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Barrett crystal Technical Manual

Manual is about: The Proven Reliable Indoor/Outdoor Powerchair

Summary of crystal

  • Page 1

    1 r.J.Mobility 100 dewsbury road, elland. England. Hx5 9bg tel.No. 01422 324830 fax.No. 01422 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 us...

  • Page 2

    2.

  • Page 3

    3 this technical manual contains important information regarding maintenance of the crystal powerchair thus ensuring its safe operation. Please make sure that you understand all instructions thoroughly. It is recommended that maintenance is undertaken at six monthly intervals for a wheelchair that i...

  • Page 4: Contents

    4 contents section 1 user categories 2 specifications 3 powerchair diagram 4 maintenance checks 5 tool requirements 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 ...

  • Page 5

    5 section 1: user categories a2 attendant controlled. Degree of upper body control to maintain sitting position. A4 occupant capable of using one hand to control the powerchair having spatial awareness, co-ordinated motor skills and sufficient manual dexterity to operate the control- ler. The occupa...

  • Page 6: Section 2: Specifications

    6 section 2: specifications (dimensions based on seat size 43cm x 43cm (17inch x 17inch) 1 overall length 100cm (39.5 inch) 2. Overall width nominal width+17.5cm (7 inch) 3. Folded length 78cm (31 inch) 4. Folded width 55cm (21.5 inch) 5. Folded height 55cm (21.5 inch) 6. Complete weight 70kg (154 l...

  • Page 7

    7 section 3: wheelchair diagram 3.1 crystal self-propelling 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 breake...

  • Page 8

    8 section 4: maintenance checks 4.1 open the powerchair, all movements should be free throughout the folding range. 4.1.1 examine the seat and backrest fabrics for wear, damage or staining. Examine retaining screws for tightness and general condition. (see section 6) 4.1.2 examine armrest pads for w...

  • Page 9: Important

    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 ...

  • Page 10

    10 section 5: tool requirements spanners: 1/4inch whitworth legrest clamp see section 8 10mm af heel loops see section 8 8mm af parking brake see section 9 1/4inch whitworth anti-tip device see section 11 1 5/16inch or 34mm af castors see section 12 1 5/16inch or 34mm af power drive system see secti...

  • Page 11: Section 6: Upholstery

    11 section 6: upholstery 6.1 diagram 6.2 parts list rj part no seat fabric ninian 14 x 17 inch 35.5cm x 43cm sf61-14-17 ninian 15 x 17 inch 38cm x 43cm sf61-15-17 ninian 16 x 17 inch 40.5cm x 43cm sf63-16-17 ninian 17 x 17 inch 43cm x 43cm sf63-17-17 ninian 18 x 17 inch 45.5cm x 43cm sf63-18-17 back...

  • Page 12

    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...

  • Page 13: Section 7: Armrests

    13 section 7: armrests 7.1.1 diagram (non-domestic) armrest assembly sp*** l/h sp*** r/h 7.1.2 parts list (non-domestic) rj part no armrest assembly complete - left xxsp2018l/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 pane...

  • Page 14

    14 7.3 inspection check armpad for excess wear or damage. Check armpad is secured to frame. Check side panel is not damaged. Ensure armrest locates in rear bracket on push handle when fitted to wheelchair. 7.4 armrest pad the armrest pad is secured to the armrest frame with three screws whilst the d...

  • Page 15: Section 8: Footrest

    15 section 8: footrest hanger assembly sp406 l/h 407 r/h 8.2 parts list rj part no footrest hanger with retaining - right sp406 clamp assembly m102 - left sp407 retaining clamp assembly m102 5/16 x 1 1/4 inch bolt, zinc plated f20 5/16 inch locking nut, zinc plated f21 5/16 inch washer, zinc plated ...

  • Page 16

    16 8.3 inspection check that footrest assembly locks into position. Apply light grease to swiveling end. Ensure that stem clamp holds footplate in position. Ensure that footplate will remain in vertical position when required. Ensure that there are no sharp edges/burrs which could injure user. 8.4 f...

  • Page 17: Section 9: Brakes

    17 section 9: brakes 9.2 parts list rj part no brake lh m-256l brake rh m-256r 9.3 inspection check levers for distortion. 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 ...

  • Page 18: Section 10: Push Handles

    18 section 10: push handles 10.1 diagram push handle assembly sp-404 l/h & sp-405 r/h (barrett style) sp-404-8l/9l l/h & sp-405-8l/9l r/h (90° 8l/9l style) 10.2 parts list rj part no push handle assy complete (barrett style) l/h sp-404 r/h sp-405 push handle assy complete (8l/9l style) l/h sp-404-8l...

  • Page 19

    19 10.3 inspection check each push handle for evidence of bending. Check each push handle for evidence of cracking through nutsert holes. Check handgrip is secure. Check for free movement of plunger. Lubricate with light oil. Check that plunger locates in the hole at rear of the side frame. Ensure n...

  • Page 20

    20 section 11: crossbrace assembly 11.1 diagram cross brace assembly sp205 there are two cross brace assemblies in this wheelchair which have identical parts. 11.2 parts list rj part no cross brace assembly 14" complete with fasteners sp-206-14 cross brace assembly 15" complete with fasteners sp-206...

  • Page 21

    21 11.3 inspection check cross braces for bending and evidence of cracks around pivot holes. Check each tab on the sideframes for evidence of bending, elongation or worn holes, and cracks in brazing or tubing. 11.4 cross brace assembly removal remove the two 1/4 unf set screws securing the cross bra...

