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Barrett Jewel, Technical Manual

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Barrett Jewel Technical Manual Download Page 17

SECTION 9: Brakes

9.1 Diagram

BRAKE ASSEMBLY 300-19-11

9.2 Parts List

GZF No

RJ No

Brake Assembly  

  

 Left     

  

    

  300-19-11L Brake Assembly

 

  

Right     

  

  

    

300-19-11R Brake Handle     Left

 

  

  

  

  

 SF172LP Brake Handle      Right

 

SF172RP Black Ball Knob    

    

   KB5-125 Brake Pivot

 

  

  

SF173P Brake Lever  

    

Left       

    

  SF171L

Brake Lever    

  

Right     

  

    

  SF171R Brake Shoe

 

  

  

  

  

  

    

  SF174A

Return Spring Zinc Plated   

 

Left     

 258    SF233L Return Spring Zinc

Plated   

 

Right     

 259    SF223R

1/16x1/2 Split Pin Zinc Plated  

   

    

    

    

    

    

    

F50

10/32x5/8 UNF Hex Head Screw Zinc Plated       

    

    

    

    

F13 1/4

UNF Plain Nut Zinc Plated   

   

    

    

   F26 2BA Wave Washer Copper

 

 

 

   

    

    

 F29  10/32  UNF  Nyloc  Nut  Zinc

Plated  

 

 

   

    

    

F24 Thread Protector

 

 

 

   

    

  199462

Summary of Contents for Jewel

Page 1: ...o 01422 372503 Email sales rjmobility com Website www rjmobility com TECHNICAL MANUAL Issue 13 May 2013 This Technical Manual will ensure that the wheelchair is maintained to the required standard and is for use by trained personnel only The Proven Reliable Indoor Powerchair Jewel ...

Page 2: ......

Page 3: ...mount If there is any doubt as to the suitability of re using existing parts they should be discarded and replaced with manufacturer approved parts User Manuals should be stamped at correct intervals following completion of mainte nance work If you fail to understand anything or have any questions concerning maintenance and operating instructions please contact RJ MOBILITY 100 Dewsbury Road Elland...

Page 4: ...nce Checks 5 Tool Requirements 6 Upholstery 7 Armrests 8 Footrests 9 Brakes 10 Backrest 11 Frame Locking Links And Cross Braces 12 Cators 13 Power Drive System 14 Electrical System 15 Programmable Controller 16 Elevating Legrest 17 Armrest Outriggers 18 Detachable Tray 19 Kerb Climber ...

Page 5: ... skills and sufficient manual dexterity to operate the controller The occupant should also have enough upper body control to maintain a sitting position A5 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 fol...

Page 6: ...to seat 36 46cm 14 18inch 15 Leg to seat angle 85º From Horizontal 16 Armrest to seat 26 35cm 9 14inch 17 Front armrest to backrest 42cm 17inch 18 Drive wheel diameter 170mm 6 5 inch 19 Tyre Pressures N A Solid Tyres 20 Maximum load capacity 114kg 18 stone 252 lbs 21 Turning Space a Spin turn 185cm 6ft b Between walls 133cm 3ft 9inch 22 Range 30 Amp hr Battery 8 8km 5 5mile 23 Static Stability a F...

Page 7: ...SECTION 3 Wheelchair Diagram 3 1 Jewel Self Propelling Powerchair ...

Page 8: ...rear locking links fully lock See Section 11 4 2 3 Check castors for free rotation of the wheel and the complete assembly Examine castors for wear in the bearings Examine locating spindle for signs of bending at the point where it is attached to the frame See Section 12 4 2 4 Examine tyres for uneven wear Check wheels for free rotation excessive end float and rim rock 4 2 5 Check controller is sec...

Page 9: ...tick is released 4 2 13 Whilst driving slowly up the gradient release the joystick and check that the powerchair does not roll back excessively before the automatic parking brakes come on 4 2 14 Check that all cables are connected to the controller batteries motors and brakes 4 2 15 Check that the circuit breaker push buttons on the battery boxes have not sprung out 4 2 16 Check that the free whee...

Page 10: ...e Section 11 5mm Kerb Climber See Section 20 5 32inch Kerb Climber See Section 20 Pozidrive Screwdriver Upholstery See Section 6 Avdel Nutsert Rivet Tool Upholstery See Section 6 Loctite Thread Locking Castors Wheels See Section 12 13 Compound Grade 241 Terminal Crimp Tool Power Drive System See Section 13 to suit 0 5mm to 6 0mm crimps Torque Wrench Minimum Operating Range 8 lbs ft 11 Nm General S...

