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Foreword This Service Manual describes the procedures for inspecting, adjusting, and assembling the E-Move, as well as how to handle errors. Symbols Used in This Manual Items concerning proper handling are indicated with the following symbols. Warning ・ Indicates that misuse may lead to fatal or severe injury, or disability. Note ・ Indicates that misuse may lead to material damage. Important ・ Indicates correct methods and key points when operating the product. Ref. ・ Provides information that user will find it useful to know. Other Precautions • For product improvement purposes, the descriptions and specifications in this manual are subject to change without notice. • Due to changes in the specifications, some of the photos and descriptions may differ from the actual product. • This manual is intended for use by persons possessing the basic technical knowledge and skills. • Persons who do not possess the general service skills and knowledge should not rely solely on this service manual to perform inspection, adjustment, disassembly, or reassembly.
1. Product Overview 1.1 Product Features Sample E-Move Installation ③ ④ ③ ⑤ ① ② E-Move Standard battery seat model E-Move Separated battery seat model ① Wheel drive unit assembly with AC servo fl at motor ② Power switch ③ Dedicated battery with built-in microprocessor Choice of nickel-metal hydride or lithium-ion battery ④ Mode switch (option) ⑤ Battery bag...
2. Installation Requirements 2.1 Strength Requirements To install the E-Move, the wheelchair frame must meet the strength requirements listed below. Warning E - M o v e ・ D o n o t i n s t a l l t h e o n a w h e e l c h a i r f r a m e t h a t d o e s n o t meet the strength ...
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2.2.1 Wheelchair frame (1) T he diameter of the axle hole is 18 mm or 20 mm. (2) The contact surfaces for the nuts around the axle hole must be fl at and have ample surface area. (3) W h e n t h e E - M o v e i s i n s t a l l e d , t h e r e m u s t b e n o i n t e r f e r e n c e b e t w e e n t h e E - M o v e a n d t h e w h e e l c h a i r .
・ D o n o t i n s t a l l t h e E - M o v e o n a w h e e l c h a i r f r a m e t h a t d o e s n o t meet the functional requirements . Even where it can be successfully installed, problems may arise during use that could cause injury or accident. 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 correct posi- tion 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...
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 specifi ed, always tighten to the specifi ed torque. Insuffi cient tightening torque will cause looseness, while excessive torque could cause dam- age. ・ Install the unit with the battery removed.
3.1 E-Move Components ③ ⑤ ⑥ ① ② OWNER’S MANUAL ⑤ ⑥ ④ ⑦⑨ ⑧⑨ ⑩ ⑮ ⑳ ⑪ ⑯ ⑫ ⑰ ㉒ ⑱ ⑬ ⑭ ⑲ ㉑ ㉓ 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) Ownerʼs Manual, Warranty, Guidelines for Safe Use, ③ Manual set Installation Manual ④...
3.2 Installing the E-Move With the exception of the cabling, the procedure for installing the E-Move in a modular-type wheelchair 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).
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(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)...
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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 sleeve (c) and the pin on the stopper arm (c) (d) and then fi t them together. Note ・ If there is interference between the wheel- chair ...
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On separated battery seat models only, install the battery bag. See “3.3 Battery Bag Installation”. Fit the cable. (q) (1) Open the cap (q) on the coupler box case (p). (p) (2) Align the white mark (r) (indicated by the (t) (u) arrow) on the end of the cable with the white mark on the wheel coupler (s) and push the cable in until it clicks into place.
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Check the status of the cable (t). (v) Check that the cable is not stretched, is not trapped or pinched when the frame is col- lapsed, and is not wrapped around or other- wise touching any moving parts. If necessary, (t) use the surface fastener tape (v) to secure the cable (t). (1) Attach the surface fastener tape (v) to the cable (t).
3.3 Battery Bag Installation (Separated Battery Seat Type) Note ・ Installing the battery bag may prevent the frame from being folded. Note ・ Secure the battery bag cables with the sur- face (hook and loop) fasteners on the bag cable retainers. When doing so, ensure that the interlocking surfaces on the fasteners are fully engaged. If the cables are not se- cured ...
