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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 is for use
by trained personnel only
The Proven
Reliable
Indoor/Outdoor
Powerchair
GemMk
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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
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 maintenance work.
If you fail to understand anything or have any questions concerning maintenance and
operating instructions please contact:
RJ MOBILITY.
100Dewsbury Road,
Elland HX5 9BG
England
Tel: +44(0) 1422 324830
Fax: +44(0) 1422 372503
Trading division of Boxford Limited, Registered No. 01699383 England and Wales
Registered office as above.
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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 Armrest Outriggers
17 Detachable Tray
18 Kerb Climber
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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 GEM MKIII
foldaway powerchair.
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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 Component 32kg (70.5 lbs)
8. Seat plane angle 8.5º (to horizontal)
9. *Seat depths available 43cm (17 inch)
40cm (16 inch)
10. *Seat widths available 38cm (15 inch)
43cm (17 inch)
11. Seat height at front 50cm (19.5 inch)
12. Backrest angle 110º (to seat)
13. *Backrest height (above seat) 45.7cm (18 inch)
14. Footrest to seat 36-46cm (14-18 inch)
15. Leg rest angle 85º (from horizontal)
16. Armrest to seat 23-30cm (9-12 inch)
17. Front armrest to backrest 42cm (17 inch)
18. Drive wheel diameter 315mm (12.5 inch)
(Tyre size 12.5 x 2.25”)
19. Tyre pressures (Rear) 40psi / 240 kilopascals (KPA)
(if pneumatic option fitted)
20. Maximum load capacity 114kg (18 stone/252 lbs)
21. Turning Space
(a) Spin turn 205cm (6ft 7 inch)
(b) 3 point turn 133cm (4ft 4 inch) (c) 28inch doorway turn
100cm (3ft 3 inch)
22. Range **(30 Amp/hr Battery) 13.5km (8.4 mile)
**(40 Amp/hr Battery) 17.8km (11 mile)
23. Static stability
(a) Front (most stable) 19º†
(b) Front (least stable) 16º†
(c) Rear 21º†
(d) Side 19º†
24. Obstacle climbing 100mm (4inch forward with
kerb climber fitted)
25. Maximum forward speed 5.5 kph (3.4 mph)
26. Maximum stopping distance 1.5m (5ft)
* 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.
† RJ Test (ref 111)
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SECTION 3: Wheelchair Diagram
3.1 Gem Self-Propelling Powerchair
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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
security 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 push handle assembly and that it is free to move and locks into
place positively. (See Section 10)
Check that the hand grips are not damaged and are securely fitted to the push handle.
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 push handles 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 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 Gem Mk III at maximum speed in forward, reverse, left and right directions
checking that the joystick response is uniform.
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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. 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.
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SECTION 5: Tool Requirements
Spanners:
1/4“ BSW Legrest Clamp See Section 8 2-8mm
A/F Spanners Parking Brake See Section 9 210mm A/F Spanners Braces & Links See Section 20 124mm AF Spanner Castors See Section 12
1-35mm AF Spanner Power Drive System See Section 20 27/16inch A/F Spanners Backrest
1-4mm A/F Hex Key Locking Brace See Section 11
No2-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 0.5 mm to 6.0 mm crimps
Torque Wrench:
Minimum Operating Range
8 lbs/ft (11 Nm) General
Small Needle Nose Pliers General Light / Soft
Head Hammer General Light Oil, e.g.
3 in 1 General Wire cutter
General Power
Drill and 6 mm Bit General 1/4“
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)
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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
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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 attachment tabs are present and secure.
Check Velcro on frame is present and secure.
6.3 Fabric Removal
If the Nutserts need replacement, use Avdel recommended tooling.
6.B Diagram
6.4 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.
REINFORCING BAR
M5 AVDEL NUTSERT
M5x20 CSK HD SCR
M5 CUP WASHER
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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 in rear bracket on push handle when fitted to powerchair.
Check armrest lock latch assembly retains armrest to frame assembly.
