Decon wheel e-move User manual

E-MOVE
Service Manual
Version: 20151203

Foreword
ThisServiceManualdescribestheproceduresforinspecting,adjusting,andassemblingtheE-Move,
aswellashowtohandleerrors.
Symbols Used in This Manual
Itemsconcerningproperhandlingareindicatedwiththefollowingsymbols.
Warning
・Indicatesthatmisusemayleadtofatalorsevereinjury,ordisability.
Note
・Indicatesthatmisusemayleadtomaterialdamage.
nImportant
・ Indicatescorrectmethodsandkeypointswhenoperatingtheproduct.
Ref.
・ Providesinformationthatuserwillnditusefultoknow.
Other Precautions
•Forproductimprovementpurposes,thedescriptionsandspecicationsinthismanualaresubjectto
changewithoutnotice.
•Duetochangesinthespecications,someofthephotosanddescriptionsmaydi󱐯erfromtheactual
product.
•Thismanualisintendedforusebypersonspossessingthebasictechnicalknowledgeandskills.
•Personswhodonotpossessthegeneralserviceskillsandknowledgeshouldnotrelysolelyonthis
servicemanualtoperforminspection,adjustment,disassembly,orreassembly.
Failuretoobservethisprecautioncanleadtomaintenanceproblemsormechanicaldamage.

Contents
1. ProductOverview ……………………………………………………………………1
1.1 ProductFeatures……………………………………………………………………1
1.2 Variations ……………………………………………………………………………2
2. InstallationRequirements…………………………………………………………3
2.1 StrengthRequirements……………………………………………………………3
2.2 StructuralRequirements…………………………………………………………3
2.3 FunctionalRequirements…………………………………………………………5
3. UnitInstallationandRemoval……………………………………………………6
3.1 E-Move Components………………………………………………………………7
3.2 InstallingtheE-Move………………………………………………………………8
3.3 BatteryBagInstallation(SeparatedBatterySeatType)……………………… 13
3.4 InstallingandRemovingtheWheelDriveUnitAssembly……………………… 17
4. Pre-DeliveryAdjustment ……………………………………………………… 19
4.1 AdjustingtheBatterySeatAngle…………………………………………… 19
4.2 AdjustingthePowerSwitchPosition……………………………………… 21
4.3 InstallingtheModeSwitch …………………………………………………… 24
4.4 AdjustingtheSwitchAngle…………………………………………………… 27
4.5 AdjustingtheSwitchLength………………………………………………… 28
4.6 RelocatingtheSwitch(Left/Right) ………………………………………… 31
4.7 ConnectingtheCouplerBoxCables ……………………………………… 34
4.8 RepositioningtheCouplerBoxCables …………………………………… 37
4.9 AdjustingtheWarningLamp(LED)Direction …………………………… 38
4.10 UsingOffsetWashers………………………………………………………… 39
4.11 AdjustingtheBatteryBagCableLength(SeparatedBatterySeatTy p e)
… 40
4.12 ChecklistAfterInstallingtheElectricPower-AssistUnit ……………………… 43
5. ComponentRemoval,InstallationandAdjustment
forInvestigationandRepair ………………………………………………… 44
5.1 RemovingandRe-installingtheHandrim ………………………………… 44
5.2 RemovingandRe-installingtheWheelAssembly ……………………… 47
5.3 RemovingandRe-installingtheCircuitBoard…………………………… 49
5.4 RemovingandRe-installingtheCouplerBox …………………………… 52
5.5 RemovingandRe-installingtheL/RConnectingCable
(StandardBatterySeatType)
 ………………………………………………… 58
5.6 RemovingandRe-installingtheBatteryBag …………………………… 60
5.7 RemovingandRe-installingtheL/RConnectingCableandCoupler
(SeparatedBatterySeatType)
 ……………………………………………… 62
5.8 AddingandRemovingtheSprings ………………………………………… 64
5.9 CopyingSettingData…………………………………………………………… 66
5.10 CalibratingtheHandrimSensorNeutralPosition …………………… 68
6. JWSmartTune……………………………………………………………………… 70
7. Warnings………………………………………………………………………………… 71
7.1 WarningsList……………………………………………………………………… 71
8. Self-diagnosis………………………………………………………………………… 73
8.1 Self-diagnosis(Self-diagnosisFunction)…………………………………… 73
8.2 FaultDetectionChart ………………………………………………………… 73
9. InspectionsandMaintenance………………………………………………… 76
9.1 InspectionChecklist …………………………………………………………… 76
10. SpecificationsandOtherInformation ………………………………… 77
10.1 Specifications ………………………………………………………………… 77
10.2 DimensionsandDiagrams…………………………………………………… 78
10.3 WiringDiagram(SeparatedBatterySeatType)………………………… 79
10.4 WiringDiagram(StandardBatterySeatType)………………………… 80

