Permobil K450 Service Manual Download

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Permobil K450

SERVICE MANUAL

Power Wheelchair

Summary of Contents for K450

Page 1: ...Permobil K450 SERVICE MANUAL Power Wheelchair US ...

Page 2: ......

Page 3: ...Produced and published by Permobil AB Sweden Version 2 2009 02 Order no 205231 US 0 How to contact Permobil Head Office of the Permobil group ...

Page 4: ...ms 20 21 Brake release cables 22 23 Magnetic brake 24 25 Brake release switch 26 Brake release controls 27 Drive motor 28 29 Actuators 30 35 Control panel 36 Power Module 37 Emergency operation of seat functions 38 ICS Master Module 39 ICS General Module 40 Fuses 41 43 Lights 44 45 Seat 46 50 Troubleshooting guide 51 65 Cabling overview 66 67 Control system 68 Index 69 ...

Page 5: ...work is performed professionally Always state the chassis number when contacting 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 Warranties Contact your dealer or Permobil Inc USA for information about the wa...

Page 6: ...6 Serial Number Plate Serial Number Plate Chassis Chassis ID number Power Module ID number Control panel ID number Power Module Control panel ...

Page 7: ...emove the upper and lower battery cover See pages 8 9 Lift pull the battery out of the chassis Battery removed Main fuse battery isolator On Off 5 Use the battery belt to pull lift the battery from the chassis 6 Disconnect the battery connections See also the sticker on the inside of the left lower battery cover Fitting Fit in the reverse order Be careful when using metal objects when working with...

Page 8: ...g 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 Removing fitting the upper battery cover 2 Unfold the cover and angle it outwards around 90 Next lift the cover out from the chassis See illustration Fitting Fit in the reverse order ...

Page 9: ...ted 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 Removing fitting the lower battery cover 2 Unfold the cover in front Next pull it forward to release the cover at the rear Fitting Fit in the reverse order ...

Page 10: ...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 Removing the chassis cover 1 Remove the bumper which is held in place with two screws See illustration 2 Remove the two screws holding the chassis cover See illustrat...

Page 11: ...ift 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 See illustration Fixing screws on the top of the cover 3 Remove the two screws on the top of the cover See illustration ...

Page 12: ...eplace damaged parts 2 Check that the parallel key is properly located and is not damaged Fit a new parallel key if necessary 3 Lubricate the axle with a thin layer of copper paste Würth 0893800x Art no 1820540 4 Fit the wheel on the axle using just your hands Check that the wheel is fully located on the axle If necessary use a rubber mallet carefully 5 Fit the wheel bolt and washers 3 Tighten the...

Page 13: ... 00 x 6 8 Screw M8x35 8 8 Fe Zn 5 C1 Item Description 2 1 8 Ensure that tire is not pressurized before the rim is taken apart otherwise there is a risk of personal injury 3 Remove the four screws holding the two halves of the rim together see illustration 4 Take the rim apart Fitting Fit in the reverse order Use a torque wrench to tighten the screws holding the rim halves in place to 17 7 ft lbs 2...

Page 14: ... wheel is fully located on the axle 3 Fit the screw 1 in the wheel fork 4 Lubricate the axle 2 with a thin layer of copper paste Würth 0893800x Art no 1820540 5 Fit the wheel 3 and axle 2 washer 4 and nut 5 and tighten the wheel 6 Fit the hub cap 6 Use a torque wrench to tighten the bolt to 24 ft lbs 33Nm Rim mounting 4 3 2 1 No type of screw washer or nut other than those stated here may be used ...

Page 15: ...C1 Item Description 2 1 8 Ensure that pneumatic tires are not pressurized before the rim is taken apart otherwise there is a risk of personal injury 3 Remove the three screws holding the two halves of the rim together see illustration 4 Take the rim apart Fitting Fit in the reverse order Use a torque wrench to tighten the screws holding the rim halves in place to 7 2 ft lbs 9 8 Nm The recommended ...