7.3 Armrest Pad
The armrest pad is secured to the armrest frame with three self-tapping screws. Removal
of the screws releases the pad. Secure the pad with the attachment screws to refit.
ARMREST
ARMREST PAD M-170
SELF TAPPER SCR F-111.
PLUG M7-2440
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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.
7.B Diagram
RJ No
Starlock Washer F-37
5mm Plain Washer Q5
Lock Lever TSD-1323 Plunger
Spring TSD-1229 Lock Pin
TSD-1306
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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 Assembly 7 1/2inch, complete Left SP-211L
with Stem and Heel Loop.(Alloy). Right SP-211R
Heel Loop complete with nuts and washers. TSD-11469/2
Footplate Spring. TSD-1349
No.4 x 1/4 Pozipan Self Tapping Scr. 0456A
CLAMP NUT F-21
WASHER F-22
CLAMP M-102
CLAMP BOLT F-20
HEEL LOOP ASSY TSD-11469/2
FOOTPLATE PLASTIC M-261
FOOTPLATE 71/2“ ALLOY M-172L/R
FOOTPLATE 81/2“ ALLOY M-172L/R
SCREW F-9
NUT F-26
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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 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.
8.4 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 semielliptic spring acting between the footplate and the pivot tube. This does not normally require
maintenance.
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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
Return Spring Zinc Plated Left G-320 Return
Spring Zinc Plated Right G-321 1/16x1/2
Split Pin Zinc Plated F-50
10/32x5/8 UNF Hex Head Screw Zinc Plated F-13
1/4 UNF Plain Nut Zinc Plated F-26 2BA Wave
Washer Copper F-29 10/32 UNF Nyloc Nut
Zinc Plated F-24 Thread Protector
199462
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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 Split Pins from the Brake Pivot shaft and Brake Lever shaft.
Remove the 2BA Wavey Washers and slide the brake assembly from the frame.
9.4 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.
9.5 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).
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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 9657-1014
SCREW F-11
STOP SF-194
SPRING F-71
SLIDING PEG G-028
SPRING PIN F-43
WASHER F-30
NYLOC NUT P-90
HANDLE G-244
SPRING PIN F-43
HAND GRIP M-57
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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 locates in the hole on the side frame.
Ensure Nyloc nut still grips thread.
10.3 Backrest Removal
Unscrew 5 off M5 countersunk screws holding the backrest fabric to the push handle
assembly.
Unscrew the 1/4 UNF nut and withdraw the bolt.
10.4 Push Handle Fitting
Insert the 1/4 UNF bolt through the push handle and hinge plates. Replace the washer and
tighten the Nyloc nut until the push handle pivots freely without excessive free-play.
Fit the 5 off M5 countersunk screws to hold the backrest fabric to the push handle assembly.
10.5 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 M-57.) 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.
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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 in the open position so that the
powerchair will not fold under load.
Check each tab on the side frame for evidence of bending, elongation or worn holes, and
cracks in the brazing or tubing.
LH SIDEFRAME G-322
RH SIDEFRAME G-323
M5 AVDEL 09657-01014
PLUG M-11
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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 frame.
M6x35 HEX SCR
M6x25 HEX SCR
M6 NYLOC NUT
M6 NYLON WASHER
15“ CROSS BRACE LONG SF-203
17“ CROSS BRACE LONG SF-182
M6x35 HEX SCR
15“ CROSS BRACE SHORT SF-203A
17“ CROSS BRACE SHORT SF-182A
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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
excessive free play. Lubricate with light oil, eg 3 in 1. Over-tightening of Cross Brace Assembly
will prevent the pivoting action and will lead to fracture of the tab on the side frame.
11.C Diagram
11.5 Parts List
RJ No
Front Locking Link Assembly 17" SF 207F
Front Locking Link Assembly 15" SF 208F
Rear Locking Link Assembly 17" GS 019
Rear Locking Link Assembly 15" GS 019
11.6 Locking Link Assembly Removal
Remove the 1/4 UNF Socket Cap Screw securing the Locking Link to each side frame.
