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Permobil K450 Service Manual

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SERVICE MANUAL
US
Permobil K450
Power Wheelchair

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Summary of Contents for Permobil K450

  • Page 1 SERVICE MANUAL Permobil K450 Power Wheelchair...
  • Page 3 How to contact Permobil Head Office of the Permobil group Produced and published by Permobil AB, Sweden Version 2, 2009-02 Order no.: 205231-US-0...

  • Page 4: Table Of Contents

    Contents Contents Introduction ...................... 5 Rating plates ....................6 Batteries ......................7 Covers ......................8-11 Rear wheels ....................12-13 Front wheels ..................... 14-15 Wheel fork ....................... 16 Shock absorbers .................... 17 Suspension ....................18-19 Link arms....................20-21 Brake release cables ................. 22-23 Magnetic brake ..................

  • Page 5: Introduction

    Permobil to ensure that the correct information is provided. Technical Support In the event of technical problems, you should contact your dealer, or Permobil Inc. USA at 800-736-0925. Spare parts Spare parts must be ordered through your dealer.
  • Page 6 Serial Number Plate Serial Number Plate Chassis Chassis ID number Power Module Power Module ID number Control panel Control panel ID number...

  • Page 7: Batteries

    Batteries Batteries There are two batteries in the chassis, one on the left side and one on the right side. Removal/fitting is the same on both sides. Removal 1. Place the wheelchair on a level surface. 2. Switch off the main power switch on the control panel.

  • Page 8: Covers

    Covers Covers Removing the upper battery cover An upper battery cover is fitted to the right or left side of the chassis. Removal/fitting is the same on both sides. 1. Remove the knob located on top of the cover. See illustration. The upper battery cover is fitted with a knob on top of the cover.
  • Page 9 Covers Covers Removing the lower battery cover A lower battery cover is fitted to the right or left side of the chassis. Removal/fitting is the same on both sides. 1. Loosen the knob on the front of the cover enough to ensure that the edge of the cover moves freely during removal.
  • Page 10 Covers Covers Removing the rear wings A rear wing is fitted to the right or left side of the chassis. Removal/fitting is the same on both sides. 1. Remove the three screws that secure the cover. See illustration. 2. Remove the rear wing by lifting it straight up. When removing the left rear wing, place the brake release’s release control in the released position to facilitate removal.

  • Page 11: Covers

    Covers Covers Removing the seat lift cover 1. Raise the seat lift to its highest position. If the seat lift cannot be raised in the usual way, use the emergency operation cable. See page 36. 2. Remove the two screws on the right and left side of the cover.

  • Page 12: Rear Wheels

    Rear wheels Rear wheels Removal 1. Switch off the main power switch on the control panel. 2. Lift up and chock up the wheelchair chassis so that the wheel in question is free of the ground. 3. Loosen and remove the hub cap (5), the rubber seal (4) and the wheel bolt and washers (3). See illustration.
  • Page 13 Rear wheels Rear wheels Taking the rim apart The rim can be taken apart to make it possible to fit/remove pneumatic tires. Solid tires can not be removed from the rim, on chassis with solid tires, remove the whole wheel incl. the rim, see page 12. 1.

  • Page 14: Front Wheels

    Front wheels Front wheels Removal 1. Switch off the main power switch on the control panel. 2. Lift up and chock up the wheelchair chassis so that the wheel in question is free of the ground. 3. Remove the hub cap (6). 4.

  • Page 15: Front Wheels

    Front wheels Front wheels Taking the rim apart The rim can be taken apart to make it possible to fit/remove solid or pneumatic tires. 1. Remove the wheel in question from the wheelchair. See the previous page. 2. If the tire is pneumatic, release the air. WARNING Ensure that pneumatic tires are not pressurized before the rim is taken apart, otherwise there is a risk of personal injury.

  • Page 16: Wheel Fork

    Wheel fork Wheel fork Removal 1. Switch off the main power switch on the control panel. 2. Lift and chock up the wheelchair chassis so that the wheel in question is free of the ground. 3. Remove the cap (1) from the top of the link arm.

  • Page 17: Shock Absorbers

    Shock absorbers Shock absorbers Adjusting nut The wheelchair chassis is equipped with shock absorbers in the rear wheel suspension. Adjusting shock absorber spring force The spring force of the shock absorber must be adjusted to the correct value (see illustration). Adjustment can be performed with the shock- Adjustment absorber mounted in the chassi.