Page 16: ...ut 2 from above See illustration Fitting Fit in the reverse order Lubricate the bolt 8 with a thin layer of copper paste Würth 0893800x Art no 1820540 Use a torque wrench to tighten the bolt to 51 6 ft lbs 70 Nm Do not use an impact wrench for the tightening torque Wheel fork 1 Cap 2 Nut DIN 934 M14x1 5 8 Fe Zn 8 C1 3 Link arm 4 Bearings 6002 2RS1 15x32x9 5 Circlips DIN 472 Ø32 6 Spacer SS EN 1027...

Page 17: ... 0 45 11 5 mm 0 47 12 mm Adjustment Fitting removing the shock absorbers Fitting 1 Adjust the spring force of the shock absorber before fitting See above 2 Lubricate the shock absorber s bearing points with grease 3 Fit the shock absorber with the two screws Fit in the middle hole on the link arm see illustration Shock absorbers The wheelchair chassis is equipped with shock absorbers in the rear w...

Page 18: ... pull lift the batteries out on both sides of the chassis 5 Remove the two screws holding the suspension mechanism on both sides of the chassis See illustration 6 Move the suspension mechanism out of the chassis through the recess on the left or right side The suspension mechanism is held in place with two screws on each side of the chassis Fitting the suspension mechanism Fit in the reverse order...

Page 19: ...t nut clockwise for harder suspension and anti clockwise for softer suspension Hold the axle using a suitable tool for instance a screwdriver in the hole in the middle of the axle See illustration Adjusting nut Body weight Adjustment Adjusting the suspension 0 33 lbs 33 66 lbs 66 99 lbs 99 125 lbs 0 22 5 5 mm 0 26 6 5 mm 0 33 8 5 mm 0 39 10 mm It is important to adjust the suspension correctly Rem...

Page 20: ...e screw that holds the link arm in place at the front See illustration Remove the screw holding the link arm in place at the rear 6 Remove the screw that holds the link arm in place at the rear See illustration 7 Remove the longer screw at the front by first holding onto the screw and loosening the nut Then loosen the screw fully 5 Fit a longer screw with nut and washer in the same screw hole Tigh...

Page 21: ... out of the chassis See illustration To remove the wheel forks and wheel see the relevant chapter Fitting Fit in the reverse order Use a torque wrench to tighten the screws holding the link arm in place to 17 7 ft lbs 24 Nm Do not use an impact wrench for the tightening torque NOTE ...

Page 22: ...ht brake release cable remove the rear wing on both the left and right sides See page 10 The protective plate is held in place with three screws 6 Loosen the brake release cable in question from the magnetic brake by pulling the cable sheath down and pulling the cable out through the cable holder groove See illustration Off On 5 Remove the protective plate which is held in place with three screws ...

Page 23: ...tment screw 2 on the cable in question Fitting Fit in the reverse order Locking nut 1 Adjusting screw 2 The cables are secured to the cotter with a lock loop 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 ...

Page 24: ...cable at the contact on the cable See illustration 6 Remove the protective plate which is held in place with three screws See illustration Thread the magnetic brake cable and on chassis with lights the light cabling through the plate s cable duct Note the cable layout for subsequent fitting 7 Loosen the cable from the magnetic brake by pulling the cable sheath down and pulling the cable out throug...

Page 25: ... 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 Check the function of the brake release after fitting When the brakes are disconnected it should not be possible to drive the wheelchair Fitting Fit in the reverse order Use a torque wrench to tighten the screws holding the magnetic brake i...

Page 26: ...Remove the protective plate which is held in place with three screws See illustration Check the function of the brake release after fitting When the brakes are disconnected it should not be possible to drive the wheelchair 6 Unplug the switch cable at the contact on the cabling 7 Remove the brake release switch which is held in place with two screws See illustration 8 Cut the cable tie holding the...

Page 27: ...om the release control Both the left and right cable are held in place in the same cotter and are secured with the same lock loop See illustration below 9 Loosen the locking nuts and fully unscrew the adjustment screws Fitting Fit in the reverse order Use a torque wrench to tighten the screws holding the magnetic brake in place to 2 1 ft lbs 2 9 Nm The protective plate is held in place with three ...

Page 28: ...ion 4 Remove the rear wing on the relevant side See page 10 Cabling for magnetic brake and drive motor 6 Remove the protective plate which is held in place with three screws See illustration 7 Remove the magnetic brake See page 24 5 Unplug the magnetic brake and the drive motor s cable at the contact on the cable See illustration Off On Main fuse battery isolator On Off 1 2 2 ...

