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Barrett Jewel Technical Manual

The proven reliable indoor powerchair
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TECHNICAL MANUAL
The Proven
Reliable
Indoor
Powerchair
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
R.J.Mobility
100 Dewsbury Road, Elland. England. HX5 9BG
Tel.no. 01422 324830
Email - sales@rjmobility.com
Website - www.rjmobility.com
Jewel
Fax.no. 01422 372503

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  • Page 1 Jewel TECHNICAL MANUAL The Proven Reliable Indoor Powerchair 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 R.J.Mobility 100 Dewsbury Road, Elland. England. HX5 9BG Tel.no.
  • Page 3 This Technical Manual contains important information regarding maintenance of the Jewel Powerchair thus ensuring its safe operation. Please make sure that you under- stand all instructions thoroughly. It is recommended that maintenance is undertaken at six monthly intervals for a wheelchair that is in constant daily use.

  • Page 4: Table Of Contents

    Contents SECTION User Categories Specifications Powerchair Diagram Maintenance Checks Tool Requirements Upholstery Armrests Footrests Brakes Backrest Frame, Locking Links And Cross Braces 12 Cators Power Drive System Electrical System Programmable Controller Elevating Legrest Armrest Outriggers Detachable Tray Kerb Climber...

  • Page 5: User Categories

    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 foldaway powerchair.

  • Page 6: Specifications

    SECTION 2: Specifications (Dimensions based on seat size 43cm x 43cm (17inch x 17inch)) Overall length 89cm (35inch) 2. Overall width 54cm (21inch) 3. Folded length 64cm (25inch) 4. Folded width 38cm (15inch) 5. Folded height 55cm (21.5 inch) 6. Maximum weight 50kg (110 lbs)
  • Page 7 SECTION 3: Wheelchair Diagram 3.1 Jewel Self-Propelling Powerchair...

  • Page 8: Maintenance Checks

    4.2.7 The battery charger is maintenance free, the only serviceable part is the fuse fitted to the mains plug. See Section 14.7 for comprehensive instruction. 4.2.8 Ensure the batteries are fully charged. 4.2.9 Drive the Jewel at maximum speed in forward, reverse, left and right directions checking that the joystick response is uniform.
  • Page 9 4.2.10 Switch off the controller, hold the joystick forward and switch the controller on; the powerchair must not drive. Release the joystick for two seconds and then the powerchair will drive normally. 4.2.11 Slowly drive the powerchair up a maximum 1 in 6 gradient and attempt to accelerate. The powerchair will climb at normal speed.
  • Page 10 SECTION 5: Tool Requirements Spanners: 1/4inch Whitworth Legrest Clamp See Section 8 10mm Heel Loops See Section 8 8mm AF Parking Brake See Section 9 7mm Socket and Drive Rear Lock Link Section 1/4inch Whitworth Anti-tip Device See Section 11 1 5/16inch or 34mm AF Castors See Section 12 1...

  • Page 11: Upholstery

    SECTION 6: Upholstery 6.1 Diagram 6.2 Parts List RJ No Backrest Fabric Ninian G295/Size Seat Fabric Ninian SF453/Size Reinforcing Bar SF176 No. 10 x 3/4 UNF Csk Screw Black Zinc Plated No. 10 Flanged Screw Cup No. 10 UNF Avdel Nutsert 09657/01014 No.
  • Page 12 6.3 Inspection Fabric: Check for staining, wear, tear and stitching. Check nut inserts in frame for security and stripped threads. Check securing screws for bending and stripped threads and burrs. Cushions (if fitted); Check cushions for staining, wear, tear and stitching. Check Velcro attachment tabs are present and secure.

  • Page 13: Armrests

    SECTION 7: Armrests 7.1 Diagram ARMREST ASSEMBLY LEFT G244-ASSL ARMREST ASSEMBLY RIGHT G244-ASSR 7.2 Parts List GZF No RJ No Armrest Frame Left G244L Armrest Frame Right G244R Armrest Pad M170 No. 12 x 1 1/4 Pozi Pan Self Tapper Screw Zinc Plated F111 5/8 x 20G Black Round Insert 7.3 Inspection...
  • Page 14 7.4 Armrest Lock Assembly To dismantle the assembly, place a screwdriver or similar tool between the starlock washer (F37) and the lock lever (TSD 1323) and prise apart. Remove the starlock washer, plain washer (Q5) and the lock lever. Withdraw the lock pin (TSD 1306) and plunger spring (TSD 1229) from the pin housing in the armrest location tube.
  • Page 15 SECTION 8: Footrest 8.1 Diagram HANGER ASSEMBLY SP231S 8.2 Parts List GZF No RJ No Footrest Hanger with retaining Right SP261S/R clamp assembly M102 Left SP261S/L Retaining Clamp Assembly M102 5/16inch x 1 1/4inch Clamp Bolt, zinc plated 5/16inch Clamp Locking Nut, zinc plated 5/16inch Washer, zinc plated F22 Footplate Assembly 8 1/2inch, complete...
  • Page 16 8.3 Inspection Check that footrest assembly locks into position. Apply light grease to swivelling end. Ensure that stem clamp holds footplate in position. Ensure that footplate will remain in vertical position when required. Ensure no sharp edges/burrs which could injure user. 8.4 Footrest Removal Remove the footrest assembly from the powerchair by lifting and rotating the hanger section.