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Attach the battery bag belt (e). (a) Run the battery bag belt (e) around the top of the back support frame (a) and fasten it in place using the fi tting tape (f) (surface fastener with hooked surfaces on both sides). There are two ways to affi x the fi tting tape (f), as de- scribed below. Note (e) ・ Run the battery bag belt (e) around the part of the top of the back support frame (a) that ...
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2. If the end of the battery bag belt (e) reaches the battery bag (g). Affix the fitting tape (f) to the battery bag (a) belt (e) so that it is at the end of the sur- face fastener (looped tape) where it emerg- (g) es from the bag. Run the belt (e) around the frame (a) and then stick the belt (e) to the fi tting tape (f) (e) to fasten it in place.
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Secure the battery bag (g). (g) (1) Remove the surface fastener on the bot- tom of the battery bag (j) and run both sides of the belt (b) through the fastener. (2) Re-affi x the surface fastener (j) to secure (b) the battery bag (g) in place. (j) (g) (b) (j) Note Vertical ・ The battery (k) should be installed so that it is ...
3.4 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 3.4.1 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 end of the cable (b) to loosen it, and then pull it upwards to disconnect the cable.
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Remove the wheel drive unit assem- 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 ・ Support the battery housing so that the wheel drive unit assembly (h) does not rotate ...
4. Pre-Delivery Adjustment 4.1 Adjusting the Battery Seat Angle When adjusting the battery seat angle because interference with the seat back makes battery removal dif- fi cult, 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 (c) unit assembly (a). Dismount the right-hand wheel drive unit as- (a) sembly (a) from the wheelchair frame. Remove the cover (b). Remove the 2 screws (c) and then remove the cover (b) below the battery seat. (b) (c)...
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Adjust the angle of the battery seat Vertical (d). Remove the 3 bolts (e) and adjust the angle of the battery seat (d). (f) Important ・ The battery seat (d) can be adjusted through 4 steps. Adjust the battery so ・ The seat angle shifts through roughly 15 ° for each that it is inclined at step. no more than ±15° from vertical in the direction of chair movement.
4.2 Adjusting the Power Switch Position Required tools: Philips-head screwdriver, nippers, 4 mm hexagonal wrench (Allen key), 10 mm socket, socket wrench, torque wrench Dismount the right-hand wheel drive (c) unit assembly (a). If the right-hand wheel drive unit assembly (a) (a) is installed in the wheelchair frame, dismount Remove the cover (b). Remove the 2 screws (c) and then remove the cover (b) below the battery seat. (b) (c)...
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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) (d) (3) Cut the cable tie (h) and pull the cable (d) (i) (d) (h) for the power switch (i) out of the channel in the unit back plate (a). Note ・ When cutting the cable tie (h), take care not to cut the cable (d). (a) (4)Loosen and remove the cable tie (j) under the battery seat. (j) Adjust the position of the power (k)...
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Secure the cable (d). (d) (l) (a) (1) Starting from the power switch (i), fi t 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) (m) cable (d). ・ Fasten the cable tie (l) as shown in the fi gure so that it does not touch the wheel (m). (2) Install the battery seat (f) secure it in (e) (f) place with the 4 bolts (e).
4.3 Installing the Mode Switch Install the optional mode switch using the procedure below. Required tools: Philips-head screwdriver, nippers, 4 mm hexagonal wrench (Allen key), 10 mm socket, socket wrench, torque wrench Dismount the left-hand wheel drive (b) unit assembly (a). If the left -hand wheel drive unit assembly (a) is installed in the wheelchair frame, dismount (c)...
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Remove the grommet (i). (i) Remove the grommet (i) from the coupler box bottom cover (j). (j) Connect the mode switch cable (k) Connect the mode switch cable (k) to the cou- pler inside the box. (k) Secure the mode switch cable (f) (j) Run the mode switch cable (k) through the grommet (l), fi t it into the coupler box bottom cover.