Page 11: ... Fabric Ninian G295 Size Seat Fabric Ninian SF453 Size Reinforcing Bar SF176 No 10 x 3 4 UNF Csk Screw Black Zinc Plated F15 No 10 Flanged Screw Cup F38 No 10 UNF Avdel Nutsert 09657 01014 No 10 x 5 8 UNF Csk Screw Black Zinc Plated F138 Canvas Location Spigot G27 ...

Page 12: ...re present and secure Check Velcro on frame is present and secure 6 4 Fabric Removal If the Nutserts need replacement use Avdel recommended tooling 6 5 Fabric Fitting Slide reinforcing bar into stitched section on each side of the seat fabric only Fit countersunk screws through flanged cups and fit through holes in fabric and reinforcing bars Place fabric on seat and backrest tubes and tighten scr...

Page 13: ... Plated F111 5 8 x 20G Black Round Insert M5 7 3 Inspection Check armpad for excess wear or damage Check armpad is secured to frame Ensure armrest ocates in srear bracket on push handle when fitted to powerchair Check armrest lock latch assembly retains armrest to frame assembly 7 4 Armrest Pad The armrest pad is secured to the armrest frame with three screws Removal of the screws releases the pad...

Page 14: ...n the pin housing inside the armest location tube Pull the lock pin TSD 1306 through the pin housing using a small pair of pliers and place a length of tube in the armest location tube or reverse the armrest in the location tube This will retain the lock pin inside the pin housing Fit the lock lever TSD 1323 and plain washer Q5 over the lock pin and press a new starlock washer F37 onto the end of ...

Page 15: ...mp Bolt zinc plated F20 5 16inch Clamp Locking Nut zinc plated F21 5 16inch Washer zinc plated F22 Footplate Assembly 8 1 2inch complete Left 111 SP356 with Stem and Heel Loop Right 110 SP357 Footplate Assembly 7 1 2inch complete Left 111 SP358 with Stem and Heel Loop Right 110 SP359 Footplate Spring TSD1349 Heel Loop complete with nuts and washers 112 TSD11469 2 No 4 x 1 4 Pozipan Type Self Tappi...

Page 16: ...embly from the powerchair by lifting and rotating the hanger section Loosen the clamp with a 1 4inch Whitworth spanner and slide the stem assembly out 8 5 Footrest Fitting Re assemble heel loop to footplate and tighten nuts to 10 lbs ft 13 5Nm Insert footplate stem into hanger tube and tighten clamp to 35 lbs ft 47Nm The footplate should remain in the vertical position when required This is mainta...

Page 17: ...P Black Ball Knob KB5 125 Brake Pivot SF173P Brake Lever Left SF171L Brake Lever Right SF171R Brake Shoe SF174A Return Spring Zinc Plated Left 258 SF233L Return Spring Zinc Plated Right 259 SF223R 1 16x1 2 Split Pin Zinc Plated F50 10 32x5 8 UNF Hex Head Screw Zinc Plated F13 1 4 UNF Plain Nut Zinc Plated F26 2BA Wave Washer Copper F29 10 32 UNF Nyloc Nut Zinc Plated F24 Thread Protector 199462 ...

Page 18: ...e Lever shafts through the bushes on the frame Fit the 2BA Wavey Washers on each shaft and fit two new Split Pins Retain the Split Pins in the holes by bending the ends apart using small pliers Replace with a new Return Spring if necessary Ensure pivot bolts are not over tightened as this will lead to fracture of the brazed tabs on the brake handle Lubricate with light oil 9 6 Brake Adjustment The...

Page 19: ...SECTION 10 Backrests 10 1 Diagram BACKREST ASSEMBLY LEFT G223 BACKREST ASSEMBLY RIGHT G224 ...

Page 20: ...Ensure Nyloc nut still grips thread 10 4 Backrest Removal Unscrew 5 off No 10 UNF countersunk screws holding the backrest fabric to the backrest assembly Unscrew the 1 4 UNF nut and withdraw the bolt 10 5 Push Handle Fitting Insert the 1 4 UNF bolt through the backrest and hinge plates Replace the washer and tighten the Nyloc nut until the backrest pivots freely without excessive free play Fit the...

