Barrett Jewel User manual

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 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
The Proven
Reliable
Indoor
Powerchair
Jewel

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.
The safety of the wheelchair user is paramount. 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 mainte-
nance work.
If you fail to understand anything or have any questions concerning maintenance and
operating instructions please contact:
RJ MOBILITY.
100 Dewsbury Road
Elland HX5 9BG
England
Tel: [phone]
Fax: [phone]
Trading division of Boxford Limited, Registered No. 01699383 England and Wales
Registered office as above.

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 Backrest
11 Frame, Locking Links And Cross Braces 12
Cators
13 Power Drive System
14 Electrical System
15 Programmable Controller
16 Elevating Legrest
17 Armrest Outriggers
18 Detachable Tray
19 Kerb Climber

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
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 Jewel
foldaway powerchair.

SECTION 2: Specifications
(Dimensions based on seat size 43cm x 43cm (17inch x 17inch))
1. 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)
7. Heaviest Component 21kg (47 lbs)
8. Seat plane angle 8.5º (To Ground)
9. *Seat depths available 43cm (17inch)
40cm (16inch)
10. *Seat widths available 43cm (17inch)
40cm (16inch)
38cm (15inch)
36cm (14inch)
11. Seat height at front 49cm (19inch)
12. Backrest angle 11.5º (To seat perpendicular)
13. Backrest height 43cm (17inch) above seat
14. Footrest to seat 36-46cm (14-18inch)
15. Leg to seat angle 85º (From Horizontal)
16. Armrest to seat 26-35cm (9-14inch)
17. Front armrest to backrest 42cm (17inch)
18. Drive wheel diameter 170mm (6.5 inch)
19. Tyre Pressures N/A (Solid Tyres)
20. Maximum load capacity 114kg (18 stone/252 lbs)
21. Turning Space
(a) Spin turn 185cm (6ft)
(b) Between walls 133cm (3ft 9inch)
22. Range ** (30 Amp/hr Battery) 8.8km (5.5mile)
23. Static Stability
(a) Front 21º (b) Rear
24º (c) Side 18º
o24. Maximum forward speed 2.2kph (1.4mph)
25. Maximum stopping distance 1.5m (5ft)
26. Dynamic stability uphill 18º
* Note: Please be aware, other sizes may be available to special request.
** Note: The range test was conducted in accordance with ISO 7176 Pt 4, capacity is affected
by ambient temperature, user weight, topography, kerb climbing and battery maintenance.

SECTION 3: Wheelchair Diagram
3.1 Jewel Self-Propelling Powerchair

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 wear or damage and tightness of attachment screws. (See
Section 7)
4.1.3 Examine armrest locking assembly for wear and tear and that each armrest is securely
retained. (See Section 7)
4.1.4 Examine footrest hanger for effective locking when fully forward and back. Examine clamp
assembly for secure location of footplate assembly stem tube. Check that footplates
remain vertical when raised. Examine heel loops for damage or excessive wear and se-
curity of attachment. (See Section 8)
4.1.5 Examine the parking brake assemblies for wear, damage or misalignment. (See Section
9)
4.1.6 Check operation of folding backrest assembly and that it is free to move and locks into
place positively. (See Section 10)
4.1.7. Ensure that tube plugs and ends are fitted to:
Front of seat tubes.
Front of bottom frame tubes.
Armrests front and rear.
Top of backrest tubes.
4.2 Lift the front of the powerchair and rest the backrests on the floor.
4.2.1 Examine the structure of the frame for damage.
4.2.2 Check the pivot points for undue slackness, caused by loose nuts 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 float and
rim rock.
4.2.5 Check controller is secure to mounting bracket and that this can be secured to powerchair
by knurled knob/handle on armrest. Examine controller for damage, particularly any which
may allow ingress of fluid. Check joystick knob is secure to controller, speed control knob
and charging socket cover are in place. Move joystick around quadrant checking for any
roughness or stickiness, on release the joystick must self-centre immediately otherwise
braking of the powerchair will be compromised. Ensure that all LED's are functional so that
it can be determined when controller is switched on/off and that any diagnostic information
is accurate.
Check that beau plug on wiring loom fits securely.
4.2.6 The batteries fitted are gel-filled and require no maintenance except to check for damage
and security of connections. See Section 14.7 for comprehensive instruction.
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.

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.
4.2.12 Reverse down a 1 in 6 slope and check that the powerchair will come to a halt if the joystick
is released.
4.2.13 Whilst driving slowly up the gradient release the joystick and check that 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 cover are in good condition.
4.3.1 Check the insulation condition of all cables.
4.3.2 Check that the controller is securely mounted.

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
7mm Socket and Drive Rear Lock Link See Section 11
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 Section 13 10mm
Socket and Driver Power Drive System See Section 13 10mm
Socket and Driver Kerb Climber See Section 20
7/16inch AF General
Allen Keys:
3/16inch AF Locking Link See Section 11
2/5mm Locking Link See Section 11 5mm
Kerb Climber See Section 20
5/32inch Kerb Climber See Section 20
Pozidrive Screwdriver Upholstery 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 Drill and
6mm Bit General 1/4inch Receptacle wire crimp tool
General Snap Rivet tool General P&G PP1b programmer &
diagnostics device See Section 15 Control Dynamics programmer &
diagnostics device See Section 15
Advised:
Watt/Minute meter (Current Draw)

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 F15
No. 10 Flanged Screw Cup F38
No. 10 UNF Avdel Nutsert 09657/01014 No. 10 x 5/8 UNF
Csk Screw Black Zinc Plated F138
Canvas Location Spigot G27

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.
Check Velcro on frame is 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 to exert excessive
force to flatten the flange cup or cut into the fabric.