Page 29: ...r and gear housing in place to 7 2 ft lbs 9 8 Nm Drive motor and gear housing Check the function of the brake release after fitting When the brakes are disconnected it should not be possible to drive the wheelchair NOTE 3 1 Hexagon socket head cap screw M5x12 8 8 Fe Zn 5 C1 2 Hexagon socket head cap screw M8x25 8 8 Fe Zn 5 C1 TAPTITE 3 Hexagon socket head cap screw M6x60 8 8 Fe Zn 5 C1 Item Descri...

Page 30: ...functions cannot be moved in the usual way the function can be moved manually using the accompanying emergency operation cable See pages 36 37 3 Fit the seat lift lock turn the lock so that the beveling on its edge is facing down to the left and facilitates fitting See illustration Turn the seat lift lock 180 to secure its fitting Fitting the seat lift lock 4 With the seat lift lock in place turn ...

Page 31: ...e function Support point for the seat to floor function Be particularly careful when adjusting the service tool Careless operation of the actuator with the service tool fitted may damage the seat structure as well as the tool Take great care when working with the seat and its actuators there is always a risk of personal injury caused by crushing or pinching The service tool is fitted with the scre...

Page 32: ...ower switch on the control panel 4 Switch the main fuse to OFF See illustration 5 Remove the actuator s upper fixing screw See illustration 6 Remove the upper fixing screw for the seat to floor function actuator See page 34 Next move the upper part of the seat to floor function actuator forward and out of the way This provides access to the seat angle function actuator s lower fixing screw Take gr...

Page 33: ...n 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 The actuator must be calibrated after fitting Detailed information on calibration is available in the technical manual for the ICS control system WARNING ...

Page 34: ...actuator s upper fixing screw See illustration 6 Remove the actuator s lower fixing screw See illustration 7 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 Take great care when working with the seat and its actuators there is always a risk of personal injury caused ...

Page 35: ...crew Upper fixing screw of the actuator Lower fixing screw of the actuator 6 Remove the actuator s upper fixing screw See illustration 7 Remove the 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 Take great care when w...

Page 36: ...reat care When the seat is operated in the emergency mode all safety functions in the control system are bypassed There is a risk of crushing and a risk of damage to the wheelchair Never drive the wheelchair and use the emergency operation cable at the same time Following emergency operation the relevant actuator must be recalibrated Detailed information on calibration is available in the technica...

Page 37: ...th the relevant actuator from the General Module Connect the cable from the actuator with the emergency operation cable 4 Connect the cables from the actuator with the emergency operation cable See illustration 5 Use the control lever on the emergency operation cable to operate the function you have chosen to connect to one of the holes See illustration below Maneuvering using the emergency operat...

Page 38: ...if there is one fitted see illustration Fitting Fit in the reverse order The control panel is held in place with two screws 1 2 The position of the control panel s bracket is locked with a screw Removal incl bracket 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 sub...

Page 39: ...ssis cover See page 10 4 Disconnect the electrical connections from the power module Note their positions see illustration below Motor 1 Left Motor 2 Right Battery Inhibit External charging socket 5 Remove the power module by unscrewing its two fixing nuts See illustration Fitting Fit in the reverse order The power module is fitted with two nuts Off On Main fuse battery isolator On Off ...

Page 40: ...itch the main fuse to OFF See illustration 3 Remove the chassis cover See page 10 40 ICS Master Module The ICS Master Module stage is fitted with Velcro 5 Pull the cover off 6 Cut off the cable ties that hold the cables in place and detach the electrical connections Note their positions for subsequent fitting Fitting Fit in the reverse order 4 ICS Master Module is fitted with Velcro Remove it by p...

Page 41: ...for Seat to floor function 3 General Module for Seat lift 4 Remove the General Module in question It is held in place with two nuts on the left side see illustration Removing nos 2 and 3 is easier if the contact blocks are removed These are held in place with two nuts each See illustration below 5 Remove the actuator s cable from the General Module in question 6 Remove the General Module s cable f...