1
ProductOverview
1
1.1 ProductFeatures
1. ProductOverview
SampleE-MoveInstallation
① WheeldriveunitassemblywithACservoflatmotor
② Powerswitch
③ Dedicatedbatterywithbuilt-inmicroprocessor
Choiceofnickel-metalhydrideorlithium-ionbattery
④ Modeswitch(option)
⑤ Batterybag
④
③
①
③⑤
②
E-MoveStandardbatteryseatmodel E-MoveSeparatedbatteryseatmodel

1
ProductOverview
2
1.2 Variations
Model E-Move
Product Tiresize Note
E-Move 20"
22"
24"
25"
26"
SelectablePart
Handrims: Stainlesssteel/Plasticcoated
 Battery: Nickel-metalhydride/Lithium-ion
OptionalPart
Modeswitch(Drivingmodechangingsystem)
E-Move
E-Move
E-Move
E-Move

2
InstallationRequirements
3
（1） Thewheelchairframemustnothaveacamberangle.
（2）Thewheelchairframemustbesufficientlystrong.(Notethatthestrengthofawheelchairframemayde-
clinewithprolongeduse.)
Example:
・Playordeformationincomponentssuchasrivets,boltfasteningsorcasters.
・Componentswithvisiblewearorcorrosion.
2.1 StrengthRequirements
ToinstalltheE-Move,thewheelchairframemustmeetthestrengthrequirementslistedbelow.
Warning
・DonotinstalltheE-Moveonawheelchairframethatdoesnotmeetthestrength
requirement.
2.2 StructuralRequirements
ToinstalltheE-Move,thewheelchairframemustmeetthestructuralrequirementslistedbelow.
Warning
・DonotinstalltheE-Moveonawheelchairframethatdoesnotmeetthestructural
requirements. Even where it can be successfully installed, problems may arise during use that
could cause injury or accident.
2. InstallationRequirements

2
InstallationRequirements
4
2.2.2 Casters
Seven-inchorlargercastersarerecommendedforthefrontcasters.
Withsmall-diametercasters,itisdifficulttogetoverlargebumps.Theshockexperiencedgoingoverbumps
isalsogreaterifthecastersaresmall.
Largediameter
(easytogetoverbumps)
Smalldiameter
(difficulttogetoverbumps)
2.2.1 Wheelchairframe
（1）Thediameteroftheaxleholeis18mmor20mm.
（2）Thecontactsurfacesforthenutsaroundtheaxleholemustbeflatandhaveamplesurfacearea.
（3）WhentheE-Moveisinstalled,theremustbenointerferencebetweentheE-Moveand
the wheelchair.
（4）Onseparatedbatteryseatmodels,a50mmwidebeltcanbethreadedthroughtheframeatthetopof
thebacksupport.Thepartthroughwhichthebeltisthreadedisconstructedsuchthatoncethreaded,
beltisheldsecureandwillnotslipdown.A25mmwidebeltcanalsobethreadedthroughtheframe
atthebottomofthebacksupport.
Accommodates
a50mmwidebelt
Accommodates
a25mmwidebelt
Backsupport
nImportant
・ Ifyouareusingoffsetwasherstoavoidsuchinterference,checkthetwoitemsbelowandinstalluptothree
washersoneachside.
 − Thenutseatsarecompletelysecure.
 − Thewheelchairbrakeseatsarecompletelysecure.

2
InstallationRequirements
5
2.3 FunctionalRequirements
Warning
・DonotinstalltheE-Moveonawheelchairframethatdoesnotmeetthefunctional
requirements.Evenwhereitcanbesuccessfullyinstalled,problemsmayariseduringuse
thatcouldcauseinjuryoraccident.
ToinstalltheE-Move,thewheelchairframemustmeetthefunctionalrequirementslistedbelow.
（1） Theframemustbeconstructedtoallow22-or24-inchwheelstobeattached.
（2）Thewheelchairisequippedwithaparkingbrakethatcanberelocatedandadjustedtothecorrectposi-
tiononthetires.Whenapplied,thebrakemustbecapableofstoppingthewheelchairwiththeE-Move
installedona7°forwardorbackwardincline.
（3）WiththeE-Move installed,itmustbepossibletotipthewheelchairforwardandbackbyatleast 
20° andtothesidebyatleast15°.
(Abackwardtippingangleofatleast25°isrecommended.)
Forwardtippingangle Backwardtippingangle Sidetippingangle
Minimum
20°
Minimum
20°
Minimum
15°
（4）Takecaretoensurethatthefunctioningofthewheelchairframeisnotimpairedbytheinstallationof
theE-Move.
Example:
・Movementofmoveablearmsupports,foldingmechanism,parkingbrakeeffectiveness,etc.

