ALCO CLASSIC line AL-83056 User manual
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COMPONENTS
Your power wheelchair is shipped partially dissembled to protect it during shipping. After
unpacking, please check whether you have received the following main components as our
standard specification (See Fig.1).
1. Chassis 6. Handle support frame
2. Seat 7.Footrest frame (Right)
3. Charger 8. Footrest frame (Left)
4. Handle bar9.Footrest (Right)
5. Basket 10.Footrest (Left)
1 2 3 4
5 6 7 8 9 10
(Fig 1)
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SAFETY INSTRUCTION
Operation of Wheelchair
1.Always ensure that the power is switched off when getting in or out of the
wheelchair. This will eliminate the possibility of causing injury to yourself or others.
2.Always check that the drive wheels are engaged (drive mode) before driving.
3.Set the speed control knob according to your driving ability and the environment in
which you are going to operate. We recommend that you keep your speed at the
slowest position (press the deceleration button) until you are familiar with the
driving characteristics of the vehicle. We also recommend that you use the slowest
speed when using your power wheelchair indoors.
4.Always reduce your speed when making sharp turns.
5.Do not switch off the power when the wheelchair is still moving forward. This will
bring the chair to an extremely abrupt stop.
6.Avoid jerky stop/start motions as the will result in excessive current draw from the
batteries, increased tire wear and the rapid wearing of the gearboxes and motors.
7.To brake in an emergency, simply release the forward/reverse lever.
Ramps and Curbs
8. When driving up or down ramps, be sure to check that the angle of the slope is
less than 10 degrees (slopes about 1/6). Also check that ramp surface is roughened
to prevent slipping. Never drive across the slope or turn sharply on a slope.
9. When driving up curbs, always check the height of the curb to ensure that it does
not exceed 1-1/2” height.
Transfers, Reaching and Bending
10. Transferring on and off requires a good sense of balance. To eliminate the
possibility of injury, wet recommends performing the following tasks before
attempting a transfer:
→Position the wheelchair so that the distance between your power wheelchair
and the object to which you are transferring it is close enough for a safe
transfer.
→Turn the power off
→Ensure that your power wheelchair not in freewheel mode.
→Flip up or remove armrests
11. When reaching, bending or leaning while seated on your power wheelchair, make
sure that you maintain a stable center of gravity to keep it from tipping.
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General
12. Always use a seat belt, and keep your feet on the wheelchair all the time.
13. For safety reasons, make sure that your weight does not exceed the recommended
weight limit of the wheelchair. Consult your dealer for the specified weight limits
for your particular model.
14. Do not attempt to lift or move a power wheelchair by any of its removable parts.
Personal injury and damage to the power wheelchair may result.
15. Never try to use your wheelchair beyond its limitations as described in this
manual.
16. Do not operate your vehicle if it is not functioning properly.
17. Do not connect any electrical or mechanical device to the vehicle. Failure to obey
this instruction may result in injury and will void the warranty.
18. Never use electronic radio transmitters such as CB, walkie-talkies, portable
computers or cellular phones while using the vehicle without first turning the
vehicle off.
Use While Under The Influence Of Medication Or Alcohol
19. Check with your physician if you are taking any medication that may affect your
ability to operate your power wheelchair safely.
20. Do not operate your vehicle while you are under the influence of alcohol, as this
may impair your ability to operate your power wheelchair in a safe manner.
Electromagnetic interference (EMI) from Radio Wave Sources
The rapid development of electronics, especially in the area of communications, has
saturated our environment with electromagnetic (EM) radio waves that are emitted by
television, radio and communication signals. These EM wave are invisible and their
strength increases as one approaches the source. All electrical conductors act as
antennas to the EM signals and, to varying degrees, all power wheelchairs and scoot-
ers are susceptible to electromagnetic interference (EMI). The interference could
result in abnormal, unintentional movement and/or erratic control of the vehicle. The
United States Food and drug Administration (FDA) suggests that the following
statement be incorporated to the user’s manual for all power scooters like the PT3.
Power wheelchairs and motorized scooters (in this section, both will be referred to as
powered scooters) may as susceptible to electromagnetic interference (EMI), which is
interfering electromagnetic energy emitted from sources such as radio stations, TV
stations, amateur radio (HAN) transmitter, two-way radios and cellular phones. The
interference (from radio wave sources) can cause the power scooter to release its
brakes, move by itself or move in unintended directions. It can also permanently
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damage the power scooter’s control system. The intensity of the EM energy can be
measured in volts per meter (V/m). Each power scooter can resist EMI up to a certain
intensity. This is called “immunity level”. The higher the immunity level, the greater
the protection. At this time, current technology is capable of providing at least 20 V/m
of immunity level, which would provide useful protection against common sources of
radiated EMI.
