ble (f). （l） 1. Disconnect the coupler (l) on the end of the mode switch cable. 2. Slide out the grommet (m) to disconnect （m）...
  • Page 46 5.4.2　Re-installing the Coupler Box The re-installation procedure is simply the removal proce- dure in reverse, but care should be taken with the items below. （q） Note ・ To avoid damaging the cables or terminals, d o not use excessive force w hen plu ggin g cables back in.

  • Page 47: Removing And Re-Installing The L/R Connecting Cable

    5.5　Removing and Re-installing the L/R Connecting Cable 　Required tools: Philips-head screwdriver 5.5.1　Removing the L/R Connecting Cable Remove the battery (a). Dis m o u nt th e w h e el d rive u nit as- （a） sembly R. See “3.3 Removing and Re-installing the Wheel Drive Unit Assembly”.
  • Page 48 Disconnect the couplers (e) for the （e） （d） L/R connecting cable (d). Disconnect the 4 couplers (e) on the end of the L/R connecting cable (d) in the battery seat cover (b). Rem ove the grom met (f) for the L/R （d）...

  • Page 49: Adding And Removing The Springs

    5.6　Adding and Removing the Springs The handrims are equipped with 2 sets of springs. You can adjust the force in the springs by adding or removing a spring. (There are 3 spring slots on the unit) 　Required tools: 1.5 mm and 4.0 mm hexagonal wrenches (Allen keys) Remove the battery (a).
  • Page 50 Re-install the cover (d). Left side unit Forward-rotation direction Re-install the cover (d) and tighten the hexa- gon-socket head bolts (e). Tightening torque 6.0 – 9.5 N･m Note ・ Apply force to the cover (d) in the reverse- rotation direction to ensure that there is no play, and then tighten the hexagon-socket head bolts (e) to lock the cover in place.

  • Page 51: Copying Setting Data

    5. 7　Copying Setting Data When the circuit board is replaced, first, copy the setting data with the way described in this section, and calibrate the sensor neutral position next. When the circuit board is replaced, the setting data for the driving parameters set by “JW Smart Tune”...
  • Page 52 Copy the setting data. Pull  Keep on  1. Push the right-hand wheel assembly han- 10 times pushing drim forward and hold it in that position as you pull the left-hand handrim in the reverse direction 10 times. Ensure that you start pulling the left-hand handrim within 10 seconds of pushing the right-hand handrim forward.

  • Page 53: Calibrating The Handrim Sensor Neutral Position

    5.8　Calibrating the Handrim Sensor Neutral Position If you have replaced the wheel assembly or circuit board, you should also calibrate the handrim sensor neu- tral position since the neutral position will have been lost. The calibration way for RIGHT-HAND is described bellow.
  • Page 54 Store the forward direction signal. When the buzzer emits a series of 12 short Push fully  beeps, push the right-hand wheel assembly and  handrim forward once as far as it will go and release then return the handrim to the neutral position. (Slowly let go off the handrim.) Important ・...

  • Page 55: Jw Smart Tune

    6. JW Smart Tune The E-Move features the “JW Smart Tune” dedicated software that allows its functions and running characteristics to be tailored to suit the user’s physical condition and the way the unit is used. The running characteristics can also be stored as Mode 1 and Mode 2, and installing the optional mode switch makes it easy to switch between the two modes.

  • Page 56: Warnings

    7. Warnings 7.1　Warnings List If the E-Move malfunctions while it is being used, or if an error occurs that can be recovered through a simple procedure, the buzzer sounds and a warning is displayed on the LED. When a warning is issued, resolve the problem as outlined below.
  • Page 57 Warning detail display Right-hand Left-hand unit unit Occurrence System Recovery Item conditions response conditions Buzzer The temperature of the Blinks Short beeps motor or circuit board Limits maximum motor Temperature Blinks Blinks Torque limit 1 yellow (continuous) has exceeded the spec- current to 75% drops.

  • Page 58: Self-Diagnosis

    8. Self-diagnosis 8.1　Self-diagnosis (Self-diagnosis Function) When the E-Move experiences an unrecoverable error, the buzzer sounds, an error is displayed on the self-powered LED, and the system stops to assist the operation. In this event, use the table below to diagnose the fault.
  • Page 59 Fault detail display Considerable replacement for the repair Right-hand Left-hand Right-hand Left-hand unit unit unit unit Fault Item Fault determination condition type Relay contact melted ○ Relay fault on the driver board Thermistor fault on the driver FET thermistor fault ○ board Motor temperature Thermistor fault on the encoder...
  • Page 60 Fault detail display Considerable replacement for the repair Right-hand Left-hand Right-hand Left-hand unit unit unit unit Fault Item Fault determination condition type Relay contact melted ○ Relay fault on the driver board Thermistor fault on the driver FET thermistor fault ○...

  • Page 61: Inspections And Maintenance

    9. Inspections and Maintenance 9.1　Inspection Checklist Use the checklist below when carrying out an inspection. Inspection Location Criteria Check item • No damage, deformation or play in the Damage, deformation, play screws Power switch Power switch • Switches on and off firmly Wire placement, damage •...

  • Page 62: Specifications And Other Information

    ● Note that the above data, including the specifications and appearance, is subject to change without no- tice for the purposes of product improvement. * The E-Move can bear a load of 130 kg (including the rider, luggage and frame). However, you should check with the frame manufacturer for details of the frame strength.

  • Page 63: Dimensions And Diagrams

    10.2　Dimensions and Diagrams The dimensions shown here are for the 24-inch model. Only the dimensions shown in parentheses ( ) differ on 22-inch models. *1: Tire sizes are shown on the side of the tire. *2: Handrim dimensions do not include any coatings. Left wheel Right wheel 155mm...

  • Page 64: Wiring Diagram

    10.3　Wiring Diagram...

This manual is also suitable for:

Jwx2-b24e2Jwx2-c22e2Jwx2-c24e2Jwx2-d24e2Jwx2-e24e2Jwx2-f24e2

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