11.7 Locking Link Assembly Fitting
Fit the two 1/4 UNF Socket Cap Screws to secure the Locking Link assembly to each side
frame. Tighten until the Locking Link is just securely held, then loosen the nut half a turn.
The Locking Link Assembly must be free to move without binding, but no signs of
excessive free play. Lubricate with light oil, eg 3 in 1. Overtightening of Cross Brace Assembly
will prevent the pivoting action and will lead to fracture of the tab on the side frame.
Note that the front locking link folds downwards and the rear locking link folds upwards.
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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 both castor mounting tubes are at the same angle, checking for frame
distortion due to impact damage, replace if necessary.
Check tyre security to rim and for splits, cracking or damage.
Check security of castor.
12.3 Castor Removal
Unscrew the hexagon at the top of the castor swivel, using a 24mm A/F spanner, until the castor
is removed.
12.4 Castor Fitting
Apply Loctite thread locking compound Grade 241, or equivalent, to the thread and tighten to
30-35 lbs/ft (40-47 Nm).
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 the cable as shown in fig 13.B.
MOTOR E-131L/R WITH CARTRIDGE BRUSHES
& NEUTRIC CONNECTOR.
WAVE WASHER F-65
LARGE NYLON WASHER F-67
DRIVE COUPLING M-155
SPRING M-156
STUB AXLE D-01L
HEX NUT D-09
WHEEL ASSY GS-006
SPACER M-157
SMALL NYLON WASHER F-66
DRIVE COLLAR M-159
TAB WASHER M-158
LOCK SCREW F-95
KNOB M-074
MOTOR SPACER D-023
MOTOR PLATE LH GS-0003
ANTI-TIP CASTOR ASSY GS-005
MOTOR PLATE RH GS-0004
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 bearings and/or stub axle. Maximum allowable
is 5mm total.
Check for end-float which will indicate worn thrust washers. Maximum allowable is 3mm.
Check that the free-wheel mechanism engages and dis-engages freely and that the drive
dogs do not have rounded corners.
Check the drive securing bolt in the end of the drive shaft is tight and the tab washer is bent
up for security.
Check the motor loom for damage and that the plug wiring is secure.
Check for unusual noises such as whining or rubbing which might indicate that the solenoid
brake is touching the cowl.
Move the joystick around the quadrant and check that when released it self-centres and
the brakes operate.
An audible click will be heard from each motor when the brakes are applied and released.
Raise the rear of the powerchair and support on suitable stands. Engage the drive
mechanism and move the joystick around the quadrant to simulate forward, reverse and turning.
Observe the wheel rotation to ensure it mirrors joystick movement and check for any wheel/tyre
distortion.
ANDERSON CONNECTOR
BLACK
CLIFF CONNECTOR
RED RING
NEUTRIC CONNECTOR
BLUE RING.
CARTRIDGE TYPE BRUSH
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, release the two self-tapping screws which
hold the motor cowl and slide the motor cowl along the motor loom, taking care not to apply any
force to the wiring.
The brushes are located vertically either side of the brake assembly. They are joined
together by a wire and by gently pulling this will release the brushes.
To replace, press gently into the slots and position wire so that it is not in contact with the
brake assembly. Refit the motor cowl taking care not to trap any wiring. Re-connect the motor
loom and test.
On some later model powerchairs cartridge brushes are fitted which require no disman-
tling. These are accessed from the outside of the motor and are removed by unscrewing the caps
situated below the rim of the motor cowl.
RJ Part No
Cartridge brush (pair) GS-01
Non-cartridge brush (pair) CB-174
13.4 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.
From inside the cowl pull the two brake wires through from the motor loom sheath. Using an Allen
key remove the two securing bolts on the top of the brake assembly. The brake asembly can now
be removed.