Following the warnings listed below should reduce the chance of unintended brake
release or power wheelchair movement that could result in serious injury:
1. Do not turn on hand-held personal communication devices such as citizens band
(CB) radios and cellular phones while the power wheelchair is turned on.
2. Be aware of nearby transmitters such as radio or TV stations and try to avoid
coming close to them.
3. If unintended movement or brake release occurs, turn the power wheelchair off as
soon as it is safe.
4. Be aware that adding accessories or components, or modifying the power
wheelchair, may make it more susceptible to interference from radio wave sources
(Note: It is difficult to evaluate the effect on the overall immunity of the power
wheelchair).
5. Report all incidents of unintended movement or brake release to the power
wheelchair manufacturer, and note whether there is a radio wave source nearby.
TURN OFF YOUR POWERED SCOOTER AS SOON AS POSSIBLE WHEN
EXPERIENCING THE FOLLOWING:
‧Unintentional motions
‧Unintended or uncontrollable direction.
‧Unexpected brake release
The FDA has written to the manufacturers of power scooters asking them to test new
products to be sure they provide a reasonable degree of immunity against EMI. The
FDA requires that a power wheelchair should have an immunity level at least 20 V/m,
which provides a reasonable degree of protection against more common sources of
EMI. The higher the immunity level, the greater the protection. Your power
wheelchair has an immunity level of 20 V/m which should protect against common
sources of EMI.
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ENVIRONMENTAL CONDITIONS
Environmental conditions may affect the safety and performance of your power
wheelchair. Water and extreme temperatures are the main elements that can cause
damage and affect performance.
A) Rain, Sleet and Snow
If exposed to water, your power wheelchair is susceptible to damage to electronic
or mechanical components. Water can cause electronic malfunction or promote
premature corrosion of electrical components and frame.
B) Temperature
Some of the parts of the power wheelchair are susceptible to change in
temperature. The controller can only operate in temperatures that range between
18℉and 122℉.
At extreme low temperatures, the batteries may freeze, and your power wheelchair
may not be able to operate. At extremely high temperatures, it may operate at slower
speeds due to a safety feature of the controller that prevents damage to the motors and
other electrical components.
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ASSEMBLY INSTRUCTION
Follow the procedures listed below for easy assembly of your wheelchair:
1. Installing the Seat (#2)
Insert the handle support frame (#6) into the seat frame and use the Allan key to
tighten the frame. (See Fig 2, 3)
(Fig 2) (Fig 3)
Insert the footrest frame (#7, 8) into the seat frame and use the Allan key to tighten
the frame. (See Fig 4, 5)
(Fig 4) (Fig 5)
Put the seat (#2) axle into the seat post of
the chassis (See Fig 6).
(Fig 6)
Handle
support frame
Allan key
Footrest
Frame
Allan key
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2. Installing the Handle Bar (#4)
Insert the handle bar (#4) into the handle support frame. Put the ball pin into the
desired hole and tighten the quick release lever. (See Fig 7, 8)
(Fig 7) (Fig 8)
Then connect the hardness plug. (Fig 9)
3. Install the Basket (#5)
Put the slots of basket on the hook of the bracket assembled on the handle bar. (Fig
10)
(Fig 9) (Fig 10)
3.Installing the Footrest (#9, 10)
Insert the footrest (#9, 10) into the footrest frame by side way (See Fig 11). Then
swing away the footrest in the correct position on both sides. (See Fig 12)
Handle Bar
Ball Pin
Quick
release
Lever
Hardness
Plug
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(Fig 11) (Fig 12)
ADJUSTMENTS FOR SEATING COMFORT
To maximize seating comfort, your power wheelchair lets you adjust:
→Tiller angle
→Armrest folding
→Seat rotation
→Backrest folding
A. Tiller Angle Adjustment
→loosen the angle adjustment lever
→pull up the tiller and adjust the angle
→place the tiller into the slot
→tighten the round shaped adjustment knob (See Fig 13)
B. Armrest Folding
You can fold or unfold your backrest by manual adjustment. (See Fig 14)
(Fig 13) (Fig 14)
C. Seat Rotation Adjustment
→press down on the seat rotation lever
→rotate your seat both clockwise or counter-clockwise (See Fig 15)
→let the lever lock into the corresponding notch
Note: There is a lock in 45° position
whenever you turn clockwise
or counter-clockwise.