Page 42: ...fore the fuse is reset Fold the battery connection cables under so they cannot come into contact with the battery terminals Note the direction in which the fuse is installed for subsequent fitting The ON OFF position must match the appropriate sticker on the chassis 3 Remove the two screws and spacers fitted on both sides of the chassis See illustration Replacing the main fuse 1 Switch the main fu...

Page 43: ... both sides of the chassis See illustration 10 Refit the batteries See page 7 11 Switch the main fuse to ON Check that the cables are firmly attached 8 Fit the new main fuse in place in the chassis 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 Refitt the two screws on both sides of the ...

Page 44: ...le The front lights are fixed in place with two screws on each link arm 5 Remove the two screws that hold each of the lights in place These are on top of the link arm See illustration Removing fitting the front light 6 Lift the light straight up and pull the cable from the link arm Fitting a new light on the same link arm is made easier if a piece of string is tied to the cable at its contact befo...

Page 45: ... 7 2 Remove the light see above 3 Unplug the light cable at the contact on the cable See illustration 4 Undo the cable at the binding clips and pull the cable out of the chassis ducts Note the cabling layout for subsequent fitting Fitting Fit in the reverse order 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 que...

Page 46: ...e crush guard is held in place with two screws each The seat plate is held in place with four screws 3 Remove the crush guard held in place underneath the seat plate with two screws and nuts on both the left and right side See illustration 4 Remove the seat cushion by lifting it straight up until the Velcro on the back releases it 5 Remove the seat plate which is held in place by four screws See i...

Page 47: ...th four screws The accessory rails are held in place with a screw and nut 4 Remove the rear back rest plate which is held in place by four screws See illustration Fitting Fit in the reverse order Removing accessory rails There are three rails on the rear of the back rest for fitting an arm rest and accessories such as a head rest When changing the back rest plate move the rails over to the new bac...

Page 48: ...sh 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 Crush guard sensor 3 Unplug the switch cable at the contact on the cabling Fitting Fit in the reverse order Check the function of the crush guard after fitting NOTE ...

Page 49: ...witch on the control panel 3 Remove the leg support in question held in place with three screws on each side under the seat See illustration The leg support is held in place with three screws on each side Fitting Fit in the reverse order The leg support is heavy Once the screws have been removed loosen the leg support s mounting rails and locking knob This should be done by two people NOTE ...

Page 50: ...anel see page 38 Fitting Fit in the reverse order The arm rest is held in place with four screws The arm rest cushion is held in place with two screws underneath Removing the arm rest cushion 1 Switch off the main power switch on the control panel 2 Remove the two screws underneath the arm rest that are holding the arm rest cushion in place See illustration Fitting Fit in the reverse order ...

Page 51: ...ir cannot be Battery charger connected Stop charging and disconnect driven the charging cable from the wheelchair s charging socket Brake release activated Reset the brake release The wheelchair is locked Unlock the wheelchair See user manual An exclamation mark on Electronics fault See pages 52 65 the control panel display is flashing rapidly and the wheelchair cannot be driven The wheelchair can...

Page 52: ...chair s electrical system NB If the fault is in a module that is not currently being used it will still be possible to drive the wheelchair but the diagnostic screen will be displayed occasionally Switch the wheelchair off and leave it off for a few minutes Then restart the wheelchair If the fault persists you must switch off the wheelchair and contact your service contact Write down the informati...

Page 53: ...otection circuit has been triggered PM Low Battery 2C00 Error code Identified module Error message PM 0506 Controller Fault 2 1 4 Example The screen example shown below displays the following information Identified module Power module error Error message Low Battery Error code 2C00 This means that the battery needs charging or that the battery has not been connected properly Check the battery conn...

Page 54: ...n 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 Select Diagnostics from the menu The diagnostics screen will now appear showing the connected modules and version history See the illustration below If a module has experienced no errors the message No Entries will be displayed otherwise something si...

Page 55: ...ror Go to section 3 5 M2 Motor Error Go to section 3 5 Inhibit Active Go to section 3 6 Jstick Cal Error Go to section 3 7 Latched Timeout Go to section 3 8 Brake Lamp Short Go to section 3 9 Left Lamp Short Go to section 3 10 Right Lamp Short Go to section 3 10 L Ind Lamp Short Go to section 3 11 R Ind Lamp Short Go to section 3 11 L Ind Lamp Failed Go to section 3 12 R Ind Lamp Failed Go to sect...