  • Page 18: Suspension

    Suspension Suspension The wheelchair’s front wheel suspension is equipped with spring suspension. Removing the suspension mechanism 1. Switch off the main power switch on the control panel. 2. Lift up and chock up the wheelchair chassis so that both front wheels are free of the ground. 3.
  • Page 19 Suspension Suspension Adjusting the spring force The spring force must be adjusted to the right value. See illustration. The spring force can be adjusted to suit different body weights by means of the adjusting nut. Reduce the value for a softer suspension, and increase the value for a harder suspension.

  • Page 20: Link Arms

    Link arms Link arms Removing the front link arm 1. Switch off the main power switch on the control panel. 2. Lift up and chock up the wheelchair chassis so that both front wheels are free of the ground. 3. Remove the suspension mechanism on the relevant side.

  • Page 21: Link Arms

    Link arms Link arms 8. Remove the link arm by pulling it out of the chassis. See illustration. To remove the wheel forks and wheel, see the relevant chapter. Fitting Fit in the reverse order. torque wrench tighten screws holding the link arm in place to 17.7 ft-lbs (24 Nm).

  • Page 22: Brake Release Cables

    Brake release cables Brake release cables Removal 1. Place the wheelchair on a level surface. 2. Switch off the main power switch on the control panel. 3. Switch the main fuse to OFF. See illustration. 4. Remove the left rear wing. When replacing the right brake release cable, remove the rear wing on both the left and right sides.

  • Page 23: Brake Release Cables

    Brake release cable Brake release cable 7. Unhook the brake release cable spring from the magnetic brake. Unhook the brake release cable spring. 8. Remove the cable from the release control. Both the left and right cables are held in place in the same cotter and are secured with the same lock loop.

  • Page 24: Magnetic Brake

    Magnetic brake Magnetic brake Removal 1. Place the wheelchair on a level surface. 2. Switch off the main power switch on the control panel. 3. Switch the main fuse to OFF. See page 42. 4. Remove the rear wing on the relevant side. See page 10.
  • Page 25 Magnetic brake Magnetic brake 8. Unhook the brake release cable spring from the magnetic brake. Unhook the brake release cable spring. 9. Remove the magnetic brake, which is held in place with three screws. See illustration. There is also the release control on the left side of the chassis, held in place with the same screws.

  • Page 26: Brake Release Switch

    Brake release switch Brake release switch Removal 1. Place the wheelchair on a level surface. 2. Switch off the main power switch on the control panel. 3. Switch the main fuse to OFF. See illustration. 4. Remove the left rear wing. See page 10. 5.

  • Page 27: Brake Release Controls

    Brake release control Brake release control Removal 1. Place the wheelchair on a level surface. 2. Switch off the main power switch on the control panel. 3. Switch the main fuse to OFF. See illustration. 4. Remove the left rear wing. See page 10. 5.

  • Page 28: Drive Motor

    Drive motor Drive motor Removal 1. Place the wheelchair on a level surface. 2. Switch off the main power switch on the control panel. 3. Switch the main fuse to OFF. See illustration. 4. Remove the rear wing on the relevant side. See page 10.
  • Page 29 Drive motor 8. Remove the two screws holding the drive motor and gear housing in place. See illustration. Fitting Fit in the reverse order. Use a torque wrench to tighten the screws holding the drive motor and gear housing in place to 7.2 ft-lbs (9.8 Nm) The drive motor and gear housing are NOTE...

  • Page 30: Actuators

    Actuators Actuators Fitting service tools When removing the actuator, the work is made easier if you use a service tool that holds the seat function in place when the actuator is removed. 1. Place the wheelchair on a level surface. 2.
  • Page 31 Actuators Actuators 6. Fit the service tool using the screw previously removed (1). See illustration. 7. Carefully adjust the seat-to-floor function and the seat angle, so that the service tool’s support points (2-4) move freely, but is still so close to the material of the seat structure, around 1-10 mm that the tool “catches”...
  • Page 32 Actuators Actuators Removing the actuator for the seat angle function. 1. Place the wheelchair on a level surface. 2. Fit the service tool. See pages 30-31. 3. Switch off the main power switch on the control panel. 4. Switch the main fuse to OFF. See illustration. WARNING The seat angle function’s actuator Take great care when working with the seat and its actuators,...
  • Page 33 Actuators Actuators 7. Remove the seat angle function actuator’s lower fixing screw. See illustration. 8. Unplug the actuator’s cable at the contact on the cabling. Fitting Fit in the reverse order. Use a torque wrench to tighten the screws holding the actuator in place to 35 ft-lbs (47Nm) Lower fixing screw of the actuator WARNING The actuator must be calibrated after fitting.
  • Page 34 Actuators Actuators Removal of the actuator for the seat- to-floor function. 1. Place the wheelchair on a level surface. 2. Fit the service tool. See pages 30-31. 3. Switch off the main power switch on the control panel. 4. Switch the main fuse to OFF. See illustration. WARNING The seat-to-floor function’s actuator.
  • Page 35 Actuators Actuators Removing the seat lift’s actuator. 1. Place the wheelchair on a level surface. 2. Fit the seat lift lock. See page 30. 3. If required, move the seat-to-floor function down a little to allow better access to the actuator’s upper fixing screw.