  • Page 17: Brakes

    SECTION 9: Brakes 9.1 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...
  • Page 18 9.3 Inspection Check ball knob for security. Check levers for distortion. Check brazed joints for cracks. Check pivot shafts for distortion. Replace pivot bolts if necessary due to excessive wear. Ensure no oil/grease on brake pad. 9.4 Brake Assembly Removal Remove the two 1/16inch Split Pins from the Brake Pivot shaft and Brake Lever shaft.

  • Page 19: Backrest

    SECTION 10: Backrests 10.1 Diagram BACKREST ASSEMBLY LEFT G223 BACKREST ASSEMBLY RIGHT G224...
  • Page 20 10.2 Parts List GZF No RJ No Backrest Assembly Left G223 Backrest Assembly Right G224 Backrest Frame Left 335/965 G246L Backrest Frame Right 336/966 G246R Sliding Peg Sliding Peg Handle G244 Black Plastic Bung Knurled Plastic Nut 3/16x1 Spring Pin Black Zinc Plated 1/4 Brass Washer 1/4 UNF Type P Nyloc Nut Zinc Plated Sliding Peg Spring...
  • Page 21 SECTION 11: Frame, Locking Links And Cross Brace 11.1 Diagram SIDE FRAME ASSEMBLY LEFT 300-19L SIDE FRAME ASSEMBLY RIGHT 300-19R 11.2 Parts List GZF No RJ No Side Frame Assembly Left G1 Side Frame Assembly Right G2 3/4 Square Black Plastic Bung M11 1 3/8x5/8 Black Plastic Bung M195 No.
  • Page 22 11.4 Diagram CROSS BRACE ASSEMBLY SF 205 11.4 Parts List GZF No. RJ No Cross Brace Assembly 17" Complete with Fasteners SF205 Cross Brace Assembly 15" Complete with Fasteners SF206 1/4 UNF Nyloc Nut 1/4 x 1 5/8 UNF Hex Head Bolt Zinc Plated 1/4 x 1 3/4 UNF Hex Head Bolt Zinc Plated 1/4 Brass Washer F30 1/4 x 1 UNF...
  • Page 23 11.8 Cross Brace and Locking Link Assembly Fitting Fit the two 1/4 UNF set screws securing the Cross Braces to each side frame. 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.
  • Page 24 11.12 Locking Link Assembly Removal Remove the 1/4 UNF Socket Cap Screw securing the Locking Link to each side frame. 11.13 Locking Link Assembly Fitting Fit the two 1/4 UNF Socket Cap Screws to secure the Locking Link assembly to each side frame. Tighten until the Locking Link is just securely held, then loosen the nut half a turn.
  • Page 25 SECTION 12: Castors 12.1 Diagram 190mm Wide Profile M51 12.2 Parts List GZF No RJ No 190mm wide profile MCP 12.3 Inspection Check for excessive wear in crown bearings and wheel spindle. Replace castor if necessary. Check for condition of stud which screws into frame. View frame and check both castor mounting tubes are at the same angle, checking for frame distortion due to impact damage, replace if necessary.

  • Page 26: Power Drive System

    SECTION 13: Power Drive System 13.1 Diagram 13.2 Parts List GZF No RJ No Motor & Gearbox Left E95L Motor & Gearbox Right E95R Motor Brush Replacement (Not Shown) Wheel Assembly G297/ASS Stub Axle Hex Nut Drive Coupling M155 Spring M156 Bronze Bush Drive Collar M159 Spacer...
  • Page 27 13.3 Inspection The motor/gearbox/wheel assembly is mounted securely to the motor, which should be securely attached to the side frame. Check the tyre for excessive wear and the wheel for signs of damage. Check for rim-rock which will indicate worn bearings and/or stub axle. Maximum allowable is 5mm total.
  • Page 28 13.6 Motor Brake Removal IMPORTANT Investigate warranty status before proceeding. Failure to do so may invalidate your warranty. Motor and gearbox maintenance is limited to complete assembly replacement except replacing motor brakes and brushes. Check Brake and Motor functions operate correctly after any maintenance when completed.
  • Page 29 13.9 Drive Coupling Removal and Replacement If it is only necessary to remove part of the drive assembly the following procedure applies. Support the rear of the powerchair on suitable stands and disconnect the motor wiring loom from the main loom. Bend the tab washer (M158) away from the bolt head and using a 10mm spanner remove the drive securing bolt (F95).