Page 56: ...ween the control system and the batteries Check the batteries and their connection to the control system If the error persists after the batteries and connections have been checked the power module may be defective Read more in section 5 3 4 Brake Error This occurs when the control system detects a problem in the solenoid brakes or the connections to them 1505 M1 Brake Error 1506 M2 Brake Error Ch...

Page 57: ... in the brake lamp electrical circuit Read more about connectors in section 2 3 Check the brake lamps their cables and the connections to the control system 3 10 Lamp Short This occurs when the control system detects a short circuit in the electrical circuit of one of the lamps 7205 Short circuit left hand lamp 7209 Short circuit right hand lamp Check the lamps their cables and the connections to ...

Page 58: ...voltage If this has dealt with the error Connect one third party module at a time and cycle the voltage each time If the error recurs after one of the voltage cycles the last module to be connected must be defective If the error persists after the checks listed above the power module may be defective Read more in section 5 3 18 PM Memory Error This is a specific error in the power module Check all...

Page 59: ...ings Check all parameter settings and then reprogram the control system with the help of R net s PC programmers Make a note of the current parameter settings and then reset the control system to the standard settings Reprogram the required settings in small groups and cycle the voltage after each group to see if the error recurs If the error persists after the checks listed above the power unit ma...

Page 60: ...n 5 3 23 Gone to Sleep energy saving mode This occurs when the system has not been used for a period that exceeds the Sleep Timer parameter used for setting the energy saving mode Each time this occurs it is registered in the system log 3 24 Charging This occurs when the control system detects that a charger has been connected to either inhibit contact 1 or inhibit contact 3 Read more about connec...

Page 61: ... securely installed Do not over tighten the fixing screws WARNING The tests described are minimum recommendations It is the responsibility of the repair engineer s to perform other tests on the basis of the original error source and the wheelchair model The necessary information on other tests is available in the wheelchair service manual Permobil cannot be held responsible for losses of any kind ...

Page 62: ...moothly and is easy to maneuver Repeat the test with the speed control set to the highest possible value 4 4 Gradient test Run the wheelchair forwards up its steepest permitted gradient Release the joystick when the wheelchair is on the upward slope and check that the wheelchair stops and that the brakes function as they should without the front wheels lifting from the ground Bring the joystick fo...

Page 63: ...g that is in the seat and light module ISM 4 7 Test of inhibit signal Connect a suitable battery charger or equivalent inhibit connecting device in the charging contact on the joystick module and check that the wheelchair is prevented from running If inhibit contacts 2 3 4 and 5 are used for inhibiting or speed restriction an appropriate test should be performed in order to check that they are fun...

Page 64: ...chair s electrical system NB If the fault is in a module that is not currently being used it may still be possible to drive the wheelchair but the diagnostic screen will be displayed occasionally Switch the wheelchair off and leave it off for a few minutes Then restart the wheelchair If the fault persists you must switch off the wheelchair and contact your service contact Write down the informatio...

Page 65: ...dentified module Error message PM 0506 Controller Fault Repair of defective units Apart from specific OEM approved spare parts contact Permobil for further information on these there are no replaceable parts in the R net control system Consequently defective units must be sent to Permobil or a Permobil approved repairer for repair NOTE If any part is replaced without Permobil s approval the wheelc...

Page 66: ...66 Cabling overview A B C D E F 1 2 3 4 ...

Page 67: ...67 Cabling overview Cabling overview A B C D E F 5 6 7 8 ...

Page 68: ...e wheelchair while also maintaining a high level of safety regardless of the wheelchair s other settings and options of the wheelchair 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: ...11 D Drive motor 28 E Emergency operation of seat functions 36 37 F Front wheels 14 15 Fuses 42 43 I ICS General module 41 ICS Master module 40 Introduction 5 L Lights 44 45 Link arms 20 21 M Magnetic brake 24 25 Maintenance 5 P Power Module 39 R Rating plates 6 Rear wheels 12 13 S Seat 46 50 Shock absorbers 17 Suspension 18 19 T Technical support 5 Troubleshooting guide 51 65 W Wheel fork 16 Inde...

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Page 72: ...Order no 205231 US 0 ...

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Permobil K450, Service Manual

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