Lever
Lever
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(Fig 15)
D. Backrest Folding Adjustment
You can fold your backrest by pulling the tension knob, then the tension knob will
lock into the corresponding notch. (See Fig16)
(Fig 16)
Tension
Knob
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OPERATION
The power wheelchair is simple to operate. However, we recommend that you
carefully read the following instructions to become familiarized with your new
vehicle.
A Word of Caution:
Before you turn the power on, always be aware of the environment that surrounds you
to select your desired speed. For indoor environments we recommend that you select
the slowest speed setting. For outdoor operation of this vehicle we recommend that
you select a safe, comfortable speed.
The following steps are required to operate your vehicle safely with the controller
(See Fig. 17) The fig shows the display of your power wheelchair.
(Fig 17)
Button functions
1. Remaining Fuel Meter: When your wheelchair is switched on, the needles on the
meter will move across the scale from the left 'red' sector towards the 'green'
sector, indicating the state of charge in your batteries. As the power is used up in
your batteries the needle will move towards the 'red' sector indicating the state of
charge at that precise time. When the needle is fully over to the right, the batteries
are fully charged. When the needle falls towards the red sector your batteries are
losing power, but you will still have power to spare. When the needle falls into the
red sector your batteries are low in power and need to be recharged. It is wise to
recharge your batteries when the needle enters the red zone (see Batteries and
Battery Charging section of this manual).
Key
Horn
Button
Remaining
Fuel Meter
Power On/Off
Light
Manual
Speed
Adjuster
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2. Manual Speed Adjuster: This allows you to pre-select your desired speed. The
adjuster is proportional to speed and can be set anywhere between 1 and 5
increments. Turn the adjuster knob counter-clockwise to minimum for a very
gentle operation, and clockwise towards maximum to increase your speed.
3. Power ON/OFF Light: The light will turn on if you insert the key. The light will
turn off if you take the key out.
4. Horn button: Press this button to sound the horn. (Easy operation for left hand or
right hand)
A. Driving:
Insert the key to turn the wheelchair on (Remove the key to shut off the power).(See
Fig 17) Swing the finger lever control forward or backward to control the driving
direction of the vehicle (The finger lever control located both sides of the controller
(See Fig 18).
1. Controller ON/OFF Switch
(Fig 18)
Returning the finger lever control to its neutral position, (center), will
reduce the speed and stop the vehicle by automatically applying the electromagnetic
brakes.
2.Speed Control
1. Turn the adjuster knob clockwise towards maximum to increase your speed,
and counter-clockwise toward minimum to slow down your speed.
2. Finger Lever Control
The finger lever control controls the speed of your vehicle. The farther away
(forward / backward) the finger lever control is from the neutral position, the faster
the vehicle will go.
Notes:
→After inserting the key into the ON/OFF port, the ON/OFF light will turn on
Finger Lever Control
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for a few seconds during the self-checking process
→When the vehicle is in operation, the surface of the charger will become
slightly hot
→In case of emergency, let go of the finger lever control and the vehicle will
come to a stop
B. Controller Display
The controller display is a multifunction visual display. It can provide a lot of
information of the vehicle. (Shown as Fig. 17)
＃When the needle falls into the red sector your batteries are low in power and
need to be recharged. We strongly recommend that you recharge your batteries
when the needle enters the red zone.
＃Power ON/OFF will flash when the battery voltage is lower than 23.3V.
That means the batteries need to be charged.
＃System will lock when the vehicle has not been used for over 30 minutes. To
restart the wheelchair, remove the key and re-insert it.
C. Free-Wheeling
The motors are designed to engage the electromagnetic brakes when the vehicle is
not in use or when the power is OFF. They also have a manual feature that allows
them to “free-wheel”. Free-wheeling is accomplished by adjusting the
free-wheeling levers to the free-wheeling position. (See Fig 19)
Warning !→Never free-wheel your power wheelchair on a slope.
→Never free-wheel the motors while operating your vehicle.
→Always remember to engage the motors before turning the power ON.
(Fig 19)
Electromagnetic Brakes:
Free Wheeling
Lever
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Your power wheelchair comes with electromagnetic brakes, i.e. an automatic
magnetic disc safety brake which is also known as a fail-safe brake. The electro-
magnetic brakes are automatic and work when the power wheelchair is ON but in a
steady state (i.e. when the wigwag is released to the neutral position), even when
the wheelchair is on a slope. The electromagnetic brakes will also be set whenever
the power wheelchair is OFF, but when the motor levers are in the engaged
(vertical) position.
Note: Please refer to the section titled to check brake in the Maintenance & Repair
section in page 18 to make sure the brakes are in good condition.