3
UnitInstallationandRemoval
6
3. UnitInstallationandRemoval
Warning
・Whencuttingcableties,donotcutonanangle.Alwayscutoffthe
surplus as close as possibletothefastener.Cabletiescut toa
pointcouldcauseinjurytothecustomer.
Note
・Inlocationswherethetighteningtorqueisspecified,alwaystightentothespecifiedtorque.
Insufficienttighteningtorquewillcauselooseness,whileexcessivetorquecouldcausedam-
age.
・Installtheunitwiththebatteryremoved.

3
UnitInstallationandRemoval
7
3.1 E-MoveComponents
OWNER’S MANUAL
①
⑦⑨ ⑩
⑪
⑫
⑬
⑭
⑮
⑯
⑰
⑧⑨
②③
⑱
⑲
⑤⑥
⑤⑥
④
㉒
⑳
㉑㉓
No. Component Remarks Qty
① Leftwheeldriveunitassembly For22-inchor24-inch(selectable) 1
② Rightwheeldriveunitassembly For22-inchor24-inch(selectable) 1
③ Manualset OwnerʼsManual,Warranty,GuidelinesforSafeUse,
InstallationManual 1
④ Cableties 10
⑤ Battery Nickel-metalhydrideorlithium-ion(selectable) 1
⑥ Charger Nickel-metalhydrideorlithium-ion(selectable) 1
⑦ Stopperarm Left 1
⑧ Stopperarm Right 1
⑨ O-rings Fittedontostopperarms 4
⑩Boss 2
⑪Washers
Forstopperarmoffset(axlesleeve)
Foraxlesleeveinstallation‒35/18.5mmdia.,
3.2mmthick
8
⑫Washers Forstopperarmoffset(boss)
28/8.5mmdia.,3.2mmthick 6
⑬ Washers Forplateoffset-18/6.2mmdia.,1.6mmthick 12
⑭ Bolts Forstopperarm‒M8 2
⑮ Bolts Forplatelock‒M6 4
⑯ Platelock 2
⑰ Axlesleeve 2
⑱ Nuts Foraxlesleeveinstallation 2
⑲ Bushes Foradjustmentfrom18→20mmdia.axlesleeve 2
⑳ Surfacefastenertape Forsecuringthecable 2
㉑ Batterybag Withbuilt-inbatteryseat 1
㉒Fittingtape Fastener(hookandloop)tapeisattachedtobothsidesof
thebagtosecurethebeltatthetopofthebatterybag 2
㉓Belt Lowerbeltforinstallingthebatterybag 1
* ThecomponentsNo.⑦~No.⑲arenotincludedinthe“withoutmountingbracket”models.
See“1.2Variations”.
* Items㉑to㉓areonlyincludedwhenaseparatedbatteryseattypeisselected.Onsuchmodels,
thebatteryseatisnotincludedintherightwheeldriveunitassembly② .

3
UnitInstallationandRemoval
8
3.2 InstallingtheE-Move
Withtheexceptionofthecabling,theprocedureforinstallingtheE-Moveinamodular-typewheelchairis
the same for both left and right sides. Accordingly, the model description given below is for
installationontheleftside.Usethesameproceduretoinstallontheright.
Requiredtools:4mmand5mmhexagonalwrenches(Allenkeys),24mmsocket,socketwrench,torque
wrench,22mmand24mmspanners
1 Removetheaxlesleeve(a)installed
onthewheelchair.
Removetheexistingwheelandaxlesleeve(a)
fromthesidebracket(b)onthewheelchair.
（a）
（b）
2 Installtheaxlesleeve(c).
（1）Installthestopperarm(d)andboss(e)on
thewheelchairside bracket(b)and tem-
porarilytightenthebolt(f).
（e）
（f）
（d）
（b）

