Barrett crystal Technical Manual Download

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R.J.Mobility

100 Dewsbury Road, Elland. England. HX5 9BG

Tel.no. 01422 324830

Fax.no. 01422 372503

Email - [email protected]

Website - www.rjmobility.com

TECHNICAL MANUAL

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

The Proven

Reliable

Indoor/Outdoor

Powerchair

Crystal

Summary of Contents for crystal

Page 1: ...422 372503 Email sales rjmobility com Website www rjmobility com TECHNICAL MANUAL 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 The Proven Reliable Indoor Outdoor Powerchair Crystal ...

Page 2: ...2 ...

Page 3: ...amount 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 maintenance work If you fail to understand anything or have any questions concerning mainte nance and operating instructions please contact RJ MOBILITY 100 Dewsbury Road Ellan...

Page 4: ...ts 6 Upholstery 7 Armrests 8 Footrests 9 Brakes 10 Push Handles 11 Frame Locking Links And Cross Braces 12 Castors 13 Power Drive System 14 Electrical System 15a Programmable Controller P G Pilot 15a Programmable Controller Dynamic DL 16 Elevating Legrest 17 Armrest Outriggers 18 Detachable Tray 19 Transportation ...

Page 5: ... skills and sufficient manual dexterity to operate the control ler 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 Crystal ...

Page 6: ...85º from horizontal 16 Armrest to seat 23cm 9 inch 17 Front armrest to backrest 42cm 17 inch 18 Drive wheel diameter 315mm 12 5 inch Tyre size 12 5 x 2 25 19 Tyre pressures Rear 50psi 340 kilopascals KPA if pneumatic option fitted 20 Maximum load capacity 114kg 18 stone 252 lbs 21 Turning Space a Spin turn 205cm 6ft 7 inch b 3 point turn 133cm 4ft 4 inch c 28inch doorway turn 100cm 3ft 3 inch 22 R...

Page 7: ...ropelling Powerchair 1 POWERCHAIR FOLDED 2 BATTERY WITH CIRCUIT BREAKER 3 ARMREST 4 FOOTREST HANGER WITH FOOTPLATE 5 BATTERY TRAY 6 BATTERY STRAP 7 BATTERY TRAY RESTRAINT BAR 4 FOOTREST HANGER WITH FOOTPLATE 8 CONTROLLER 2 BATTERY WITH CIRCUIT BREAKER ...

Page 8: ...and bolts or worn parts Check that front and 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 flo...

Page 9: ... 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 wheel devices are releasing and engaging correctly 4 3 Check that controller rubber gaiter and switch...

Page 10: ...holstery 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 Small Pliers General Light Soft Head Hammer General Light Oil e g 3 in 1 General Wire cutter General Power ...

Page 11: ...m SF63 17 17 Ninian 18 x 17 inch 45 5cm x 43cm SF63 18 17 Backrest Fabric Ninian 14 x 17 inch 35 5cm x 43cm SF62 14 17 Ninian 15 x 17 inch 38cm x 43cm SF62 15 17 Ninian 16 x 17 inch 40 5cm x 43cm SF64 16 17 Ninian 17 x 17 inch 43cm x 43cm SF64 17 17 Ninian 18 x 17 inch 45 5cm x 43cm SF64 18 17 M5 x 20 long raised countersunk screw F102 No 8 flanged screw cup F101 M5 Avdel UNF Nutsert 09657 01014 R...

Page 12: ...Velcro attachment tabs are 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 screws taking care not ...

Page 13: ...P2018L 9L L Right XXSP2018L 9L R Armrest Pad Black M170 No 12 x 1 1 4 Pozipan AB self tapping screw zinc plated F111 Armrest Panel Left SF232L Right SF232R AVEX 1 8 pop rivet not shown F46 Armrest frame Left SF 604L Right SF 604R Tube plug M7 2440 ARMREST PAD M 170 BUNG M7 2440 ARMREST FRAME SF 604L SF 604R PANEL SF 232L SF 232R No12x11 4 POZIpan AB SCREW ...

Page 14: ...he armrest frame with two screws Removal of the screws releases the pad Secure the pad with the attachment screws to refit 7 5 Armrest Panel The plastic panel is removed by carefully drilling off the heads of the two pop rivets using a 1 4 or equivalent drill bit Slide the panel forwards on the armrest frame until the moulded hooks release from the tube The plastic panel is fitted by placing the m...