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 632 G244L
Armrest Frame Right 631 G244R
Armrest Pad 119 M170
No. 12 x 1 1/4 Pozi Pan Self Tapper Screw Zinc Plated F111
5/8 x 20G Black Round Insert M5
7.3 Inspection
Check armpad for excess wear or damage.
Check armpad is secured to frame.
Ensure armrest ocates in srear bracket on push handle when fitted to powerchair.
Check armrest lock latch assembly retains armrest to frame assembly.
7.4 Armrest Pad
The armrest pad is secured to the armrest frame with three screws. Removal of the screws
releases the pad. Secure the pad with the attachment screws to refit.

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.
To assemble, place the plunger spring (TSD 1229) over the lock pin (TSD 1306) and locate in the
pin housing inside the armest location tube.
Pull the lock pin (TSD 1306) through the pin housing using a small pair of pliers and place a length
of tube in the armest location tube or reverse the armrest in the location tube. This will retain the
lock pin inside the pin housing.
Fit the lock lever (TSD 1323) and plain washer (Q5) over the lock pin and press a new starlock
washer (F37) onto the end of the lock pin. Thumb pressure should be sufficient to fit the starlock
washer or alternatively tap with a light hammer.
RJ No
Starlock Washer F37
5mm Plain Washer Q5
Lock Lever TSD1323 Plunger Spring
TSD1229 Lock Pin
TSD1306

SECTION 8: Footrest
8.1 Diagram
HANGER ASSEMBLY SP231S
8.2 Parts List
GZF No RJ No
Footrest Hanger with retaining Right 113 SP261S/R clamp
assembly M102 Left 114 SP261S/L
Retaining Clamp Assembly M102 5/16inch x 1
1/4inch Clamp Bolt, zinc plated F20
5/16inch Clamp Locking Nut, zinc plated F21
5/16inch Washer, zinc plated F22 Footplate
Assembly 8 1/2inch, complete Left 111 SP356
with Stem and Heel Loop Right 110 SP357 Footplate
Assembly 7 1/2inch, complete Left 111 SP358
with Stem and Heel Loop Right 110 SP359 Footplate Spring
TSD1349 Heel Loop
complete with nuts and washers 112 TSD11469/2 No.4 x 1/4 Pozipan
Type Self Tapping
Screw, zinc plated 0456A

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.
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 is maintained by semi-
elliptic spring acting between the footplate and the pivot tube. This does not normally require
maintenance.

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 Right SF171R Brake Shoe
SF174A
Return Spring Zinc Plated Left 258 SF233L Return Spring Zinc
Plated Right 259 SF223R
1/16x1/2 Split Pin Zinc Plated F50
10/32x5/8 UNF Hex Head Screw Zinc Plated F13 1/4
UNF Plain Nut Zinc Plated F26 2BA Wave Washer Copper
F29 10/32 UNF Nyloc Nut Zinc
Plated F24 Thread Protector
199462

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.
Remove the 2BA Wavey Washers and slide the brake assembly from the frame.
9.5 Brake Assembly Fitting
Fit the Brake Pivot and Brake Lever shafts through the bushes on the frame. Fit the 2BA Wavey
Washers on each shaft and fit two new Split Pins. Retain the Split Pins in the holes by bending
the ends apart using small pliers. Replace with a new Return Spring if necessary.
Ensure pivot bolts are not over tightened as this will lead to fracture of the brazed tabs on the
brake handle.
Lubricate with light oil.
9.6 Brake Adjustment
The Brake Shoe position can be adjusted by loosening the lock nut and repositioning the shoe.
The nuts should be adjusted to allow an operating force at the knob to be between 10lbf to 13lbf
(44 to 58 N) with the tyres inflated to the correct pressure (50psi/340 KiloPascals).

SECTION 10: Backrests
10.1 Diagram
BACKREST ASSEMBLY LEFT G223
BACKREST ASSEMBLY RIGHT G224

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 G28
Sliding Peg Handle G244
Black Plastic Bung M14
Knurled Plastic Nut F47
3/16x1 Spring Pin Black Zinc Plated F43
1/4 Brass Washer F30
1/4 UNF Type P Nyloc Nut Zinc Plated P90
Sliding Peg Spring F71
Plunger stop SF194
1/4 x 1 3/4 UNF Hex Head Bolt Zinc Plated F11
No. 10 Avdel Nutsert 09657/01014
10.3 Inspection
Check each backrest for evidence of bending.
Check each backrest for evidence of cracking through nutsert holes.
Check for free movement of the plunger. Lubricate with light oil.
Check that the plunger locates in the hole on the side frame.
Ensure Nyloc nut still grips thread.
10.4 Backrest Removal
Unscrew 5 off No. 10 UNF countersunk screws holding the backrest fabric to the backrest
assembly.
Unscrew the 1/4 UNF nut and withdraw the bolt.
10.5 Push Handle Fitting
Insert the 1/4 UNF bolt through the backrest and hinge plates. Replace the washer and tighten
the Nyloc nut until the backrest pivots freely without excessive free-play.
Fit the 5 off No. 10 UNF countersunk screws to hold the backrest fabric to the backrest assembly.
10.6 Handgrip Fitting
1-Clean all residue from the handle and ensure the handle is clean using detergent if
necessary and dry off.
2-Select new handgrip (RJ part no M57.) and blow into open end (this deposits a small
amount of water vapor inside the handgrip).
3- Push the handgrip onto the handle, it may be necessary to use a soft mallet for the
last 25mm of travel.
4- Wait 1 minute and check that the handgrip cannot be removed by hand.