Page 21: ...t G1 Side Frame Assembly Right G2 3 4 Square Black Plastic Bung M11 1 3 8x5 8 Black Plastic Bung M195 No 10 Avdel Nutsert 09657 01014 11 3 Inspection Check Armrest Locking assembly operates effectively Check each tab on the sideframes for evidence of bending elongation or worn holes and cracks in brazing or tubing Check tube inserts are fitted correctly Examine frame for damage ...

Page 22: ...ed F11 1 4 Brass Washer F30 1 4 x 1 UNF Hex Head Bolt Zinc Plated F139 1 4 x 1 1 8 UNF Hex Head Bolt Zinc Plated F4 1 4 Plastic Spacer F65 11 6 Inspection Check Cross Braces for bending and evidence of cracks around pivot holes Check each tab on the side frames for evidence of bending elongation or worn holes and cracks in brazing or tubing Check securing bolts for excessive wear 11 7 Cross Brace ...

Page 23: ...racture of the tab on the side frame 11 9 Diagram 11 9 Parts List GZF No RJ No Front Locking Link Assembly 17 109 SF 207F Front Locking Link Assembly 15 005 SF 208F 1 4 x 1 UNF Socket Cap Screw Zinc Plated F137 1 4 UNF Nyloc Nut Zinc Plated P90 1 4 Brass Washer F30 6mm Nylon Washer F86 11 10 Inspection Check Locking Links for security of thumb catch and correct operation The locking link should op...

Page 24: ...ecure the Locking Link assembly to each side frame Tighten until the Locking Link is just securely held then loosen the nut half a turn The Locking Link Assembly must be free to move without binding but no signs of excessive free play Lubricate with light oil eg 3 in 1 Overtightening of Cross Brace Assembly will prevent the pivoting action and will lead to fracture of the tab on the side frame ...

Page 25: ... and check both castor mounting tubes are at the same angle checking for frame distortion due to impact damage replace if necessary Check tyre security to rim and for splits cracking or damage Check security of castor 12 4 Castor Removal Unscrew the hexagon at the top of the castor swivel using a 24mm 15 16inch AF spanner until the castor is removed 12 5 Castor Fitting Apply Loctite thread locking...

Page 26: ...ASS Stub Axle D9L Hex Nut 314 D9 Drive Coupling 958 M155 Spring 959 M156 Bronze Bush 320 M89 Drive Collar 962 M159 Spacer 960 M157 Nylon Washer Large F67 Nylon Washer Small F66 1 4 x 1 1 4 UNF Hex Head Bolt Zinc Plated F7 M74 Tab Washer M158 M6x10 Hex Head Screw Zinc Plated F95 10mm Spacer D23 1 4 Spring Washer F33 Wavey Washer F65 Clamp Bolt F20 Clamp Washer F22 Clamp Nut F21 Knob ...

Page 27: ... around the quadrant and check that when released it self centres and the brakes operate An audible click will be heard from each motor when the brakes are applied and released Raise the rear of the powerchair and support on suitable stands Engage the drive mechanism and move the joystick around the quadrant to simulate forward reverse and turning Observe the wheel rotation to ensure it mirrors jo...

Page 28: ...on Reconnect the motor to the main loom and test 13 8 Motor Brush Removal Replacement Disconnect the motor loom from the main loom release the two self tapping screws which hold the motor cowl and slide the motor cowl along the motor loom taking care not to apply any force to the wiring The brushes are located vertically either side of the brake assembly They are joined together by a wire and by g...

Page 29: ...e stub axle D9L the motor will require removal from the mounting plate Using a 7 16 AF spanner release the three retaining bolts and withdraw being careful not to lose the spacers The motor can now be removed by sliding the drive shaft out of the stub axle Using spanners 34mm AF and 35mm AF remove the stub axle Replace the stub axle D9L apply thread locking compound and tighten to 35 lbs ft 47Nm t...

Page 30: ...Electrical System 13 1 Diagram 14 2 Parts List GZF No RJ No Main Wiring Loom G202 Battery Loom 201 18 Motor Assembly Left 624 E94LL Motor Assembly Right 623 E94R 30 Amp Hr Battery 620 E75 30amp hr Circuit Breaker ...