3
UnitInstallationandRemoval
9
（2）Fittheaxlesleeve(c)intothestopperarm
(d)andsidebracket(b).
nImportant
・ Inserttheaxlesleeve(c)fromthestopperarmside.
・ The outerdiameterofthethreaded sectionofthe
axlesleeve(c)is18mm.Ifthediameteroftheaxle
holeinthewheelchairsidebracket(b)is20mm,
insertthebush(g)between theaxleholeandaxle
sleeve(c).
（3）Fitthe3.2mmthickwasher(h)ontothe
axlesleeveandtemporarilytightenthenut
(i).
（4）Fullytightenthenut(i)andbolt(f)inthe
sequencebelow.
1. Nut(i)
Tighteningtorque 40‒50N･m
2. Bolt(f)
Tighteningtorque 8.5‒12N･m
Note
・Ifthewheelchairframeinterfereswiththe
stopperarm(d).inserta3.2mmthickoffset
washerbetweenthestopperarm(d)andthe
wheelchairsidebracket(b).Fordetails,see
4.10UsingOffsetWashers.
・Useupto3offsetwashersoneachside.For
details,see4.10UsingOffsetWashers.
（b）
（f）
（c） （d）
（h）
（g）
（i）
3 Installtheplatelock(j)onthewheel
driveunitassembly(k).
Installtheplatelock(j)onthewheeldriveunit
assembly(k)andsecureitusingthebolts(l).
Tighteningtorque 8.5‒12N･m
nImportant
・ Installtheplatelock(j)sothatitfacesinthedirec-
tionindicatedinthefigure.
・Oncethewheeldriveunitassembly(k)isinstalled,
usewasherstoadjustthespacingsothatstopper
arm(d)engagescorrectlywiththeholeintheplate
lock(j).For details,see4.10UsingOffsetWash-
ers.
・ Useupto3washersoneachside.Fordetails,see
4.10UsingOffsetWashers.
（l）
（k）
（j）

3
UnitInstallationandRemoval
10
4Installthewheeldriveunitassem-
bly(k).
（1） Liftupthehandleplate(m).
（2）Aligntheholesintheaxle(n)andplate
lock(j)withtheaxleholeintheaxle
sleeve(c)andthepinonthestopperarm
(d)andthenfitthemtogether.
Note
・Ifthereisinterferencebetweenthewheel-
chair frameandcomponentssuch as the
powerswitch,insert3.2 mmthickoffset
washersbetweentheaxlesleeve(c)andthe
stopperarm(d).Fordetails,see4.10Using
OffsetWashers.
・Useupto3offsetwashersoneachside.For
details,see4.10UsingOffsetWashers.
（3）Setthehandleplate(m)backdownand
checkthatthewheelretainingball(o)is
locked.
（m）
（j）
（d）
（c）
（n）
（o）

3
UnitInstallationandRemoval
11
6 Fitthecable.
（1） Openthecap(q)onthecouplerboxcase
(p).
（q）
（p）
（u） （t）
（p）
（u）
（r）
（s）
5 Onseparatedbatteryseatmodels
only,installthebatterybag.
See“3.3BatteryBagInstallation”.
（2）Alignthewhitemark(r)(indicatedbythe
arrow)onthe endofthecablewiththe
whitemarkonthewheelcoupler(s)and
pushthecableinuntilitclicksintoplace.
Note
Onseparatedbatteryseattypes,notethefol-
lowing:
・Thereareright-handandleft-handcables.
Toensurethat you donotmix uptheleft
and rightcables,matchuptheidentification
marks(w)onthecable(t)andcouplerbox(p)
whenconnectingthecable.
・Oncethecableisconnected,checkthatthe
connectionissecure.Ifyoucannotconnect
thecablebecauseit is stretched oristoo
short, lengthenthecable. See4.11Adjust-
ingtheBatteryBagCableLength.

3
UnitInstallationandRemoval
12
（v）
（t）
7 Checkthestatusofthecable(t).
Checkthatthecableisnotstretched,isnot
trappedorpinchedwhentheframeiscol-
lapsed,andisnotwrappedaroundorother-
wisetouchinganymovingparts.Ifnecessary,
usethesurfacefastenertape(v)tosecurethe
cable(t).
（1） Attachthesurfacefastenertape(v)tothe
cable(t).
（v）
（t）
（w）
（2）Securethecable(t)asdescribedinthe
examplebelow.
Attachmentexample①
Fixthecable(t)bysecuringitaroundthe
frame(w).
（v）
（t）
（x）
（x）
Attachmentexample②
Fixthecable(t)bytrappingitintheback
supportsurfacefastener(x).