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Secure the cable (k) (g) (n) (k) Secure the mode switch cable (k) in the chan- nel in the unit back plate (g) and fasten the cable in place using the cable tie (n). (n) (g) Assemble the coupler box. (c) Note (m) ・ If you removed the coupler box (m) from the unit back plate for this procedure, be sure to install the collars (n) in the coupler box (m) when re-assembling the coupler box.
4.4 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. Required tools: 10 mm socket, socket wrench, torque wrench, 10 mm spanner 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) Ad j u s t t h e a n g l e o f t h e p owe r switch (b).
4.5 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. Required tools: Philips-head screwdriver, nippers, 4 mm hexagonal wrench (Allen key), 10 mm socket, socket wrench, torque wrench Dismount the right-hand wheel drive (c) unit assembly (a). If the right-hand wheel drive unit assembly (a) (a) is installed in the wheelchair frame, dismount Remove the cover (b). Remove the 2 screws (c) and then remove the cover (b) below the battery seat. (b) (c)...
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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) (d) (3) Cut the cable tie (h) and pull the cable (d) (h) (d) for the power switch (i) out of the channel in the unit back plate (a). Note ・ When cutting the cable tie (h), take care not to cut the cable (d). (i) (a) (4)Loosen and remove the cable tie (j) under the battery seat. (j) Adjust t h e le ng t h of t h e p owe r switch (i).
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Secure the cable (d). (d) (l) (1) Starting from the power switch (i), fi t 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) (m) cable (d). ・ Fasten the cable tie (l) as shown in the fi gure so that it does not touch the wheel (m). (2) Install the battery seat (f) and secure it in (e) (f) place with the 4 bolts (e). Tightening torque 8 ‒ 13 N・m (3) Secure the cables (d) with the cable ties (n).
4.6 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. Required tools: Philips-head screwdriver, nippers, 4 mm hexagonal wrench (Allen key), 10 mm socket, socket wrench, torque wrench Dismount the left or right wheel (c) drive unit assembly (a). If the left or right wheel drive unit assembly (a) is installed in the wheelchair frame, dismount (a) Remove the cover (b). Remove the 2 screws (c) and then remove the cover (b) below the battery seat. (b) (c)...
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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 ・ When cutting the cable tie (j), take care not (j) to cut the cable (d). (3) Loosen and remove the cable tie (k) under the battery seat. (k) (4) Disconnect the coupler (l) on the end of the cable (d) for the power switch (i). Important ・...
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Remove the mode switch (r). (m) (t) (s) (r) (1) Remove the bolt (s) and remove the mode switch (r). (2) Cut the cable tie (t). Note ・ When cutting the cable tie (t), take care not to also cut the cable (m). Remove the coupler box case (u). (u) (1) Remove the 4 screws (v) holding the cou- (v) pler box case (u). (v) Remove the grommet (w). (w) Remove the grommet (w) from the bottom cov- er (x) of the coupler box. (x) Switch the power switch (h) and mode switch around.
For installation, carry out the removal procedure in reverse, noting the points outlined below. Note Right unit back plate ・ Install the switches so they face in the direc- tions indicated in the fi gure. Failing to do so will cause the switches to interfere with the frame. ・ Apply thread-locking compound to the power switch and mode switch bolts (i, s) during installation. Tightening torque 8 ‒ 12 N・m ・ Coupler box case mounting screws (v) Left unit back plate Tightening torque 0.6 ‒ 0.8 N・m ・...
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Remove the coupler box case (f). (f) (1) Remove the 4 screws (g) holding the cou- (g) pler box case (f). (g) Remove the grommet (h). (h) Remove the grommet (h) from the bottom cov- er (i) of the coupler box. (i) For installation, carry out the removal procedure in reverse, noting the points outlined below. Note (f) (i) ・ Stow the surplus switch cable (j) inside the coupler box case (f). Once you have deter- mined how much of the switch cable (j) to stow ...