D. Thermal Protection:
Your power wheelchair controller is equipped with a safety system called thermal
rollback. A built-in circuit monitors the temperature of the controller and motors,
and the controller reduces the motor voltage and speed of the power wheelchair.
The reduction of the speed allows the electrical components to cool down.
Although your power wheelchair will resume its normal speed when the
temperature returns to a safe level, we recommend that you turn the power off and
wait for 5 minutes before restarting to allow the components to cool down if you
find that you have lost speed suddenly.
E. Main Circuit Breaker:
The PF6 main circuit breakers reset button located in the rear of the base frame
after taking out of the shroud.(See Fig 20 )
one minute and then depress the button to reset it (Fig 20)
Then turn on the controller power, and continue normal operation. If the main circuit
breaker continues to trip repeatedly, contact your authorized dealer.
The main circuit breaker monitors the
electric current drawn from the battery.
It is a safety feature built in your power
wheelchair for your extra safety. When the
batteries and motors are heavily strained
(e.g., from excessive loads),the main
circuit breaker will trip to prevent damage
to the motor and the electronics. If the
circuit breaker trips, wait for approximate
Brake
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BATTERIES & CHARGER
BATTERY
We recommend that you use deep-cycle batteries that are sealed and maintenance
free for your power wheelchair. Both sealed lead-acid (SLA) and gel cell are
deep-cycle batteries and are similar in performance. Deep-cycle batteries are
specifically designed to provide power, drain down, and then accept a relatively
quick recharge. Lead-acid batteries should be charge as often as possible.
Specification of the battery that we recommend:
Type:
Size:
Voltage:
Amp Hours:
Deep –cycle sealed lead-acid or gel cell
34AH
12V each
34 amp hours
Depending on the use, terrain and driving conditions, the batteries will provide a
range of 18 miles of travel. However, even if the power wheelchair is not in use,
we recommend that the batteries be charged periodically.
Note:
→Do not use any automotive batteries. They are not designed to handle a long,
deep discharge and also are unsafe for use in the power wheelchair.
CHARGER
The battery charger takes the standard wall outlet voltage (alternating current) and
converts it into VDC (direct current). The batteries use the direct current to run
your power wheelchair. When the batteries are fully charged, the amperage from
the charger is almost at zero. This is how the charger maintains a charge but does
not overcharge the battery.
Note: The batteries are not chargeable after they are discharged to nearly zero
voltage.
CHARGING INSTRUCTIONS
To recharge the batteries, follow the steps below:
→Place your power wheelchair close to a standard electrical wall outlet.
→Remove your key to let the power OFF
→Slide the charger port door open. (The direction of opening port door refers
with the printing on the plastic cover. See Fig. 21 )
→Plug the XLR connector of the charger to the charger port. (See Fig 22)
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→Plug the other end of the power cord into a standard wall outlet.
→When charging is completed, fuel capacity indicator is shown.
→Disconnect the charger power cord from the wall outlet when the batteries are
fully charged.
(Fig 21)
Important!
Do not use for voltage input except the specified. Make sure your present voltage
input (110V or 220V) and adjust manually. (See Fig 23)
plug-in controller plug-in wall outlet (Fig 23)
(Fig 22)
1. Recharge battery only when the key is in off position. Your battery will be
fully recharged when the inhibit is at the low position.
2. Battery capacity only goes higher when recharging is in progress, regardless
the battery voltage.
Note:
→Always charge your batteries in well-ventilated areas.
→The charger is intended for indoor use only. Protect from moisture.
→For maximum performance, it is recommended that you replace both batteries
at the same time if the batteries are weak.
→If the vehicle will not be used for a long period of time, arrange to have the
Charge
Port Door
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batteries fully charge for at least once every month.
According to the battery type and condition of the batteries, batteries usually can
be fully charged in 4-10 hours. This will be indicated when the status light in the
battery charger side panel turns green; charging the battery longer than necessary
will not harm the battery. We recommend that you charge the batteries for 8 to
10 hours after daily use. Do not charge the batteries for more than 24 hours.
Note: There is a battery circuit diagram labeled on the backside of the shroud.
Please refer this diagram before you assemble the battery.
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MAINTENANCE & REPAIR
Your power wheelchair is designed for minimal maintenance. However, like any
motorized vehicle it requires routine maintenance.
To keep your power chair for years of trouble-free operation, we recommend
you follow the following maintenance checks as scheduled.
DAILY CHECKS
1. Visually inspect the controller harnesses. Make sure that they are not frayed,
cut or have any exposed wires.
2. Inspect the battery condition meter on the controller to determine if batteries
need to be charged.