13.5 Motor Brake Removal
The brake is not serviceable so a new one must be fitted. Place on top of the motor and
secure with Allen bolts after applying small quantity of thread locking compound. Torque to
10lbs/ft (13.5Nm). Feed the two brake wires through the grommet in the cowl alongside the motor
loom and refit the cowl. Cut off the brake wires to the required length and fit new spade
connectors. Tape the brake wires to the outside of the motor loom to give complete protection.
Reconnect the motor to the main loom and test.
IMPORTANT
Investigate warranty status before proceeding.
Failure to do so may invalidate your warranty.
Motor and gearbox maintenance is limited to
complete assembly replacement except replacing
motor brakes and brushes.
Check Brake and Motor functions operate
correctly after any maintenance when completed.
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 bolt head and using a 10mm spanner
remove the drive securing bolt (F-95). This is made easier if the drive is engaged.
The drive components can now be withdrawn from the motor drive shaft and care should
be taken not to lose any parts.
Examine the components for damage or wear as indicated from the previous checks. If the
wheel bushes need replacing these can be removed by the use of a soft drift and hammer.
Replacement of wheel bushes requires the use of a press to prevent burring the edges of the
bushes.
If it is necessary to replace the stub axle (D-01L) the motor will require removal from the
mounting plate. Using a 7/16 A/F spanner release the three retaining bolts and withdraw, being
careful not to lose the spacers. The motor can now be removed by sliding the drive shaft out of
the stub axle. Using a 35mm AF spanner remove the stub axle nut (D-09). Replace the stub axle
(D-01L), apply thread locking compound and tighten to 35 lbs/ft (47Nm) torque. Refit the motor to
the mounting plate, insert spacers and tighten bolts to 10 lbs/ft (13.5Nm) torque.
Re-assemble the thrust washers, metal wavy (F-65) first, large nylon washer (F-67)
second. Fit the wheel and small nylon washer (F-66). Fit the drive collar (M-159), cup washer
(M-157), spring (M-156) and drive dog (M-155). Use a new tab washer (M-158) and bolt (F-95).
Apply threadloc compound (Grade 66) to the bolt threads and tighten 10 lbs/ft (13.5Nm) torque.
Finally bend the tabs up ensuring that they are in contact with the bolt head.
13.7 Power System Removal
If it is necessary to remove the complete drive assembly as one unit the following
procedure applies.
Support the rear of the powerchair on suitable stands and disconnect the motor wiring
loom from the main loom. Using 7/16 AF spanners release the four nuts/bolts which attach the
mounting plate to the side frame. Withdraw the bolts and remove the assembly.
13.8 Power System Replacement
Replacement is a straightforward reversal of the above procedure. The attachment nuts
and bolts should be renewed and tightened to a torque of 35 lbs/ft (47Nm).
IMPORTANT
Motor and gearbox maintenance is limited to
complete assembly replacement except
replacing motor brakes and brushes.
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 higher 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 flat floor.
2-Raise the front castors onto blocks that are 100mm high as shown in the following
sketch.
3-Adjust the anti-tip rollers so that they touch the floor, as shown.Tighten nuts to 10Nm.
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) E148 Battery Tray (15“)** G-348B-15 Battery Tray (17“)**
G-348B-17 Battery Tray Strap
G-243
Note;- * To be specified with type of connector required, ie Neutric, Cliff, Anderson
powerpole, Or Anderson shroud.
* * Battery tray is supplied with the rear support over long, this is to be shortened
on assembly to obtain a snug fit between the motor mounting plates.
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 Block Lock E-089 Crimp Connector
E-027
CLIFF CONNECTOR SOCKETS
WIRING CONNECTIONS.
LOOM WITH ANDERSON POWERPOLE + SHROUD CONNECTORS A10-01.
LOOM WITH ANDERSON POWERPOLE CONNECTORS & SPADE BRAKE CONNECTORS 24V G209.
LOOM WITH ANDERSON POWERPOLE CONNECTORS & SPADE BRAKE CONNECTORS 12V G-202.