  • Page 22

    22 11.7 parts list rj part no locking link assembly 14" complete with fasteners sp208-14 locking link assembly 15" complete with fasteners sp208-15 locking link assembly 16" complete with fasteners sp207-16 locking link assembly 17" complete with fasteners sp207-17 locking link assembly 18" complete...

  • Page 23: Section 12: Castors

    23 section 12: castors 12.1 diagram 190mm wide profile m-20 12.2 parts list rj part no 190mm wide profile mcp m-20 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...

  • Page 24

    24 section 13: power drive system 13.1 diagram 13.2 parts list rj part no motor & gearbox left e-131l right e-131r wheel/tyre assembly g-297/ass stub axle d-09l hex nut d-09 drive coupling m-155 spring m-156 bronze bush m-89 drive collar m-159 spacer m-157 nylon washer (large) f-67 nylon washer (sma...

  • Page 25

    25 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 ...

  • Page 26

    26 13.6 motor brake removal remove the motor cowl by releasing the two self-tapping screws and lifting off the motor cowl, being careful to feed the loom through the grommet so that no force is applied to the wiring. Disconnect the motor plug and brake wires and cut off the crimped spade connectors....

  • Page 27

    27 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 he...

  • Page 28: P&g Pilot

    28 section 14a: electrical system p&g pilot 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

    29 section 14b: electrical system 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

    30 14.3 electrical 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 31

    31 14.6 batteries and battery charging the batteries and battery charger require no maintenance but a check for function should be carried out. 14.6.1 battery inspection remove the batteries from the powerchair. Examine the batteries for any damage. Beware: acid-gel may leak from a damaged battery w...

  • Page 32

    32 section 15 a: programmable controller p&g pilot (25a & 40a) 15a.1 diagram.

  • Page 33

    33 15a.2 parts list rj part no controller pilot 25a (d49509) e-156 controller pilot 40a (d49525) e-109 controller extension a03-134 controller mounting plate g-278a m6x30 hex. Hd screw zinc plated f4125 m6 nyloc nut zinc plated p80 m5x8 pozipan screw zinc plated f18 black plastic bung m8 15a.3 inspe...

  • Page 34

    34 controller lights flash the penny & giles pilot controller has a built-in diagnostics system, which shows the re- lated fault by the number of lights flashing. A diagram below shows the related faults to the number of lights flashing (see fig 1). Controller lights on but powerchair will not drive...

  • Page 35

    35 functions notes setting set acceleration 75% set deceleration 55% set turn acceleration 35% set turn deceleration 60% set forward speed 50% set reverse speed 30% set turn speed 40% set sleep timer 0 sec set steer correct veer compensation. 0 read fault log display fault code history. Preset contr...

  • Page 36

    36 p&g pilot 40a (d49525) parameters functions notes setting set acceleration 50% set deceleration 50% set turn acceleration 45% set turn deceleration 50% set forward speed 100% set reverse speed 30% set turn speed 40% set sleep timer 0 sec set steer correct veer compensation. 0 read fault log displ...

  • Page 37

    37 section 15 b: programmable controller dynamic dl (40a) 15b.1 diagram.

  • Page 38

    38 15a.2 parts list rj part no controller extension g-067a controller mounting plate g-066a control dynamics dl controller (d40udh1) e-157 m5x8 pozipan screw zinc plated f-18 black plastic bung m-8 15b.3 settings the controller is set to program 2 (default settings). 15b.3 inspection check the m5 po...

  • Page 39

    39 15b.6 inspection (cont) 1) low battery voltage. 2) high battery voltage. 3) left motor fault. 4) right motor fault. 5) left/right park brake fault. 6) controller fault. 7) motor stalled or joystick out of neutral. 1. Controller lights on but powerchair will not drive. 1. Check that the drive clut...

  • Page 40

    40 section 16: elevating legrest 16.1 diagram elevating legrest assembly sp333 16.2 parts list rj part 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 ...

  • Page 41

    41 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 po...

  • Page 42

    42 section 17: armrest outriggers 16.1 diagram armrest assembly sp201-8l/9l armrest assembly sp364 (domestic) 16.2 parts list rj part no armrest socket extension assembly sf-307 armrest outrigger tab sf-305 1/4”unfx21/2” bolt zinc plated f-80 1/4” unf nut zinc plated p-90 2ba x 3/8 pozi pan machine ...

  • Page 43

    43 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 ...

  • Page 44

    44 section 18: detachable tray 18.1 diagram 18.2 parts list rj part no tray bracket - left sf316l - right sf316r tray gwd 837 tray bracket gwd 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 ...

  • Page 45

    45 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 re-tighten. Insert the tubular mounting stems complete with stem brackets supplied with the tra...

  • Page 46

    46 section 17: reclining backrest 17.1 diagram reclining backrest assembly g104. 17.2 parts list rj 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 ...

  • Page 47

    47 certificate 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: Section 19: Transportation

    48 section 19: transportation 19.1 diagram all of the wheelchairs in our range are designed to be easily transported and most of them dismantle into manageable parts in seconds. Consideration should be given to the type of vehicle in which the wheelchair may be carried. A small car with a heavy powe...

  • Page 49: Amendment Record

    49 the wheelchair should be secured to the vehicle floor in-line with the direction of travel. The occupant should be separately restrained to the vehicle and not to the wheelchair. Installers and operators of restraint systems should be trained in their correct use by the restraint manufacturer, or...

  • Page 50

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