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  5. Technical Manual

R.J.Mobility GEM MK III Technical Manual

Manual is about: The Proven Reliable Indoor/Outdoor Powerchair

Summary of GEM MK III

  • Page 1

    Page 1 r.J.Mobility 100 dewsbury road, elland. England. Hx5 9bg tel.No. 01422 324803 fax.No. 01422 372503 email - sales@rjmobility.Com website - www.Rjmobility.Com technical manual issue 15 january 2013 this technical manual will ensure that the wheelchair is maintained to the required standard and ...

  • Page 2

    Page 2 gem mk this technical manual contains important information regarding maintenance of the gem mkiii 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 whe...

  • Page 3: Contents

    Page 3 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 15 elevating legrest 16...

  • Page 4

    Page 4 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 controller. The occ...

  • Page 5: Section 2: Specifications

    Page 5 section 2: specifications (dimensions based on seat size 43cm x 43cm (17inch x 17inch) 1 overall length 100cm (39 inch) 2. Overall width 63cm (25 inch) 3. Folded length 76cm (30 inch) 4. Folded width 36cm (14 inch) 5. Folded height 64cm (25 inch) 6. Maximum weight 57kg (125.7 lbs) 7. Heaviest...

  • Page 6

    Page 6 section 3: wheelchair diagram 3.1 gem self-propelling powerchair.

  • Page 7

    Page 7 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 ...

  • Page 8

    Page 8 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 5 gradient and attempt to accelerate....

  • Page 9

    Page 9 section 5: tool requirements spanners: 1/4“ bsw legrest clamp see section 8 2-8mm a/f spanners parking brake see section 9 2- 10mm a/f spanners braces & links see section 20 1- 24mm af spanner castors see section 12 1-35mm af spanner power drive system see section 20 2- 7/16inch a/f spanners ...

  • Page 10: Section 6: Upholstery

    Page 10 section 6: upholstery 6.A diagram 6.1 parts list rj no backrest fabric ninian sf-062-15-17 sf-064e-17-17 seat fabric ninian g-83 sf-063e-17-17 backrest seat screw f-102 reinforcing bar sf-176 m5 screw cup f-101 m5 avdel 09657-01014.

  • Page 11

    Page 11 6.2 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 attac...

  • Page 12: Section 7: Armrests

    Page 12 section 7: armrests 7.A diagram adjustable armrest assy left gs-009 adjustable armrest assy right gs-010 7.1 parts list rj no armrest frame left g-244l armrest frame right g-244r 7.2 inspection check armpad for excess wear or damage. Check armpad is secured to frame. Ensure armrest locates i...

  • Page 13

    Page 13 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...

  • Page 14: Section 8: Footrest

    Page 14 section 8: footrest 8.A diagram hanger assy lh sp-406 hanger assy rh sp-407 8.1 parts list rj no footrest hanger with footplate assy complete left sp-261l plastic. Right sp-261r footplate assembly 8 1/2inch, complete left sp-306l with stem and heel loop.(alloy). Right sp-306r footplate assem...

  • Page 15

    Page 15 8.2 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. 8.3 footrest r...

  • Page 16: Section 9: Brakes

    Page 16 section 9: brakes 9.A diagram brake assembly gs-015/6 9.1 parts list rj no brake assembly left gs-015 brake assembly right gs-016 brake handle left g-255l brake handle right g-255r black ball knob kb5-125 brake pivot sf-173 brake lever left gs-001 brake lever right gs-002 brake shoe sf-174a ...

  • Page 17

    Page 17 9.2 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 there is no oil/grease on brake pad. 9.3 brake assembly removal remove the two 1/16inch ...

  • Page 18: Section 10: Push Handles

    Page 18 section 10: push handles 10.A diagram backrest assembly left g-223 backrest assembly right g-224 10.1 parts list rj no backrest assembly left g-223 right g-224 backrest tube assy left g-324l right g-324r plastic bung m-14 plastic bung m-14 plastic bung m-14 push handle l/r g-324l/r m5 avdel ...

  • Page 19

    Page 19 10.2 inspection check each backrest for evidence of bending. Check each backrest for evidence of cracking through nutsert holes. Check that push handle is secure to backrest. Check handgrip is secure. Check for free movement of the plunger. Lubricate with light oil. Check that the plunger lo...

  • Page 20

    Page 20 section 11: frame, locking links and cross brace 11.A diagram side frame assembly left gs007 side frame assembly right gs008 11.1 inspection check locking links for security of thumb catch and correct operation. The locking link should open/close easily and the thumb catch must hold securely...

  • Page 21

    Page 21 11.B diagram cross brace assembly 15“-sf 206 17“-sf 205 11.2 parts list rj no cross brace assembly 17" complete with fasteners sf205 cross brace assembly 15" complete with fasteners sf206 11.3 cross brace assembly removal remove the two m6 hex screws securing the cross braces to each side fr...

  • Page 22

    Page 22 11.4 cross brace and locking link assembly fitting fit the two m5 hex 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...

  • Page 23: Section 12: Castors

    Page 23 section 12: castors 12.A diagram 190mm wide profile m-171 12.1 parts list rj no 190mm wide profile mcp m-171 12.2 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 bo...

  • Page 24

    Page 24 section 13: power drive system 13.A diagram 13.1 parts list rj part no complete motor/wheel/plate/anti-tip assy left gs-011 complete motor/wheel/plate/anti-tip assy right gs-012 when ordering replacement motor/gearbox (e131l/r) assemblies it is necessary to specify the type of connector on t...