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Note ・ Install the collars (e) in the coupler box case (c) (f) during assembly. (f) ・ Coupler box case mounting screws (g) Tightening torque 0.6 ‒ 0.8 N・m ・ Coupler box mounting bolts (c) (e) Tightening torque 8 ‒ 13 N・m Note (f) (j) (m) ・ Run the cable tie (l) through the hole (m) in the coupler box case to secure the cable. ・ In section , bundle together the coupler box cable (n) and the switch cable (j) and secure them to the coupler box case (f) with a cable (l) tie (l). (m) (l) (n)...
4.8 Repositioning the Coupler Box Cables This explanation of how to reposition the coupler box cables describes the procedure for the left side as a guide for both sides. The procedure for the right side is the same. Required tools: 10 mm socket, socket wrench, torque wrench, nippers Dismount the left-hand wheel drive unit assembly (a). (c) If the left-hand wheel drive unit assembly (a) is installed in the wheelchair frame, dismount it from the frame. Adjust the angle and position of the coupler box (b). (1) Remove the 2 bolts (c) and adjust the (b) angle and position of the coupler box (b). To change the position, cut the cable tie (d).
4.9 Adjusting the Warning Lamp (LED) Direction Adjust the direction in which the warning lamp (LED) (a) faces so that it is readily visible when the wheelchair is being operated. (a) Important ・ The warning lamp (LED) (a) direction is adjustable through 360° . However, the range of adjustment is restricted if the switch cables are routed past the warning lamp unit.
4.10 Using Off set 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) stopper arm (a) must be off set outwards. In this case, fi t 3.2 mm thick off set washers (e, f) on the (f) axle sleeve (d) and on the bolt (c) between the stopper arm (a) and the wheelchair side bracket (b).
4.11 Adjusting the Battery Bag Cable Length (Separat- ed Battery Seat Type) Required tools: Phillips-head screwdriver 4.11.1 Disconnection Procedure R e m o v e t h e 4 s c r e w s ( b ) a n d (a) washers (c) in the bottom of the battery bag (a).
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R e m o v e t h e c a b l e t i e ( j ) a n d (m) (k) adjust the length of the left unit (l) connecting cable (k) and the right u nit ...
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4.11.2 Reconnection Procedure Reconnect the cables by carrying out the disconnection (p) procedure in reverse, noting the points outlined below. (l) (k) Note ・ There are identification marks (o) on the ends of the left unit connecting cable (k) and the right unit connecting cable (l) indicating (o) the side to which they should be connected. Connect the cables so that the identifi cation marks match those on the coupler box, using ...
4.12 Checklist After Installing the Electric Power-Assist Unit Item Checked Check that all components are securely tightened (recheck the installation status). The power switch and mode switch are not interfering with the tires or frame. When you get into or out of the wheelchair, your body does not hit the power switch and turn the power on. The power switch and mode switch cables are fi rmly secured. The stopper arm pin engages correctly with the plate lock hole. (In modular wheelchairs, the 2 O-rings should be hidden.) The anti-roll bar is installed correctly. (When the anti-roll bar makes contact with the ground, the caster height is no more than 10 cm and the auxiliary wheels on the anti-roll bar are behind the rearmost point of the rear wheels.) The cable condition (the cables are not stretched, are not trapped or pinched when the frame is collapsed, and are not tangled in or touching any moving parts) Check the tire pressures Standard:20-inch…420kPa/4.2kg/cm ; 22/24-inch…450kPa/4.5kg/cm Parking brake action Check for abnormal noise or vibration On removable models, check that the unit only releases when the handle plate is pulled. On Separated Battery Seat Types, check the battery bag installation (play or looseness in the top and bottom belts, the surface (hook and loop) fasteners on the upper and lower belts and on the bag cable retainers are fully pressed down and engaged, and the ...
5. Component Removal, Installation and Adjustment for Investigation and Repair 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), fl at-head screwdriver 5.1.1 Removing the Handrim Remove the battery (a). (a) The figure shows the procedure for a nickel-metal hydride battery. Release the rotation lock on the handle plate (b). Raise the lever on the handle plate (b) and turn the lock screw (c) two or three times to loosen Only loosen the screw; you do not need to re- move it.