  • Page 36: Emergency Operation Of Seat Functions

    Emergency operation of seat functions Emergency operation of seat functions If any of the electric seat functions cannot be operated in the normal way because of a fault other than discharged batteries or a faulty actuator, the function can be operated manually using the emergency operation cable supplied.
  • Page 37 Emergency operation of seat functions 3. Remove the cables associated with the relevant actuator from the General Module. See illustration. Remove the cables associated with the relevant actuator from the General Module. 4. Connect the cables from the actuator with the emergency operation cable.
  • Page 38 Control panel Control panel Removal 1. Switch off the main power switch on the control panel. 2. Remove the cable ties holding the control panel cable in place under the arm rest. Note the positions of the cable ties for subsequent fitting.
  • Page 39 Power Module Power Module Removal 1. Switch off the main power switch on the control panel. 2. Switch the main fuse to “OFF”. See illustration. 3. Remove the chassis cover. See page 10. 4. Disconnect the electrical connections from the power module.

  • Page 40: Ics Master Module

    ICS Master Module ICS Master Module The wheelchair is equipped with an ICS control system. The seat is controlled from the system’s “ICS Master Module”. This is fitted in the wheelchair chassis. Removal 1. Switch off the main power switch on the control panel.
  • Page 41 General module General Module The seat’s actuators are all controlled via their own General Module. These are held in place with two nuts each on the rear of the chassis. Removal 1. Switch off the main power switch on the control panel.

  • Page 42: Fuses

    Fuses Fuses Resetting the main fuse The main fuse also functions as a battery isolator but it is usually called the main fuse. It is not normally necessary to replace the main fuse as it is automatic and can be reset when it has been tripped.
  • Page 43 Fuses & Control System Fuses 5. Remove the cables from the main fuse by unscrewing the screws. See illustration. 6. Switch the new main fuse to “OFF”. 7. Fit the cables to the new main fuse. NOTE Check that the cables are firmly attached. 8.

  • Page 44: Lights

    Lights Lights (accessories) Removing the front lights 1. Switch off the main power switch on the control panel. 2. Remove the battery on the relevant side of the chassis, see page 7. 3. Unplug the light’s cable at the contact on the cable, which is above the battery.

  • Page 45: Lights

    Lights Lights (accessories) Removing rear light 1. Switch off the main power switch on the control panel. 2. Remove the rear wing on the side in question, see page 10. 3. Unplug the cable at the contact on the rear of the light.

  • Page 46: Seat

    Seat Seat Removing the seat plate 1. Switch off the main power switch on the control panel. 2. Remove the two crush guard sensors held in place underneath the seat plate with two screws and nuts on both the left and right side. See illustration.
  • Page 47 Seat Seat Removing the back rest plate 1. Switch off the main power switch on the control panel. 2. Remove the back rest cushion by pulling it straight up until the Velcro on the back releases it. 3. Remove the front back rest plate, which is held in place with six screws.
  • Page 48 Seat Seat Removing the crush guard sensor 1. Switch off the main power switch on the control panel. 2. Remove the crush guard sensor in question, which is held in place with two screws under the seat. See illustration. The crush guard sensor is held in place with two screws.
  • Page 49 Seat Seat Removing the leg support 1. If possible, raise the seat lift to its highest position and angle the seat back to the maximum position for easier access. 2. Switch off the main power switch on the control panel. 3.
  • Page 50 Seat Seat Removing the arm rest 1. Switch off the main power switch on the control panel. 2. Remove the four screws holding the arm rest in place. See illustration. For removal of the control panel, see page 38. Fitting Fit in the reverse order.