  • Page 25

    Page 25 13.B motor connectors 13.C motor brushes 13.2 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 be...

  • Page 26

    Page 26 13.3 motor brush removal & replacement when ordering replacement motor brushes it is necessary to determine whether the motor has cartridge brushes or non-cartridge brushes as shown in fig 13.C for non cartridge brushes proceed as follows. Disconnect the motor loom from the main loom, releas...

  • Page 27

    Page 27 13.6 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 (m-158) away from the b...

  • Page 28

    Page 28 13.9 anti-tip roller setting the function of anti-tip rollers on a power chair is to inhibit forward motion if an obstruction high- er than 100mm is encountered. Setting of the anti-tip rollers should be carried out as per the following instructions. 1-place the wheelchair on a suitable hard...

  • Page 29: 14.0 Batteries, Looms

    Page 29 14.0 batteries, looms & controls 14.A 14.1 parts list rj no battery box a12-10 battery box lid (front) g-352 battery box lid (rear) g-351 battery spacer a12-10 motor assembly * left e-131l motor assembly * right e-131r 30 amp/hr battery e-133 40 amp/hr battery e-128 circuit breaker (35a) e- ...

  • Page 30

    Page 30 14.2 battery looms earlier variants. 14.B 14.C 14.D 14.E 14.3 parts list rj no cliff plug assy e-142 cliff socket assy e-130 anderson powerpole shell e-112 anderson powerpole connector (red) e-013 anderson powerpole connector (black) e-014 anderson powerpole blade connector e-031 anderson bl...

  • Page 31

    Page 31 14.4 battery looms mk 111 pilot controller (standard) 14.5 parts list rj no pilot controller d49525 (40a) e-109 controller mtg plate g-278a controller arm a03-134 rear battery box lid and loom a10-16 neutric socket (nl4mp) e-149 neutric plug (nl4fcs) e-150 neutric crimp connector (4-per plug...

  • Page 32

    Page 32 p&g pilot 40a (d49525) parameters functions notes setting set acceleration 75% set deceleration 55% set turn acceleration 35% set turn deceleration 60% set forward speed 100% set reverse speed 50% set turn speed 40% set sleep timer 0 sec set steer correct veer compensation. 0 read fault log ...

  • Page 33

    Page 33 14.6 battery looms pilot plus 14.7 parts list rj no neutric socket (nl4mp) e-149 neutric plug (nl4fcs) e-150 neutric crimp connector (4-per plug) e-151 pilot plus control arm a10-12 pilot plus bus cable e-141 rear battery box lid and loom a10-16 pg80-b battery connector kit e-162 pg80-m moto...

  • Page 34

    Page 34 p&g pilot plus 50a (d49671) parameters functions notes setting set acceleration 60% set deceleration 55% set turn acceleration 15% set turn deceleration 60% set forward speed 100% set reverse speed 40% set turn speed 30% set sleep timer 0 sec set steer correct veer compensation. 0 read fault...

  • Page 35

    Page 35 14.8 battey looms dynamic dl 14.9 parts list rj no rear battery box lid and loom a10-16 neutric socket (nl4mp) e-149 neutric plug (nl4fcs) e-150 neutric crimp connector (4-per plug) e-151 controller extension g-067a controller mounting plate g-066a rear battery box loom a10-04. Front loom g-...

  • Page 36

    Page 36 dynamic dl 40a (dl40udh1) parameters.

  • Page 37

    Page 37 14.10 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 d...

  • Page 38

    Page 38 14.13 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 ...

  • Page 39

    Page 39 pilot & pilot plus 14.18 trouble shooting controller lights do not come on 1 check the circuit breaker push buttons have not sprung out. 2 check the cable are connected correctly to the: controller batteries motors 3 ensure the batteries are fully charged (and that the charger is not still c...

  • Page 40

    Page 40 dynamic dl controller 14.19 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 that the charger is not sti...

  • Page 41

    Page 41 section 15: elevating legrest 15.1 diagram elevating legrest assembly sp333l/r 15.2 parts list 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 legre...

  • Page 42

    Page 42 15.3 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. 15.4 elevating legrest removal remove the footrest assembly from t...

  • Page 43

    Page 43 section 16: armrest outriggers 16.1 diagram 16.2 parts list 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 ...

  • Page 44

    Page 44 16.3 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. 16.4 dismantling release ...

  • Page 45

    Page 45 section 17: detachable tray 17.1 diagram 17.2 parts list rj no tray bracket - left 296/32/l - right sf316r tray tray bracket 17.3 inspection check for damage to the tray, particularly for wooden splinters. Check security of attachment screw 'b' and check tray attachment screws for security. ...

  • Page 46

    Page 46 17.4 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...

  • Page 47: Section 18: Kerb Climber

    Page 47 section 18: kerb climber 18.1 diagram 18.2 parts list rj no kerb climber assembly g220 actuator g215 cross bar tube g220/3 sleeve g220/6 cross bar spring plate g220/4 m6x40 socket countersunk screw black zinc plated f91 m6x35 skt hd screw zinc plated f90 m6 nyloc nut zinc plated p80 m6x20 pl...

  • Page 48

    Page 48 18.3 kerb climber inspection with the kerb climber attached to the powerchair grasp the actuator and move backwards and forwards through an arc. Feel for any jerkiness which will indicate that the return spring is ruptured. This can be corroborated by measuring the height to the front edge o...

  • Page 49: Technical Manual

    Page 49 technical manual amendment record issue section date amended comments 12 all 26-10-04 complete re-write 13 14 22-01-08 pilot & pilot plus parameters revised.

  • Page 50

    Page 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.