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) E-151
CONTROL LOOM ( BEAU) G-349E
FRONT LOOM G-350D
NEUTRIC SOCKETS WIRING
LH MOTOR E-131L
RH MOTOR E-131R
E-109
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 Display Fault Code History.
Preset Control System
Restore Factory Defaults.
Help Mode
Diagnostics Read Fault code
Engineering Menu
Set Soft Reverse Prevent Reversing Digging In. 70%
Set Current Limit Max & Min Current Limits. 40A Max-40A Min
Set Foldback Temp Reduce Current At This Temp.
55°C
Set Timed Foldback Reduce Current After This Stall Time. 25%-60sec
Set Compensation Match Motor Impedance.
130 m-ohm
Set Battery Menu Match Controller to Loom Resistance 64 m-ohm
Set Park Brake Trip Chairs With No Brakes. No
Set Front Drive Front Wheel drive chairs. No
Set Min Accn 43%
Set Min Decel’n 57%
Set Min Turn Accn 50%
Set Min Turn Decel’n 66%
Erase Fault Log
Preset Eng Values Set To Factory Defaults.
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 Motor connector kit E-163
JOYSTICK MODULE TYPE JSM (D49671) E-139
COMPLETE WITH BUS CABLE.
POWER MODULE 50A (D49975) E-138
CONTROL LOOM A10-05B.
REAR BATTERY BOX LOOM A10-04B.
P&G MOTOR PLUGS WIRING
LH MOTOR E-131L
RH MOTOR E-131R
FRONT LOOM G-350D
LH MOTOR
RH MOTOR
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 Log Display Fault Code History.
Preset Control System
Restore Factory Defaults.
Help Mode
Diagnostics Read Fault code
Engineering Menu
Set Soft Reverse Prevent Reversing Digging In. 70%
Set Current Limit Max & Min Current Limits. 40A Max-40A Min
Set Foldback Temp Reduce Current At This Temp.
55°C
Set Timed Foldback Reduce Current After This Stall Time. 25%-60sec
Set Compensation Match Motor Impedance.
160 m-ohm
Set Battery Menu Match Controller to Loom Resistance 64 m-ohm
Set Park Brake Trip Chairs With No Brakes. No
Set Front Drive Front Wheel drive chairs. No
Set Min Accn 43%
Set Min Decel’n 57%
Set Min Turn Accn 50%
Set Min Turn Decel’n 66%
Erase Fault Log
Preset Eng Values Set To Factory Defaults.
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-350D
LH MOTOR E-131L
RH MOTOR E-131R
NEUTRIC SOCKETS WIRING
CONTROL LOOM A10-15
DYNAMIC DL CONTROLLER WITH DX
CONNECTORS (DL40UDH1) E-116
Page 36
Dynamic DL 40A (DL40UDH1) Parameters
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 damage. Check the beau plug connector
which should be tight fitting so that it is not easily dislodged in use.
Check the plugs connecting the main loom to the motor and battery looms should be
examined to ensure that the wiring is secure with no evidence of chafing or damage. The contacts
inside the plugs should be inspected for prominence to ensure good contact is made.
A stall-test should be performed to check that the circuit breakers function correctly. Place
the powerchair with the castor wheels against a solid object and ensuring the drive wheels do not
spin, push the joystick forward. After a short period the power to the motors will be cut by the
operation of the circuit breakers.
Reset the circuit breakers by pushing in the buttons which are found on the battery boxes.
14.11 Wiring Loom Removal and Replacement
Disconnect the beau-plug from the rear of the controller. Disconnect the motor and battery
loom plugs from the main loom and withdraw the main loom.
To replace, feed the main loom underneath the seat from the same side as the controller.
Connect the motor and battery loom plugs to the main loom and re-connect the beau plug to the
controller. The application of petroleum grease to the contacts will assist in assembly and offer
protection against moisture.
14.12 Battery Loom Removal and Replacement
There are two distinct looms fitted depending on which battery box is being worked upon.
When viewed from the rear of the powerchair the front battery box has a loom with one grey plug,
the rear battery box has a loom with two plugs - one grey and one black.