3
UnitInstallationandRemoval
13
3.3 BatteryBagInstallation(SeparatedBatterySeatType)
Note
・Installingthebatterybagmaypreventtheframefrombeingfolded.
1 Attachthebelt(b).
（1）Runthebelt(b)aroundtheframe(a)at
thebottomofthebacksupportandfasten
thehookedsectionsofthesurfacefas-
tener(c)tosecurethebelt.
Note
・Takecaretofastenallofthetwohookedsec-
tionsofthesurfacefastener(c)ateachend
ofthebelt(b).
（2）Slidethebelt(b)aroundsothatthe2fas-
tenedends(d)areascloseaspossibleto
mid-waybetweenthewheels.
Note
・Keeptheendsofthebelt(d)awayfromthe
frame (shadedarea in the figure)toen-
surethattheydonottouch orbecomeen-
tangledinmovingparts.
・Ensurethatthatthereisnoplayorslack
whenattachingthebelt(b).
（a）
（c）
（b）
NG
（b）
（b）（d）（d）
（a）
（d）
Note
・Securethebatterybagcableswiththesur-
face(hookandloop)fastenersonthebag
cableretainers.When doing so,ensure that
theinterlockingsurfacesonthefasteners
are fullyengaged.If the cablesarenot se-
curedorthesurfacefastenersarenotfully
engaged, the cablescould touchand/orbe-
comeentangledinmovingparts.

3
UnitInstallationandRemoval
14
2 Attachthebatterybagbelt(e).
Run thebatterybagbelt(e)aroundthetop
oftheback supportframe (a)andfastenitin
placeusingthefittingtape(f)(surfacefastener
withhookedsurfacesonbothsides).There
aretwowaystoaffixthefittingtape(f),asde-
scribedbelow.
Note
・Runthebatterybagbelt(e)aroundthepart
ofthetopofthebacksupportframe(a)that
isconstructedtoholdthebeltsothatitwill
notslidedown.
・Sticktheentiresurfaceofthefittingtape(f)
tothebatterybagbelt(e).
・Ensurethatthatthereisnoplayorslack
whenattachingthebatterybagbelt(e).
（g）
（e）
（e）
（a）
（g）
（e）
（f）
（a）
（g）
（e） （f）
（a）
1. Iftheendofthebatterybagbelt(e)
doesnotreachthebatterybag(g).
Attachthefittingtape(f)sothatitisatthe
endofthebatterybagbelt(e).
Runthebelt(e)aroundtheframe(a)and
thenstickthefittingtape(f)attheendof
thebelttothebelt(e)tofastenitinplace.

3
UnitInstallationandRemoval
15
2. Iftheendofthebatterybagbelt(e)
reachesthebatterybag(g).
Affixthefittingtape(f)tothebatterybag
belt(e)sothatitisattheendofthesur-
facefastener(loopedtape)whereitemerg-
esfromthebag.
Runthebelt(e)aroundtheframe(a)and
thenstickthebelt(e)tothefittingtape(f)
tofastenitinplace.
Securetheremainingend ofthe beltin
placebybrieflypeelingofftheloopedtape
fastener(h)offthebatterybag(g)and
stickingtheendofthebelttothehooked
fastener(i)onthebatterybag(g).
Afterstickingthebelt(e)inplace,re-affix
theloopedtapefastener(h).
（g）
（e）
（f）
（a）
（g）
（e） （f） （i）
（a）
（h）

3
UnitInstallationandRemoval
16
3 Securethebatterybag(g).
（1） Remove thesurface fastener onthebot-
tomofthebatterybag(j)andrunboth
sidesofthebelt(b)throughthefastener.
（2）Re-affixthesurfacefastener(j)tosecure
thebatterybag(g)inplace.
Note
・Thebattery(k)shouldbeinstalledsothatit
isinclinedatnomorethan±30°fromverti-
calinthedirectionofchairmovement.
・Takecaretoinstallthebatterybagsothatit
isnottrappedorpinchedwhentheframeis
collapsed.
・Install the bagsothat itdoesnottouch or
becomeentangledinmovingparts.
（j）
（g）
（g）
（b）
（b）
（j）
Vertical
30°orless
30°orless
（k）
Ensurethatthe
batteryisinclined
atnomorethan
±30°fromvertical.