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Remove the handle plate (b). Turn the handle plate (b) counterclockwise to remove it. Important ・ Fit a fl at-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)...
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If there are notches with two tabs on inner circumference of the cap There are two tabs (i) in each location. With your finger or a similar implement, push the tabs out to remove them. Do this in two loca- tions and remove the wheel cap assembly (e). (e) (i) Remove the handrim (g). (g) Remove the 3 bolts (h) and then remove the handrim (g). (h) (h) 5.1.2 Re-installing the Handrim The re-installation procedure is simply the removal procedure in reverse. Bolts (h) ...
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. See 5.10. Required tools: 17 mm deep socket, socket wrench, 10 mm spanner 5.2.1 Removing the Wheel Assembly Remove the battery (a). Remove the handle plate. (a) See “5.1 Removing and Re-installing the Han- drim”. The figure shows the procedure for a nickel-metal hydride battery. Remove the self-locking nut (b). (c) Important ・ Use a spanner to hold the two fl at sides (c) on the end of the wheel axle on the inside of the chair if the ...
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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 ‒ 35.0 N・m When the rear wheel assembly was replaced to new one, the spring covers should be re-assembled with ad- justment. Note ・ Always use a new self-locking nut (b) when re-installing the wheel assembly (e). Re-using the old nut could cause the nut to come loose.
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. Required tools: Philips-head screwdriver 5.3.1 Removing the Circuit Board Remove the battery (a). Warning (a) ・ Always remove the battery. Failure to do so could ...
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Remove the transparent cover (d). (c) Remove the 3 screws (b) and the clip spring (c). (d) Then remove the transparent cover (d). (b) (b) Disconnect the coupler (e) and the (j) (j) cables (f, g, h, i). 1. Disconnect the 5 couplers (e) (6 couplers (e) on the right). (i) (f) 2. Remove the 5 screws (j) and disconnect (h) the 2 cables (f) and the 3 cables (g, h, i). (g)...
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5.3.2 Re-installing the Circuit Board Re-install the removed components. The re-installation procedure is simply the re- (m) 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 affi xed. If the sheet is not stuck down properly, fi x it in place neatly. Note (e) ・ Run the cables (f, g, h, i) and the couplers (e) (f) as shown in the figure and connect them to (i)...
5.4 Removing and Re-installing the Coupler Box This explanation of how to remove and re-install the coupler box describes the procedure for the left side as a guide for both sides. The procedure for the right side is the same. Required tools: Nippers, Phillips-head screwdriver, 10 mm socket, socket wrench, 2.5 mm hexagonal wrench (Allen key), torque wrench 5.4.1 Removing the Coupler Box Remove the battery (a). Discharge the electricity in the cir- cuit board. (a) To discharge the electricity in the circuit board, remove the battery and set the power switch to ON for 1 second and the set it back to OFF. The figure shows the procedure for a nickel-metal hydride battery. Note ・ You must always discharge the circuit board. Failure to do so could result in a short-circuit and damage the circuit board. Remove the left-hand wheel drive unit assembly.
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Cut the cable tie (b). Note ・ When cutting the cable tie (b), take care not to also cut the cable (c). (c) (b) Cut the cable tie (d). (e) (f) (g) Turn the drive unit (e) over and cut the cable tie (d) holding the cables (c, f) to the coupler box case (g).
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Remove the screws (j). (g) Remove the 4 screws (j) holding the coupler (j) box case (g). (j) Open the coupler box bottom cover and pull out the cable (f). (k) (f) Disconnect the mode switch cable (f). (l) 1. Disconnect the coupler (l) on the end of the mode switch cable. 2. Slide the grommet (m) out of its slot. (m) (f)...