Remove the rear battery box from the powerchair and remove the lid. The connections to
the battery terminals should be removed and then pull off the connections to the circuit breaker.
Re-fitment is a reversal of the above. Note that the grey plug is positioned to the front and
the black plug exits from the rear.
Remove the front battery box from the powerchair and remove the lid. The connections to
the battery terminals should be removed and then pull off the connections to the circuit breaker.
Re-fitment is a reversal of the above. Note that the grey plug exits from the rear of the lid.
Red Wire = Positive
Black Wire = Negative
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 serrated nut on the outside and release.
Re-fitment is a reversal of the above.
14.14 Batteries and Battery Charging
The batteries and battery charger require no maintenance but a check for function should
be carried out.
14.15 Battery Inspection
Remove the batteries from the powerchair and from their containers. It should be noted if
the battery connections are tight.
Examine the batteries for any damage. Beware : acid-gel may leak from a damaged
battery which is highly corrosive. Any contamination should be washed off immediately with
copious amounts of clean water. Seek medical advice if any irritation persists. The battery
condition should be checked. Ideally this should be done using specialised equipment such as a
discharge tester. However this may take several hours as the battery will be left in a discharged
state and will require re-charging. At the least a 'drop-test' should be performed using a simple
car battery load tester. This measures internal resistance and it is known that the internal
resistance of a battery increases as the battery ages and performance decreases. This type of
test does not provide an assurance that the battery is fully capable of delivering its rated active
energy and is dependent on the experience of the test engineer. All testing should be performed
on fully charged batteries and the test engineer should satisfy himself that this is so.
14.16 Battery Replacement
If the batteries are deemed fit for further use they may be re-fitted to the powerchair.
Replace in their containers and smear the terminals with petroleum grease. Ensure the connections are tight and the battery wiring looms are undamaged. Refit to the powerchair.
14.17 BATTERY CHARGER
YELLOW MAINS LIGHT ON ONLY
NO LIGHTS
The mains supply is not reaching the charger. Check that the mains is working, and that the mains
plug and fuse are in correct working order.
FLASHING LIGHTS
This indicates that the battery voltage is low.
The charger has a safety feature which prevents it from commencing to charge if the
battery voltage is lower than 8 volts for a 12 volt battery. This low voltage battery condition is
usually the result of a very deep discharge or totally worn out battery.
YELLOW MAINS LIGHT ON ONLY
If one yellow light is on only and goes out when mains is disconnected, the battery is not
properly connected or may be flat. Check the integrity of the battery connections. Disconnect the
mains supply.
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 connected).
CONTROLLER LIGHTS FLASH
The Penny & Giles Pilot controller has a built-in diagnostics system, which shows the related 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
1 Check that the drive lock devices are engaged.
2 If no click audible from the motor when joystick is first moved; check the brake connections.
3 If clicks are heard, check motor connections.
A P&G PROGRAMMER (REF PP1) MAY BE USED TO PROGRAM PARAMETERS AS LISTED IN THE FOLLOWING TABLES.
Parameters should only be modified by a qualified person.
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
still connected).
CONTROLLER LIGHTS FLASH
The Control Dynamics DL controllers have a built-in diagnostics system, which shows the
related fault by the number of times the lights flash. In order to identify the fault count the number
of times the lights flash and refer to the tables below. The diagrams below show the light displays
(see FIG 1).
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 clutch dog’s are engaged.
2. If no “click“ is audible from the motor when the joystick is moved then check the
brakes.
3. If “clicks” are audible the check the motor connections.
2. POWERCHAIR DOES NOT DRIVE STRAIGHT
1. Check motor connections.
2. Check brake connections.
3. Check for one brake dragging, (the casing will be warmer).
4. Check that both parking brakes are released.
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 Legrest Carrier
Bracket, Left or Right SF95
Calf Pad Swivel Bracket SF89
Stem Swivel Tube, Left or Right SF88
Calf Pad MCP TSD10241
Clamp Assembly M102
1/4 UNF Nyloc Nut, zinc plated P90
1/4 UNF x 1 7/8 HT Bolt, zinc plated F12
1/4 UNF x 1 1/4 HT Bolt, zinc plated F7
1/16 x 1/2 Split Pin F153
1/4 x 18G Plastic Plug M9
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 the powerchair by lifting and rotating the hanger section.