  • Page 51: Troubleshooting Guide

    The following troubleshooting guide describes a number of faults and events which may occur when you use your wheelchair, together with suggested remedies. Note that this guide cannot describe all the problems and events which may occur and you should always contact your service contact or Permobil in case of doubt.

  • Page 52: Troubleshooting

    Diagnostics should only be performed by persons with sound knowledge of the wheelchair’s electronic control system. Incorrect or poorly performed repair work may make it dangerous to use the wheelchair. Permobil accepts no liability for any personal injury or damage to the wheelchair and its surroundings that may occur on account of incorrect or poorly performed repair work.
  • Page 53 Troubleshooting Troubleshooting Example of a screen showing a system fault Identified module Error message Controller Fault Low Battery Error code 0506 2C00 Identified module This indicates the control system module that detected the problem. PM = Power module JSM = Joystick module Error message The error message provides a brief description of the error type.
  • Page 54 The system log is accessed by means of programming directly in the system (On Board Programming, OBP). Contact Permobil or your repair engineer for more information on OBP. Go to OBP mode • Select System from the menu.
  • Page 55 Troubleshooting Troubleshooting Definitions of diagnostics messages When an error message has been displayed and the defective module has been identified, you can use the following definitions to determine the possible cause of the error and what remedial action is required to correct it.
  • Page 56 Troubleshooting Troubleshooting Joystick Error The commonest cause for this error is that the joystick was moved away from its central position before and during the time at which the control system was switched on. The screen for a shifted joystick is displayed for 5 seconds.
  • Page 57 Troubleshooting Troubleshooting Joystick Calibration Error This occurs when joystick calibration has been unsuccessful. • Go to OBP mode and recalibrate. If the error persists, the joystick module may be defective. Read more in section 5. Latched Timeout This occurs when the control system detects that the programmed block time has been exceeded. This can, for example, be due to the signal units (joystick, main steering device, suction and blowing device, etc.) not having been used frequently enough.
  • Page 58 Programming should only be performed by persons with sound knowledge of control systems from PGDT. Incorrect programming can mean that the wheelchair is not safe to use. Permobil cannot be held responsible for losses of any kind if the control system...
  • Page 59 Troubleshooting Troubleshooting 3.19 Bad Cable This occurs when the control system detects a connection error in the communication cables between the modules. • Check all cables and connections to ensure there is no stoppage. • Replace any cables with visible damage. Then cycle the voltage. •...
  • Page 60 Troubleshooting Troubleshooting 3.22 System Error This occurs when the control system detects an error that cannot be ascribed to a specific module. • Check all cables and connections. • Cycle the voltage. If the error persists and the system includes third-party modules: •...
  • Page 61 The necessary information on other tests is available in the wheelchair service manual. Permobil cannot be held responsible for losses of any kind that may arise when these tests are conducted, or that arise as a consequence of further relevant tests not being conducted.
  • Page 62 Troubleshooting Troubleshooting Brake test These tests should be carried out on an even surface with at least one yard of free space around the wheelchair. • Switch on the control system. • Check that the screen remains on after start-up. •...
  • Page 63 If any part is replaced without Permobil’s approval, the control system’s warranty lapses. NOTE Permobil cannot be held responsible for losses of any kind arising as a result of a component of the R-net control system being opened, adjusted or modified without permission.
  • Page 64 Diagnostics should only be performed by persons with sound knowledge of the wheelchair’s electronic control system. Incorrect or poorly performed repair work may make it dangerous to use the wheelchair. Permobil accepts no liability for any personal injury or damage to the wheelchair and its surroundings that may occur on account of incorrect or poorly performed repair work.

  • Page 65: Example Of A Screen Showing A System Fault

    NOTE If any part is replaced without Permobil’s approval, the wheelchair’s warranty lapses. Permobil cannot be held responsible for losses of any kind arising as a result of a component of the R-net control system being opened, adjusted or modified without...
  • Page 66 Cabling overview...

  • Page 67: Cabling Overview

    Cabling overview Cabling overview...

  • Page 68: Control System

    The control system can also be programmed in order to make adjustments needed for a specific user. To get more information about standard parameter files, contact your dealer, or Permobil Inc. USA.

  • Page 69: Index

    Index Index Actuators ........30-35 Lights ..........44-45 Link arms ........20-21 Batteries ..........7 Brake release cables....22-23 Magnetic brake ......24-25 Brake release mechanism ....27 Maintenance ........5 Brake release switch ......26 Power Module ........39 Cabling overview......
  • Page 72 Order no.: 205231-US-0...

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