Page 15: ...16 inch Locking Nut zinc plated F21 5 16 inch Washer zinc plated F22 Footplate Assembly 8 1 2 inch complete with Stem and Heel Loop Left SP306L Right SP306R Footplate Assembly 7 1 2 inch complete with Stem and Heel Loop Left SP211L Right SP211R Footplate Spring TSD1349 Heel Loop complete with nuts and washers TSD 114 69 2 No 4 x 1 4 Pozipan Type Self Tapping Screw zinc plated 0456A M6 x 30 Hex Hd ...

Page 16: ...rest assembly 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 i...

Page 17: ...on 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 Adjust to allow an operating force at the handle to be between 10lbf to 13lbf 44 to 58 N with the tyres inflated to the correct pressure 50psi 340 KiloPascals ...

Page 18: ...mplete Barrett style L H SP 404 R H SP 405 Push Handle Assy complete 8L 9L style L H SP 404 8L 9L R H SP 405 8L 9L Push Handle LH Barrett style SF 160L Push Handle RH Barrett style SF 160R Push Handle LH 90 8L 9L style SF 577L Push Handle RH 90 8L 9L style SF 577R 1 4 UNFx3 4 hex head bolt zinc plated hex head bolt zinc plated F10 1 4 UNF self locking thin nut zinc plated F P90 Hand grip M57 ...

Page 19: ...ad 10 4 Push Handle Removal Unscrew 4 off M5x20 countersunk screws holding the seatback upholstery to the Push Handle Assembly Unscrew 1 4 UNF nut and withdraw the bolt 10 5 Push Handle Fitting Insert 1 4 UNF bolt through Push Handle and hinge bush Tighten the nyloc nut until Push Handle pivots freely without excessive free play Fit 4 off M5x20 countersunk screws to hold the seat back upholstery t...

Page 20: ... SP 206 14 Cross Brace Assembly 15 complete with fasteners SP 206 15 Cross Brace Assembly 16 complete with fasteners SP 205 16 Cross Brace Assembly 17 complete with fasteners SP 205 17 Cross Brace Assembly 18 complete with fasteners SP 205 18 M6 x 35 long HT hexagon head bolt zinc plated F126 M6 self locking nut zinc plated P80 1 4 Diameter Nylon plain washer F86 M6 x 25 HT hexagon head set screw ...

Page 21: ...rame 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 Tighten until the Cross Brace is just securely held then loosen the nut half a turn The Cross Brace Assembly must be free to move without binding but show no signs of excessive free play Lubricate with light oil eg 3 in 1 Over tightening of Cross Brace Assembly sc...

Page 22: ...must hold securely in the open position so that the wheelchair will not fold under load Check each tab on the side frames for evidence of bending elongation or worn holes and cracks in brazing or tubing 11 9 Locking Link Assembly Removal Remove the M6 x 25 Screw securing the Locking Link Assembly to each sideframe 11 10 Locking Link Assembly Fitting Fit two 1 4 UNF High Tensile Cap Screws to secur...

Page 23: ...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 24: ...c Plated F 7 Tab Washer M 158 M6x10 Hex Head Screw Zinc Plated F 95 10mm Spacer D 23 1 4 Spring Washer F 33 Wavey Washer F 65 Clamp Bolt F 20 Clamp Washer F 22 Clamp Nut F 21 Knob F KN0065 BLK MOTOR E 131L R WAVE WASHER F 65 LARGE NYLON WASHER F 67 DRIVE COUPLING M 155 SPRING M 156 STUB AXLE D 09L LOCKING BOLT SF 602 HEX NUT D 09 WHEEL TYRE ASSY G 297 SPACER M 157 SMALL NYLON WASHER F 66 DRIVE COL...

Page 25: ...t 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 joystick movement and check for any ...

Page 26: ...tion 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...

Page 27: ...lace the 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 13 8 A F remove the stub axle Replace the stub axle D9L apply thread locking compound and tighten to 35 lbs ft 47Nm torqu...

Page 28: ...ilot 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: ... 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: ...t breakers by pushing in the buttons which are found on the battery boxes 14 4 Wiring Loom Removal and Replacement P G controllers Disconnect the 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 control ler Connect the motor and battery loom...

Page 31: ...ent 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 6 2 Battery Replacement If the batteries are deemed fit for further use they may be re fitted to the powerchair Replace and smear the terminals with petroleum grease Ensure the connections are tight and the battery wiring looms are un...

Page 32: ...32 SECTION 15 a Programmable Controller P G Pilot 25A 40A 15a 1 Diagram ...