Release stem clamp and withdraw footplate and stem.
Release nuts securing calf pad and remove.
Release pivot bolt and separate elevating section from swiveling section.
Remove rubber end cap from adjustment rod, and holding trigger withdraw rod.
15.5 Elevating Legrest Fitting
Assemble elevating section to swivelling section. Use new pivot bolt, if necessary.
Slide adjustment rod through bracket and trigger ensuring spring is positioned to force trigger
forward. Replace rubber end cap.
Assemble calf pad to bracket. Tighten nuts to 10 lbs/ft (13 Nm).
Insert footplate stem into tube and tighten clamp to 35 lbs/ft (47 Nm).
Apply light grease to swivelling end and insert into castor tube.
Ensure no grease/oil on adjustment rod or it will cause slippage.
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 Outrigger Spacer
G274
1/4 x 7/8 UNF Hex Head Bolt Zinc Plated F3
1/4 x 1 1/8 UNF Hex Head Bolt Zinc Plated F4
1/4 UNF Nyloc Nut Zinc Plated P90
7/8 Black Plastic Bung M17
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 nuts securing sockets to side frame and remove.
Slide sockets away from frame and remove spacers.
Release extension bracket from backrest.
16.5 Fitting
Replace spacers in side frame sockets.
Slide outrigger sockets into position and insert bolts.
Tighten nuts to 10 lbs/ft (13 Nm).
Hook rear bracket over backrest loop and tighten screw to 3 lbs/ft (4 Nm).
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.
Check all adjustment knobs are present, undamaged and hold tray at the required position.
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 tray, into the
armrest stem assembly with the horizontal extensions of the mounting stems projecting forward.
Place the tray symmetrically on the stem brackets, ensuring that the flat plates are located
between the two guide strips on the under-side of the tray.
Mark through the screw holes in the stem brackets.
Remove the tray and brackets from the powerchair and secure brackets to tray with screws
supplied.
Refit tray assembly to the powerchair. Screw the two loose knurled knobs supplied with the tray
assembly, into nuts welded to the armrest stem assembly item 'C'.
Adjust tray position and tighten the four knobs.
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 Plain Washer Zinc
Plated F207 Spacer
TSD 3708 M6 form C washer
Zinc Plated F204 Spring
G298 Spring Cover
M152 M6x25 Skt Hd Screw Zinc Plated
F206 Spring Spacer
G220/10 M4x40 Csk Skt Hd Screw Zinc
Plated F84 Actuator Bush
G222 Retaining clips (Not Shown)
F136
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 of the actuator
which should be between 115-125mm.
Check the rubber pad is securely bonded to the actuator foot and is not badly damaged.
Remove the kerb climber and check security of all nuts and bolts. Thoroughly inspect the
cross-bar and actuator for signs of bending and cracking.
Inspect side-frame anchorage points for signs of distortion, bending or cracking.
18.4 Kerb Climber Dismantling
Remove kerb climber from powerchair. Undo nut and bolt attaching lower spring location
to actuator. Withdraw bolt and retain spacer and washers.
Moving to cross-bar undo nut and bolt securing collar which is not attached to the spring
and slide off cross-bar. Release the upper spring location from the actuator and withdraw the bolt,
retaining the spacer and washers. The actuator can now be removed from the cross-bar.
Remove the nut and bolt securing the collar which had spring attached and slide the collar off the
cross-bar.
18.5 Kerb Climber Assembly
Assembly is a reversal of the above procedure. Ensure that new nuts (Nyloc or similar) and
bolts are used and are torque tightened to 10 lbs/ft (13 Nm).
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
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
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