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Disconnect the coupler box cable (c). (n) 1. Remove the 2 bolts (n). 2. Remove the plate (o) and the grommet (p) and pull out the coupler box cable (c). (o) Note (p) ・ To avoid damaging the cable (c) or the termi- nal, do not use excessive force when pulling out the cable. (c)...
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5.4.2 Re-installing the Coupler Box Re-install the coupler box by carrying out the removal pro- cedure in reverse, noting the points outlined below. Note (p) ・ To avoid damaging the cable or the terminal, do not use excessive force when re-inserting the cable. ・ Push the grommets (p and m) fully and se- curely back into their respective slots. (m) Note ・ Install the collars (i) in the coupler box case (g) during assembly. (g)...
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Note (g) ・ When tightening the bolts (h) used to install the coupler box case (g), the torque must be set to between 8.0 and 13.0 N・m. (h) Note (g) (f) (q) ・ Run the cable tie (d) through the hole (q) in the coupler box case to secure the cable. ・ In section , bundle together the coupler box cable (c) and the switch cable (f) and secure them to the coupler box case (g) with a cable (d) tie (d). (q) (d) (c) Note (r)...
5.5 Removing and Re-installing the L/R Connecting Cable (Standard Battery Seat Type) Required tools: Philips-head screwdriver 5.5.1 Removing the L/R Connecting Cable Remove the battery (a). Dismount the wheel drive unit as- (a) sembly R. See “3.4 Installing and Removing the Wheel Drive Unit Assembly”. The figure shows the procedure for a nickel-metal hydride battery. Remove the battery seat cover (b). (c) Remove the 2 screws (c) and then remove the battery seat cover (b). (b) (c)...
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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). Remove the grommet (f) for the L/R (d) connecting cable (d). Slide the grommet (f) for the L/R connecting cable (d) upwards to remove it.
5.6 Removing and Re-installing the Battery Bag 5.6.1 Removing the Battery Bag Remove the battery (a). (a) The figure shows the procedure for a nickel-metal hydride battery. Disconnect the left-right cable (b). (c) (b) 1. Turn the ring (d) on the coupler (c) on the end of the cable (b) and pull the cable up- wards to disconnect it. 2. Place the cap (f) over the coupler (e). (d) (f) (e) Remove the battery bag (g). Disconnect the surface fastener (h) and pull out the belt (i). (h) Disconnect all belts (i) and remove the battery ...
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5.6.2 Re-installing the Battery Bag The installation procedure, see 3.3 Battery Bag Installation (Separated Batttery Seat Type).
5.7 Removing and Re-installing the L/R Connecting Cable and Coupler (Separated Battery Seat Type) ・ This explanation of how to remove and re-install the L/R connecting cable and coupler describes the pro- cedure for the JW Swing as a guide for other models also. The procedure for the E-Move Separated Battery Seat Type is the same. ・ T he L/R connecting cable is a cable that connects to the left-hand power unit assembly. The coupler is a cable that connects to the right-hand power unit assembly. Required tools: Phillips-head screwdriver 5.7.1 Removing the L/R Connecting Cable and Coupler Remove the battery bag (a). (a) See “5.6 Removing and Re-installing the Bat- tery Bag”. Remove the 4 screws (b) and washers (c) in the bottom of the bag. (c) (b) Remove the surface fastener (e) (f) holding the cable (d) and remove the battery box (f) from the bag. (e) (d) Remove the screw (g) in the battery (h) seat and then remove the 4 screws (h) in the bottom of the battery box ...
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Remove the cable tie (j) and the 6 (k) (l) couplers (k), and then disconnect (m) t h e L / R c o n n e c t i n g c a b l e (connection ...
5.8 Adding and Removing the Springs The handrims are equipped with 1 or 2 set(s) of spring(s). 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). Remove the handle plate and the (a) wheel cap. See “5.1 Removing and Re-installing the Han- drim”. The figure shows the procedure for a nickel-metal hydride battery. Add or remove the spring (c). Install the spring (c) in the wheel assembly (b). Alternatively, remove the spring. At least one set of springs must be installed on one of the wheels.
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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.