Page 33: ... Plastic Bungs 15a 4 Programmable Controller Removal Remove the two M5x8 Pozipan screws which secure the Controller to the Controller mounting plate Release the two M6 Nyloc nuts from the underside of the Controller Extension and remove the M6x30 Bolt holding the Controller Mounting Plate 15a 5 Programmable Controller Replacement Follow 15 4 in reverse 15a 6 Trouble shooting CONTROLLER LIGHTS DO N...

Page 34: ... lights flashing see FIG 1 CONTROLLER LIGHTS ON BUT POWERCHAIR WILL NOT DRIVE 1 Check that the drive lock devices are engaged 2 If no click audible from the motor when joystick is first moved check the brake connections 3 If clicks are heard check motor connections A P G PROGRAMMER REF PP1 MAY BE USED TO PROGRAM PARAMETERS AS LIST ED IN THE FOLLOWING TABLES Parameters should only be modified by a ...

Page 35: ...Soft Reverse Prevent Reversing Digging In 70 Set Current Limit Max Min Current Limits 25A Max 25A Min Set Foldback Temp Reduce Current At This Temp 55 C Set Timed Foldback Reduce Current After This Stall Time 25 60sec Set Compensation Match Motor Impedance 130 m ohm Set Battery Menu Match Controller to Loom Resistance 64 m ohm Set Park Brake Trip Chairs With No Brakes No Set Front Drive Front Whee...

Page 36: ... Fault code Engineering Menu Set Soft Reverse Prevent Reversing Digging In 70 Set Current Limit Max Min Current Limits 40A Max 40A Min Set Foldback Temp Reduce Current At This Temp 55 C Set Timed Foldback Reduce Current After This Stall Time 25 60sec Set Compensation Match Motor Impedance 130 m ohm Set Battery Menu Match Controller to Loom Resistance 64 m ohm Set Park Brake Trip Chairs With No Bra...

Page 37: ...37 SECTION 15 b Programmable Controller Dynamic DL 40A 15b 1 Diagram ...

Page 38: ...ase the four M5x8 Pozipan Screws which secure the Controller to the Controller Mounting Plate 15b 5 Programmable Controller Replacement Follow 15b 4 in reverse 15b 6 Trouble shooting CONTROLLER LIGHTS DO NOT COME ON 1 Check the circuit breaker push buttons have not sprung out 2 Check the cables are connected correctly to the Controller Batteries Motors 3 Ensure the batteries are fully charged and ...

Page 39: ...armer 4 Check that both parking brakes are released BATTERY CHARGER YELLOW MAINS LIGHT ON ONLY NO LIGHTS The mains supply is not reaching the charger Check that the mains is working and that the mains plug and fuse are in correct working order FLASHING LIGHTS This indicates that the battery voltage is low The charger has a safety feature which prevents it from commencing to charge if the battery v...

Page 40: ...F123 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 Type U rivet 2x1 4 F98 1 4 x 18G Plastic Plug M...

Page 41: ...ase 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 pa...

Page 42: ... fitted Check screw threads are not stripped particularly on push handle bracket Ensure armrests locate in push handle bracket when fitted to wheelchair Check for bending of armrest tube at insertion point 16 4 Dismantling Release nuts securing sockets to side frame and remove Slide sockets away from frame and remove spacers Release extension bracket from push handle 16 5 Fitting Replace spacers i...

Page 43: ... 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 scre...

Page 44: ...w 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 Place the tray symmetrically on the stem brackets ensuring that the flat plates are located between two guide strips on the under side of the tray Mark through...

Page 45: ...ns 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...

Page 46: ...J 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 F58 No 10 UNF Nyloc Nut zinc plated F24 M6 x 40 hex head bolt zinc plated F207 M6 Nyloc Nut zinc plated P80 M6 x 45 hex head bolt zinc plated F11 ...

Page 47: ...TE 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: ...er transfers to a vehicle seat and the wheelchair is transported separately However if this is not possible and the user intends to travel in a moving vehicle whilst seated in the wheelchair it is essential they follow clear safety guidelines and understand that this is not as safe as using the vehicle seat and is at their own risk It is the responsibility of the transport operator and the wheelch...

Page 49: ...ommend the Unwin 4 Point Tie Down system However it is important to ensure that the user restraint buckle is facing away from the wheelchair rear wheel to avoid danger of accidental unlatching This product has been used to transport users in motor vehicles over many years without serious incident and it must be decided by the user carer whether to do so at their own risk It is not as safe as trave...

Page 50: ...50 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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