Forums

Welcome Guest 

Show/Hide Header

Welcome Guest, please login or register.





Pages: [1]
 ReplyRSS feed   
Author Topic: New user - New (used) Redman owner
Guest
Newbie
Posts: 3
Permalink
Post New user - New (used) Redman owner
on: October 24, 2012, 02:15
Quote

Hi,
I am the new owner of a 2003 107SRX Redman, S/N 24455, that I purchased a few days ago from the original owner.

I'm a T-5 paraplegic since March of 2010, and am looking forward to standing again, once I get the chair modified to fit me physically, and possibly to better fit my lifestyle...

As I'm more than a bit of an electronics and mechanical hacker, I've been tearing the chair down to clean it up (it has a lot of accumulated crud in the innards) and make sure everything is in working order, plus I don't like using equipment that I don't understand thoroughly...

Initial impressions are pretty good overall, at the very least Redman seems to be better built than the Pride chair I'm sitting in at the moment... However I've run into some significant issues...

1. Data cable between Power Module and Actuator Module was severely crushed between Power Module and seat pan. I was seeing an intermittent connection error on the pod lights, I'm wondering if this could have been cause?

2. Serious wobble / side play in swingarm pivot - left motor. It appears that swingarm pivot was ground down on one side, with slop partially filled w/ nylon & metal washers

3. Seat back pushes me to far forwards, doesn't allow bolster to go in holes. This appears to be the key fitting problem. The seat is the same size as my own (18x18") but I think the original owner is shorter than I am.

4. Plunger cable for footrest disconnected (I reattached?) Not sure why it was unhooked to begin with?

5. Horn only pulls power from one battery BAD DESIGN!!!! (If I put it back, I will need to install a DC-DC converter to enable proper installation...

6. U1 (to small) batteries were crap (and slightly out of balance, presumably due to #5) Need to figure out way to replace with Group 24's

7. Right motor, swingarm bolt loose.

8. Both motors, hub slightly loose on shaft (inherent in keyed design, especially if no setscrews used)

9. Footrest bracket pins overly long - lots of play between arm and support

10. Broken mounting tab on frame for seat lift actuator (very bad weld)

I have lots of photos of my disassembly so far at http://s197.photobucket.com/albums/aa193/Stoveburner/Redman%20Power%20chair/

I am also a heavy poster as "ex-Gooserider" over on WheelchairDriver.com.

Any advice on how best to deal with the above issues (and possibly a better technical manual than the blue notebook I got with the chair) would be appreciated....

ART

Guest
Newbie
Posts: 3
Permalink
Post Re: New user - New (used) Redman owner
on: October 25, 2012, 20:50
Quote

More details and photos on some of the problems I mentioned above... Not sure what the rules are for photo sizes, etc. so this may get spread over several messages.

Some of the items on my list are mostly opinion, but there are several items that are IMHO factory or service related issues, that I'm hoping something can be done about...

1. Data cable between Power Module and Actuator Module was severely crushed between Power Module and seat pan. I was seeing an intermittent connection error on the pod lights, I'm wondering if this could have been cause? I found this almost as soon as I started working on the chair - I would get an intermittent error code on the pod suggesting I had a bad connection, so I was trying to check those and found the pinched cable I mentioned - see the first photo of the cable - the dents are from the cooling fins on the power module. This has apparently been like this for a long time as this sort of damage takes a while.

Unfortunately, the cable is soldered onto the actuator circuit board, and the plug end is a special P&G connector, so replacing it isn't trivial - though if I can find a compatible cable I wouldn't hesitate to do it, the board is a pretty simple design, and the cable only has 5 wires... (BTW, I almost got a NASA Satellite soldering certification once, so my skills are more than up to it...)

2. Serious wobble / side play in swingarm pivot - left motor. It appears that swingarm pivot was ground down on one side, with slop partially filled w/ nylon & metal washers. I didn't take measurements on just how much play there was, but it was quite visible, I'd guess at least 1/8" if not 1/4" - don't know what the allowed spec is, but it certainly seems excessive. See the second photo. It's a bit blurry, but you can clearly see where the swingarm pivot metal has been ground away. The corresponding area on the right side swingarm actually sticks out slightly past the metal angle it attaches to. The ground pivot is 1.763" long, while the other pivot is 1.912" long. The frame has a 1.919" gap between the pivot lugs on the right, and 1.916" on the right. The frame lugs all show bright metal on the contact surfaces, while the three non-ground faces of the swingarms all show undamaged powder coating (which suggests to me that the gap is a bit excessive to begin with...)

The right side swingarm pivot also shows perceptible play, but it isn't as bad as the left side, and might even be tolerable given the slow speeds involved.

Will continue this in my next post...

Image
Image

Guest
Newbie
Posts: 3
Permalink
Post Re: New user - New (used) Redman owner
on: October 25, 2012, 21:17
Quote

10. Broken mounting tab on frame for seat lift actuator (very bad weld)

When I was taking the seat lift actuator off to clean it, and the frame around it, I discovered that one of the two tabs on the frame that it fits between was broken off the frame. There was little or no corrosion on the broken weld, but the rest of the chair also shows no signs of corrosion, so it is hard to say how long the weld had been broken.

A couple of the welders I showed the break to were very emphatic about the poor quality of the weld (to put it very gently) and this shows very clearly in the photos. The tab was supposed to be welded on the two short ends, and one long side, as is it's mate. However examination of the failed joint shows a very small area of weld fusion on each short end, and a weld bead that ran down the long end, with absolutely NO fusion to the tab - It looks like something out of a text book on defective welds. While granted failures can happen with the best of processes, it does not inspire me with great confidence in the rest of the chair - I keep wondering what sins the powder coat is hiding on the other welds...

The first photo isn't great, but it shows the frame area the tab came off of. It's rather hard to get the camera in there to get a good shot.

The next two photos are of the broken tab end. It is worth noting that there was a pretty clear heat effected zone on the tab, just no weld penetration or fusion...

This is one that I really need to find out what (if anything) Redman will do about, as if they won't fix it, I will need to weld it back up myself (I've had about 5 hours of TIG training, and my instructor tells me I can do a better job than the person that made the weld initially....)

ART
Image
Image
Image

Guest

Posts: 1
Permalink
Post Re: New user - New (used) Redman owner
on: November 7, 2012, 01:56
Quote

Just as an update, I've stripped the powder coat off the battery box frame and the broken frame lug.

I've welded the lug back on.

I have cut the battery box frame apart, and have partially welded it back together in the process of enlarging it so that I can run either two Group 24 batteries or a Lithium-Iron-Phosphate (LiFePO4) pack of 64 12Ah Headway cells (11cells wide x 6 high, less two cells on the top row, configured as an 8s x 8p package - this give 96 USABLE Ah, which is a huge improvement over the useless U-1 batteries that the chair came with...

ART

Quick Reply:


Enter Security Code: (required)
Pages: [1]
 ReplyRSS feed   
Mingle Forum by cartpauj
Version: 1.0.34 ; Page loaded in: 0.063 seconds.