5.9 Copying Setting Data When the circuit board is replaced, fi rst, 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” is lost, so the setting data should be copied. The copying way from the left-hand to the right-hand circuit board is described below. Important ・ The same setting data values are stored on the left and right circuit boards. So the stored setting data can be copied. ・ The example given here describes the procedure for copying setting data from the left-hand to the right-hand circuit board. To copy the data from the right-hand to the left-hand circuit board, simply use the same proce- dure replacing right with left . Copying from Left unit to Right unit Park the wheelchair. Park the wheelchair on a level place. Apply the parking brake. Switch to Service mode. Set the power switch to ON. In case one of the circuit boards was replaced to the new one, an error will be detected, the ...
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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. On the 10 push, the buzzer will emit a single ...
5.10 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. In case the circuit board was replaced, copy the setting data before calibrate the neutral position. Important ・ The example given here describes neutral position calibration for the right-hand wheel assembly. For the left- hand wheel assembly, simply use the same procedure replacing right with left . Right unit calibration Park the wheelchair. Park the wheelchair on a level place. Apply parking brake. Switch to Service mode. 1. Set the power switch to On while pulling the right-hand wheel assembly handrim in Pulling Power on the reverse direction.
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Store the forward direction signal. When the buzzer emits a series of 12 short beeps, push the right-hand wheel assembly Push fully 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 ・ Move the handrim while the buzzer is emitting the series of 12 short beeps. ・ The buzzer emits a series of 12 short beeps in almost 7 seconds followed by a single long beep. ...
6. JW Smart Tune The E-Move features the “JW Smart Tune” dedicated software that allows its functions and running charac-teristics to be tailored to suit the userʼs 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. JW Smart Tune confi gures the “Function parameters” and the “Driving parameters”. Function parameters Driving parameters ① Auto power off time ① Assisting motor power ② Buzzer tone ② Assist speed limit ③ Switch brightness ③ Going Straight/Turning Characteristics setting ④ Mode switch setting ④ Response Level and left/right balance adjustment For more details, refer to the JW Smart Tune Instruction Manual supplied separately.
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 sim-ple procedure, the buzzer sounds and a warning is displayed on the LED. When a warning is issued, resolve the problem as outlined below. 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. ifi ed value. Blinks No BMC communi- No signals are coming Signals from the Blinks Blinks Able to continue running...
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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. ifi ed value. Repeated Blinks 1-second Excessive load on the Reduce the load Blinks Blinks Heavy load warning Able to continue running yellow beeps (intermit- motor.
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. 8.2 Fault Detection Chart 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 Blinks Beeps Blinks Blinks Left and right driver board set- System red for 2.5- Setting switch fault ○ ○ once once tings diff er.
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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 ○ thermistor fault board Blinks Blinks Blinks Beeps Protection Overload stop 1-1 Occurs when the board protec- 5 red 5 5 for 2.5- devices (FET overheating) tion temperature is reached. times times times...
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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 ○ thermistor fault board Protec- Blinks Blinks Blinks Beeps Overload stop 1-1 Occurs when the board protec- tion 5 5 red 5 for 2.5- (FET overheating) tion temperature is reached. devices times times...
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 • No twisting, looseness or damage • No damage, deformation or play in the Damage, deformation, play screws Mode switch Mode switch • Switches on and off firmly Wire placement, damage • No twisting, looseness or damage • Operates with no abnormal noise or vi- Abnormal noise or vibration bration Tire pressure, wear, cracking, valve • The tire pressure is correct play • There is no wear, cracking or damage • ...
10.2 Dimensions and Diagrams The dimensions shown here are for the 24-inch model. Only the dimensions shown in parentheses ( ) diff er 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 155mm Handrim Between pawls pipe diameter 14 mm ※2 19mm 316mm 97mm Tire Handrim diameter diameter 608±3 mm ※1 536mm 40mm (570±3 mm) 101mm ※1 (502mm) 39mm 151mm 232mm 38mm 38mm 78mm 78mm 87mm 92mm 92mm...