WEEKLY CHECKS
1. Check for proper tire inflation. Your power wheelchair comes with standard
flat-free solid tires. If your power wheelchair comes with optional air tires,
make sure to maintain the pressure of the tires between 30-35 psi.
2. Check the brakes. This test should be carried out on a level surface with at
least three feet of clearance around your power wheelchair.
To check the brakes (your power wheelchair may move slightly when performing
this test):
→Turn on the controller and turn down the speed and response adjustment knob.
→After one second, check that the battery condition meter remains on condition.
→Slowly push the finger lever control forward until you hear the parking brakes
click. Immediately release the finger lever control. You must be able to hear
each parking brake operate within a few seconds of lever release.
→Repeat this test of the brake for the back positions.
SEMI-ANNUAL CHECKS
1. Check the motor brushes. We recommended that your authorized dealer inspect
the brushes every six months, or sooner if your power wheelchair is not operating
smoothly. If inspection determines excessive wear on the brushes, they must be
replaced or motor damage will result.
Warning! Failure to maintain the brushes could void the power wheelchair
warranty.
To inspect or replace the motor brushes:
1.Unscrew the motor brush caps. (See Fig 24)
2.Remove the brushes.
3.Inspect the brushes for wear. (See Fig 25)
4.Replace the brushes if necessary.
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Number of
Flashes
Fault
Impact on
wheelchair
Notes
1
Battery needs
recharging
Will drive
Battery charge is running low. Recharge the batteries as soon as
possible.
2
Battery
voltage too
low
Drive
inhibited
Battery charge is empty. Recharge the batteries. If the
wheelchair is left off for a few minutes, battery charge may
recover sufficiently to allow driving for a short period of time.
3
Battery
voltage too
high
Drive
inhibited
Battery charge is too high. If a charger is plugged in, unplug it or
turn the Charge/Run switch to Run.
Wheelchairs powered by RHINO will charge the batteries when
traveling down slopes or decelerating. Excessive charging in this
manner may cause this fault. Turn the wheelchair power off and
then back on again.
4
Current limit
time out
Drive
inhibited
The wheelchair has drawn too much current for too long,
possibly because the motor has been over worked, jammed or
stalled. Turn the wheelchair power off, leave for a few minutes,
and then turn the power back on again.
The controller has detected a shorted motor. Check the loom for
shorts and check the motor. Contact your server agent.
5
Brake fault
Drive
inhibited
Check that the park brake release lever is in the engaged
position.
The park brake coil or wiring is faulty. Check the park brake and
wiring for open or short circuits. Contact your service agent.
6
Out of
Neutral at
Power Up
Drive
inhibited
Throttle is not in neutral position when tuning switch key on.
Return throttle to neutral, turn power off and back on again.
Throttle may need to be re-calibrated. Check throttle wiring.
7
Speed Pot
Error
Drive
inhibited
The throttle or its wiring is faulty. Check for open or short
circuits.
Throttle may not be correctly set up. Contact your service agent.
8
Motor Volts
Error
Drive
inhibited
The motor or its wiring is faulty. Check for open or short
circuits.
Contact your service agent.
9
Other Internal
Errors
Drive
inhibited
Contact your service agent.
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New Motor Brush Worn Motor Brush Motor Brush caps
(Fig 24) (Fig 25)
2. Inspect the state of the battery terminals every six months. Make sure that they are
not corroded and the connections are tight. Periodically apply a thin film of
petroleum jelly on the surface of terminals to guard against corrosion.
PERIODICAL CHECKS
1. Make sure to keep the controller clean while protecting it from rain or water.
Never hose off your power wheelchair or place it in direct contact with water.
2. Keep wheels free from lint, hair, sand and carpet fibers.
3. Visually inspect the tire tread. If less than 1/32”, please have your tires replaced
by your local dealer.
4. All upholstery can be washed with warm water and mild soap. Occasionally check
the seat and back for sagging, cuts and tears. Replace if necessary. Do not store
your chair in damp conditions as this will lead to mildew and rapid deterioration
of the upholstery parts.
5. All moving mechanism will benefit from simple lubrication and inspection.
Lubricate using petroleum jelly or light oil. Do not use too much oil, otherwise
small drips could stain and damage carpets and furnishings etc. Always perform a
general inspection of the tightness of all nuts and bolts.
6. RHINO Nine detecting modes of RHINO (The power ON/OFF light will flash on
when your wheelchair stays in error mode. You must count the number of the
flash, and see the list to check what kind of error happened according to the
number)
Note:
If you experience any technical problems, it is recommended that you check with
your local dealer before attempting to troubleshoot on your own.
The following symptoms could indicate a serious problem with your power
wheelchair. Contact your local dealer if any of the following arises:
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