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1.
Place the U-shaped reinforcing plate inside the battery box and the align holes in
the reinforcing plate with the pre-drilled holes in battery box.
2.
Place nuts in predrilled holes in the battery box with the recess down.
3.
Fit the 8 mm spacer onto lock plate and put the five bolts (Dahl #502800) through
the lock plate and 8 mm spacer.
4.
Mount the bolts in the nuts and tighten to a torque of 16-18 Nm.
WARNING!
Do not use any other bolts than those supplied from Dahl Engineering (part#502800
which is quality 14.9, Torx key size 27). Standard countersunk M8 bolts will not be
strong enough in the event of a collision.
5.
Cut of excess thread. It is very important that the fitter checks that the length of
the bolts are correct. If bolts are made too short to reach through all threads in
the nuts – they will not have the strength to carry the load required. If bolts are
made too long the batteries or other wheelchair components can be damaged. If
bolts are cut too short replace them with original Dahl bolts #502800 only.
6.
Apply Loctite 222 (or an equivalent product) onto treads on all bolts.
7.
Place plastic spacers, as shown inside the battery box, to avoid batteries coming
into contact with the nuts and bolt ends.
8.
Perform final check by connecting the wheelchair to the docking station. Make
sure that lock plate is securely locked and that all release methods work as
intended.
A warning tone will sound if lock plate is not properly engaged.
General description of how the Dahl Docking system Mk ll. Functions:
Securing the wheelchair in the docking station:
1. Maneuver the wheelchair slowly and in a uniform direction over the docking
station. The lock plate under the wheelchair helps to guide the wheelchair into place in
the docking station. When the lock plate is fully engaged in the docking station, a
spring-action locking pin automatically secures the lock plate.
2. The docking station is equipped with a control switch that indicates whether the
lock plate is correctly secured in the docking station. As soon as the lock plate comes
(1)
Dahl Docking station
(2)
Lock plate and spacer
(3)
Lock pin
(4)
Red LED
(5)
Green LED
(6)
Control panel
(7)
Release button
(8)
Manual emergency
release lever
(9)
Manual operating lever