  • Page 30: Electrical System

    SECTION 14: Electrical System 13.1 Diagram 14.2 Parts List GZF No RJ No Main Wiring Loom G202 Battery Loom 201/18 Motor Assembly Left E94LL Motor Assembly Right 623 E94R 30 Amp/Hr Battery E75/30amp/hr Circuit Breaker...
  • Page 31 14.3 Electerical System Inspection A full function test of the powerchair should be carried out to determine any major faults which will be indicated by flashing lights on the controller. By reference to Section 15 the fault may be diagnosed. Check the condition of the main wiring loom for damage.
  • Page 32 14.6 Circuit Breaker Removal and Refitment Follow the above procedure for removal of the battery wiring looms. When the wiring loom has been pulled off the circuit breaker it can be removed from the battery box lid. Grasp the circuit breaker with one hand and with a pair of pliers grip the serrated nut on the outside and release.

  • Page 33: Programmable Controller

    SECTION 15 : Programmable Controller 15.1 Diagram...
  • Page 34 15.2 Parts List GZF No RJ No Penny & Giles Pilot Controller Controller Extension A03/134 Controller Mounting Plate G278A P&G Pilot Controller E108 1X1 1/8 UNF Hex. HD Screw Zinc Plated 1/4 UNF Nyloc Nut Zinc Plated P90 M5x8 Pozipan Screw Zinc Plated F18 Black Plastic Bung Control Dynamics DL Controller Controller Extension...
  • Page 35 15.6 Inspection Each controller acts as a diagnostic system and if a fault is detected the battery gauge will flash to a pre-determined sequence. Control Dynamic DL Controller The three colour illuminated display onthe top surface of the DL Controller acts as both a fuel gauge and a warning gauge.
  • Page 36 Pilot Controller The battery gauge is a 10 segment illuminated display which indicates if the controller is turned on and also gives the status of the battery, the controller and the powerchair electrical system. Red, Yellow and Green bars lit Battery charger;...

  • Page 37: Elevating Legrest

    SECTION 16: Elevating Legrest 16.1 Diagram ELEVATING LEGREST ASSEMBLY SP333 16.2 Parts List GZF No RJ No Legrest Assembly Complete Left SP333L Right SP333R Legrest Trigger Spring SP234 Elevating Rod SF123 Legrest Trigger SF122 Legrest Trigger Bracket SF121 Legrest Stem, Left or Right SF120 Legrest Carrier Bracket, Left or Right SF95...
  • Page 38 16.3 Inspection Check heel loop for security. Nuts should be tightened to 10 lbs/ft (13 Nm). Check pivot bolt for wear. Check calf pad for wear/damage. Check adjustment rod for bending. Check footplate maintains set position. 16.4 Elevating Legrest Removal Remove the footrest assembly from the powerchair by lifting and rotating the hanger section.

  • Page 39: Armrest Outriggers

    SECTION 17: ARMREST OUTRIGGERS 17.1 Diagram 17.2 Parts List GZF No RJ No Armrest Outrigger Socket Assembly - Left G273/ASS/L Armrest Outrigger 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...
  • Page 40 17.3 Inspection Check for damage to sockets. Ensure spacers are fitted. Check screw threads are not stripped particularly on backrest bracket. Ensure armrests locate in backrest bracket when fitted to powerchair. Check for bending of armrest tube at insertion point. 17.4 Dismantling Release nuts securing sockets to side frame and remove.

  • Page 41: Detachable Tray

    SECTION 18: Detachable Tray 18.1 Diagram 18.2 Parts List GZF No RJ No Tray Bracket - Left 296/32/L - Right SF316R Tray Tray Bracket 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 18.4 Assembly Remove plastic bung 'A'. Remove screw 'B'. Insert 3/4 inch diameter tube item 'C' over end of armrest tube. Line up holes in item 'C' with screw hole in armrest tube. Insert screw 'B' and retighten. Insert the tubular mounting stems complete with stem brackets supplied with the tray, into the armrest stem assembly with the horizontal extensions of the mounting stems projecting forward.
  • Page 43 Technical Manual Amendment Record ISSUE SECTION DATE COMMENTS AMENDED...
  • Page 44 Maxi Independent Maxi Meteor Barrett Jewel Meteor Independent Barrett 10 Original Meteor Barrett 7 Mini Meteor Barrett Gem Baby Barrett Barrett 101 Tilt & Space Portering...

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