Page 31: ...he beau plug from the rear of the controller Disconnect the motor and battery loom plugs from the main loom and withdraw the main loom To replace feed the main loom underneath the seat from the same side as the controller Connect the motor and battery loom plugs to the main loom and re connect the beau plug to the controller The application of petroleum grease to the contacts will assist in assemb...

Page 32: ...esistance of a battery increases as the battery ages and performance decreases This type of test doeso not provide an assurance that the battery is fully capable of delivering its rated active energy and is dependent on the experience of the test engineer All testing should be performed on fully charged batteries and the test engineer should satisfy himself that this is so 14 7 2 Battery Replaceme...

Page 33: ...SECTION 15 Programmable Controller 15 1 Diagram ...

Page 34: ...ght and hold the controller securely to the Controller Extension Check the condition of the Black Plastic Bungs 15 4 Programmable Controller Removal Penny Giles Pilot Controller Remove the two M5x8 Pozipan screws which secure the Controller to the Controller mounting plate Release the two 1 4 UNF Nyloc nuts from the underside of the Controller Extension and remove the 1 4 x 1 1 8 UNF Bolt holding ...

Page 35: ... controller off then back on again out of neutral time out Control Dynamic DX System The three colour illuminated display on the top surface of the DL Controller acts as both a fuel gauge and a warning gauge When all lights are on the batteries are fully charged As the power is used the green lights and then amber lights will go out When only the red lights are left on the batteries will require r...

Page 36: ...ndicates a fault in the controller or electrical system See table below for fault diagnosis Ripple up and down of bars Joystick displaced at turn on Fault Type Description The number of flashing GREEN High battery voltage bars indicate the possible GREEN Solenoid brake faulty area of fault GREEN Possible controller fault YELLOW Possible joystick fault YELLOW Charger connected YELLOW Right motor wi...

Page 37: ...23 Legrest Trigger SF122 Legrest Trigger Bracket SF121 Legrest Stem Left or Right SF120 Legrest Carrier Bracket Left or Right SF95 Calf Pad Swivel Bracket SF89 Stem Swivel Tube Left or Right SF88 Calf Pad MCP TSD10241 Clamp Assembly M102 1 4 UNF Nyloc Nut zinc plated P90 1 4 UNF x 1 7 8 HT Bolt zinc plated F12 1 4 UNF x 1 1 4 HT Bolt zinc plated F7 1 16 x 1 2 Split Pin F153 1 4 x 18G Plastic Plug ...

Page 38: ...e pivot bolt and separate elevating section from swivelling section Remove rubber end cap from adjustment rod and holding trigger withdraw rod 16 5 Elevating Legrest Fitting Assemble elevating section to swivelling section Use new pivot bolt if necessary Slide adjustment rod through bracket and trigger ensuring spring is positioned to force trigger forward Replace rubber end cap Assemble calf pad ...

Page 39: ...utrigger Socket Assembly Right G273 ASS R Armrest Outrigger Rear Location Assembly G275 ASS Armrest Outrigger Socket G273 Armrest Outrigger Backrest location G275 Outrigger Spacer G274 1 4 x 7 8 UNF Hex Head Bolt Zinc Plated F3 1 4 x 1 1 8 UNF Hex Head Bolt Zinc Plated F4 1 4 UNF Nyloc Nut Zinc Plated P90 7 8 Black Plastic Bung M17 ...

Page 40: ...for bending of armrest tube at insertion point 17 4 Dismantling Release nuts securing sockets to side frame and remove Slide sockets away from frame and remove spacers Release extension bracket from backrest 17 5 Fitting Replace spacers in side frame sockets Slide outrigger sockets into position and insert bolts Tighten nuts to 10 lbs ft 13 Nm Hook rear bracket over backrest loop and tighten screw...

Page 41: ...32 L Right SF316R Tray 837 Tray Bracket 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 42: ... of the mounting stems projecting forward Place the tray symmetrically on the stem brackets ensuring that the flat plates are located between the two guide strips on the under side of the tray Mark through the screw holes in the stem brackets Remove the tray and brackets from the powerchair and secure brackets to tray with screws supplied Refit tray assembly to the powerchair Screw the two loose k...

Page 43: ...Technical Manual Amendment Record ISSUE SECTION DATE AMENDED COMMENTS ...

Page 44: ...Original Meteor Mini Meteor Meteor Independent Maxi Meteor Baby Barrett Tilt Space Barrett 10 Barrett Gem Barrett 7 Portering Barrett 101 Barrett Jewel Maxi Independent ...

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